Cast products & its

challenges for load bearing

applications
Presented By:
Part Saquib Bin Habib
Student Id: 1511012
1
 Casting & Cast Products
What is casting?
 Casting is a manufacturing process of producing net-shaped or near-net-shaped product by
introducing molten metal into a mould ,which contains a hollow cavity of the desired shape, and
then allowing it to solidify.
 The solidified product, also known as a casting ,is ejected or broken out of the mould to complete
the process.
 It is particularly valuable for the economical production of complex shapes, ranging from mass-
produced parts for automobiles to one-of-a-kind production of statues, jewelry, or heavy machinery.

Pour into Break up Net-

mould and mould and shaped/Near
Melt material
allow it to remove -net-shaped
solidify casting Product

2
Casting & Cast Products

3
Casting & Cast Products

4
 Defects of Cast Products
Defects in casting occur due to various reasons. There are different types of casting
defects:

Gas Defects

Shrinkage Cavities

Molding Material Defects

Pouring Metal Defects

Metallurgical Defects

5
 Defects of Cast Products
GAS POROSITY CASTING DEFECTS AND CAUSES

It occurs when the metal traps gas (most often nitrogen, oxygen or hydrogen) during casting.

Pinholes Openholes and Blowholes

Visible to naked eye
6
 Defects of Cast Products
These bubbles
The solid form appear on a
of the metal casting as
Bubbles are
cannot hold as rounded,
formed
much gas as circular
the liquid form cavities or
holes

• Poor venting of core and mold

Causes • Insufficient drying

7
 Defects of Cast Products
SHRINKAGE CASTING DEFECTS AND CAUSES

• Shrinkage occurs because metals are less dense as a liquid than a solid.
• Large shrinkage cavities can undermine the integrity of the casting and may cause it to eventually
break under stress.

Shrinkage can result in two types of casting defects.

• Open shrinkage defects

• Closed shrinkage defects

8
 Defects of Cast Products
SHRINKAGE CASTING DEFECTS AND CAUSES

A shrinkage Shrinkage
cavity is a porosity appears Cavities might
depression in a with angular also be paired
casting which edges, compared with dendritic
occurs during the to the round fractures or
solidification surfaces of gas cracks.
process. porosity.

• High Pouring Temperature

Causes • Failure to supply liquid feed metal

• Pre mature solidification

9
 Defects of Cast Products
MOLD MATERIAL CASTING DEFECTS AND CAUSES
Mold material casting defects are related to the mold material, which is most commonly sand.
• Swells • Fusion
Swells are an enlargement of the casting.  Fusion occurs when sand grains fuse with molten
metal. It appears as a thin crust with a brittle,
glassy appearance firmly adhered to the casting.

10
 Defects of Cast Products
MOLD MATERIAL CASTING DEFECTS AND CAUSES

• Cuts and Washes

• Metal Penetration

• Low strength of moulding sand Metal penetration

Causes • Insufficient ramming

• High permeability of sand

11
 Defects of Cast Products
POURING METAL CASTING DEFECTS AND CAUSES

Misrun and Coldshuts

• When the metal is unable to fill the mould cavity

completely & thus leaves unfilled cavities, it is called
as misrun defect.

• When two metal streams meeting in the mould

cavity, do not fuse together properly, causing
discontinuity or weak spot inside casting, it is called
as cold shuts.

12
 Defects of Cast Products
POURING METAL CASTING DEFECTS AND CAUSES

Misrun and Coldshuts

Cold shut

• Low pouring temperature

Causes • Lack of fluidity in molten metal

• Faulty gating system design

13
 Defects of Cast Products
METALLURGICAL CASTING DEFECTS AND CAUSES

Hot tear/crack/ shortness

A hot tear is a discontinuity that occurs during the solidification stage of a casting operation, when
the material being cast is part solid and part liquid.

14
 Defects of Cast Products
METALLURGICAL CASTING DEFECTS AND CAUSES

As a material
Some force
solidifies, it
or restraint Hot tear
will generally
impedes this occurs
want to
contraction
contract.

