ProCAST

Gravity Casting
Theory

Marek Kovac 5.9.2005 1

 Introduction

The gravity casting is the oldest and simplest

(in theory but not in practice) means of
manufacturing shaped components.
This section describes Mould casting which
can be divided into two main groups :
·         Sand casting
·         Permanent mould casting

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 Advantages

Sand:
• Wide range of Metals
• Sizes
• Low cost Permanent Mold :

• Good finish
• Low porosity
• High Production rate
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 Sand Casting
•Sand casting is used to make large parts (typically Iron, but also
Bronze, Brass, Aluminum).

•Molten metal is poured into a mold cavity formed out of sand.

•Sand casting uses natural or synthetic sand (lake sand) which is

mostly a refractory material called silica(SiO2).

•The sand grains must be small enough so that it can be packed

densely; however, the grains must be large enough to allow gasses
formed during the metal pouring to escape through the pores.

•Larger sized molds use green sand (mixture of sand, clay and some
water). Sand can be re-used, and excess metal poured is cut-off and
re-used also.

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Patterns
•The mold is made of two parts, the top half is called the cope,
and bottom part is the drag.
•The liquid flows into the gap between the two parts, called the
mold cavity. The geometry of the
•cavity is created by the use of a wooden shape, called the
pattern. A funnel shaped cavity; the top of the funnel is the
pouring cup; the pipe-shaped neck of the funnel is the sprue –
the liquid metal is poured into the pouring cup, and flows down
the sprue.
•The runners are the horizontal hollow channels that connect the
bottom of the sprue to the mould cavity.
•The region where any runner joins with the cavity is called the
gate. Some extra cavities are made connecting to the top surface
of the mold.
•Excess metal poured into the mould flows into these cavities,
called risers (feeders). They act as reservoirs; as the metal
solidifies inside the cavity, it shrinks, and the extra metal from the
risers flows back down to avoid holes in the cast part.
•Vents are narrow holes connecting the cavity to the atmosphere
to allow gasses and the air in the cavity to escape.
•Cores: Many cast parts have interior holes (hollow parts), or
other cavities in their shape that are not directly accessible from
either piece of the mold. Such interior surfaces are generated by
inserts called cores. Cores are made by baking sand with some
binder so that they can retain their shape when handled.

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 Pattern, Finish Allowance, and Wall
Thickness

Min Wall
Pattern Oversize Factor (each Finish Allowance
Metal mm
direction) (smaller number for larger sizes)
(inches)

Aluminum 1.08 - 1.12 0.5 to 1.0 %

4.75 (0.187)

Copper alloys 1.05 - 1.06 0.5 to 1.0 % 2.3 (0.094)

Gray Cast Iron 1.10 0.4 to 1.6 % 3.0 (0.125)

Nickel alloys 1.05 0.5 to 1.0 % N/A

Steel 1.05 - 1.10 0.5 to 2 % 5 (0.20)

Magnesium alloys 1.07 - 1.10 0.5 to 1.0 % 4.0 (0.157)

Malleable Irons 1.06 - 1.19 0.6 to 1.6 % 3.0 (0.125)

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 Permanent mold
•Instead of using sand as the mold material, a metal is used as a
mold. Typically cast iron or Meehanite (a dense cast iron) is used
as the mold material and the cores are made from metal or sand.
Cavity surfaces are coated with a thin layer of heat resistant
material such as clay or sodium silicate.
•The molds are pre-heated up to 200 ºC (392 ºF) before the metal
is poured into the cavity. The cavity design for these molds do not
follow the same rules for shrinkage as in sand casting molds, due
to the fact that the metal molds heat up and expand during the
pour, so the cavity do not need to be expanded as much as in the
sand castings. However, care has to be taken to ensure proper
thermal balance, by using external water cooling or appropriate
radiation techniques.

•Permanent mold castings, while not as flexible as sand castings in allowing the use of different patterns (different part
designs), lower the cost of producing a part. At a production run of 1000 or more parts, permanent mold castings produce a
lower piece cost part. Of course, the break-even point depends on the complexity of the part.
•The usual considerations of minimum wall thicknesses (such as 3mm for lengths under 75 mm), radius (inside radius =
nominal wall thickness, outside radius = 3 x nominal wall thickness), draft angles (1 to 3º on outside surfaces, 2 to 5º on inside
surfaces) etc all apply. Typical tolerances are 2 % of linear dimensions. Surface finish ranges from 2.5 µm to 7.5 µm (100 µin
to 250 µin).
•Typical part sizes range from 50 g to 70 kg (1.5 ounces to 150 lb).
•Typical materials used are small and medium sized parts made from aluminum, magnesium and brass and their alloys.
•Typical parts include gears, splines, wheels, gear housings, pipefittings, fuel injection housings, and automotive engine
pistons.