HAPE MADE FROM MOLTEN

METALS-CASTING
 THÀNH VIÊN NHÓM 13:

Thạch Thị Thu Thương – 20021194

Trần Quốc Anh – 20021085
Hà Việt Hoàng – 20021132
Trần Quốc Việt – 20021211
Nguyễn Quang Minh – 20021162
 Outlines
• Basic Casting Principle
• Main requirements of any mould
• Non-permanent mould casting method
• Type of sand using in sand casting
• Typical sand casting defects and their cause
Basic Casting Principle
 Main requirement of any mould

• Have the desire shape and size with allowances made for metal contraction
during solidification and cooling (usually 2% for steel, cast iron 1% and
aluminium 1.25%)
• Made from a material capable of withstanding the inrush of molten metal before
solidification occur
• Be design to ensure efficient feeding of metal to all parts of the mould before it
began to solidify
• Not cause a restriction to solidification and contraction after pouring and any
undue difficulties in removing the casting after cooling
• Allow easy escaped of gases from the mould during pouring
Non-permanent moulds

Permanent moulds
Non-permanent mould
casting methods
 Sand casting method

This process use sand as the

material to make the mould cavity,
but precisely how it is used in the
construction of a mould is best
explain by under example.
 Step 1:

Make an accurate pattern of the required article of

either wood or plastic.
 Step 2:

Place a square (or) circular steel surround on the pattern

plate, enclosing the pattern.
Fill the space around the pattern with special moulding sand
,and ram it up as densely as possible.
 Step 3:

Turn the complete assembly through , and carefully remove the pattern,
making sure not to damage the sand impression. Using a hand trowel, carefully
carve out a channel in the floor sand to provide a path along which the molten
metal can flow into the mould cavity- called the feeding-in gate
 Step 4:

Using a steel surround identical to that used in step 2, place two tapered
wooden plugs in position so that one will, in due course, align with the feeding-in
gate in the drag and the other will align with the main mould cavity. Fill and ram
up with sand. This assembly is called the cope.
 Step 5:

Carefully remove the two plugs from the cope, leaving two (tapered) holes in
the compacted sand. These holes, are termed the runner and riser.
After pour the molten metal into the mould through the runner hole until the
mould is full. Leave to solidify and cool.
 Step 6:

Remove the casting from the mould.

Cut off the riser and runner, remove any sand adhering to the surface of the
casting.
Type Of Sand Using In Sand Casting
 Type Of Sand Using In Sand Casting
• Green sand: It consists of silica sand, mixed with approximately 3 per cent coal dust (which gives it its
characteristic black colour), 6 per cent clay and 3.5 per cent water to act as a strength-enhancing binder. This is
the sand that actually comes into contact with the molten metal. Owing to increasing cost-consciousness in the
foundry industry and major improvements in efficiency of sand reclamation units, this practice is now rarely
used.
• setting sand: A more expensive alternative to green sand is setting sand. This is a sodium silicate-based sand
that chemically hardens when CO, gas is passed through it. It gives a much harder moulding surface than green
sand, but because of its cost and use-only-once characteristics it tends to be reserved for costly alloy steel casting
work.
• Core sand: In contrast to green sand, core sands are clay free, but they still need a binder. This is usually a resin
that hardens with the application of heat. Thin, complex cores often require reinforcing wires to give them
sufficient structural strength to withstand handling during mould assembly and to resist the forces imposed by
the molten metal during pouring. Thus, core sand must be capable of binding well to such reinforcement.
Typical sand casting defects and their cause
Scabs
Blowholes
Hard Spots
Porosity and Sponginess
Cold Shut
Displaced Cores
Cracks
Centre-line Shrinkage
THANKS FOR YOUR
ATTENTION!