• Lack of collapsibility of mould and core

Causes •

•
Hard ramming of mould

Faulty casting design

15
 Defects of Cast Products
INCLUSIONS AND WARPAGE

Inclusions Warpage
Undesirable foreign material within the metal of Undesirable deformation in a casting due to
casting. improper solidification
16
 Defects of Cast Products
SUMMARY OF DEFECTS

17
 Properties of Cast Products

Isotropic properties

Uniform Density

Presence of defects

Grain Structure
(a) pure metals; (b) solid solution alloys; and (c)grain
structure obtained by using nucleating agents.
18
 Properties of Cast Products
Cast Iron Toughness
Ductile Iron Toughness
Steel Toughness
Stress, KSI

Strain,inch

ConclusionCast products have lower ductility and toughnes

19
Cast products & its
challenges for load bearing
applications
Presented By:
Part Saquib Bin Habib
Student Id: 1511012
2
 Load Bearing Components
• Load bearing components carry the loads imposed on them and support the
structure.

• They are critical in maintaining a structure and resisting failure.

Examples

Columns
Load of body Spars of
Beams
on legs aircrafts
Trusses
21
Load Bearing Components

22
 Load Bearing Components
Different types of load:
Dead loads
Imposed loads
Wind loads Effects:
Axial loads Tension
Transverse loads Compression
Earthquake loads Shear
Vibration Bending
Fatigue Torsion
Impact
23
Load Bearing Components
Properties of load bearing components:

Tensile Compressive Flexural

strength strength strength

Stiffness Ductility Toughness

Shear Fatigue Impact

Modulus Resistance Resistance
24
 Properties of Cast Products
Cast products have lower mechanical properties due to Defects
• Cast products have equiaxed grains
• Isotropic properties Grain structure

Elongated Grains

Microstructure of AlSi7MgCu0,5 in coupled casting-forging process: as-cast state (left) and after 65 % deformation (right)

25
 Properties of Cast Products
Effects of shrinkage porosity on mechanical properties

Fig:Mechanical properties of sand cast WE54 alloy with different shrinkage porosity volume fractions

26
 Properties of Cast Products
Effects of inclusions on mechanical properties

Fig:Strength and ductility of an Al-4.5Cu-1.5 Mg alloy as a function of total area of different types of inclusions in the
fracture surface.

Cast products have lower mechanical properties

Conclusiondue to defects. 27
 Properties of Cast Products

Rolling causes the grains to elongate in the rolling

direction and introduce anisotropic properties.
Also, it removes porosity.

• Cast materials generally have a totally non-oriented

grain distribution. This limits the impact strength.
• The grain orientation in a forging can be controlled
to allow the grain to “flow” around corners and
follow the contours of the part.
• Increases the strength of the part, especially at
critical stress points.
28
 Properties of Cast Products
Working on a material , for example forging, increases its mechanical properties as compared to as
cast product of the same material. According to a study performed by the Industrial & Manufacturing
Engineering Department at the University of Toledo:

26% 37%
Higher Tensile Higher Fatigue
Strength Strength

34% 52%
Higher Yield
Higher Ductility
Strength

29
 Properties of Cast Products
Cast aluminium alloys are not often used for structural components due to their comparatively low
tensile strength.
Wrought Aluminium has exceptional mechanical properties and can be formed into various
standard and nonstandard shapes. 

Cast Aluminium Wrought Aluminium

Tensile
Tensile Yield Strength Yield
Grade Composition Strength Strength (MPa) Strength
(MPa) (MPa (MPa

2.2% to 6.8%
2xxx copper 131 – 276 90 – 345 186 – 467 76 – 345
 
6.2% to 7.5%
7xxx 207 – 379 117 – 310 228 – 572 103 - 503
Zinc
30
Properties of Cast Products

Forged/worked products have

better mechanical properties than
cast products.
31
 Conclusions
Property Forging Casting
Strength High Medium
Ductility High Low
Toughness High Medium
Fatigue crack growth Good Poor
resistance
Directional strength Yes None
capability
Internal defects Possible Many

Cast products have critical challenges for load bearing applications.

32
Thank
You