GCE 4145

FOUNDRY ENGINEERING
MST. ESMOTARA BEGUM
LECTURER
GCE, RUET
 FOUNDRY ENGINEERING

• Foundry engineering deals with the

processes of making castings in moulds
formed in either sand or some other material.
• Castings, the products of the metal founding
industry, are manufactured in a single step
from liquid metal without intermediate
operations of mechanical working such as
rolling or forging.
 PRINCIPAL METHODS OF SHAPING METALS

• Casting
• Mechanical working Casting is a process of introducing
• Fabrication by joining molten metal into a mould cavity
and allowing it to solidify
• Machining
• Powder metallurgy
A TYPICAL CASTING PROCESS
WHOLE PROCESS OF CASTINGS INVOLVES

Five stages:
• Patternmaking
• Moulding and coremaking
• Melting and casting
• Fettling
• Testing and inspection
 PATTERN MAKING
• Required to make mould cavities
• An approximate replica of the exterior of a casting
• Designed and prepared as per the drawing of the casting received from the
planning section and according to the moulding process to be employed
• If the casting is to be hollow, additional patterns, referred to as core boxes,
are prepared
 MOULDING AND COREMAKING

• The cavity in the sand mould is formed by packing sand around a pattern,
then separating the mould into two halves and removing the pattern
• Adequate gating system and feeding system are required in the mould to
direct the liquid metal into the mould cavity and to feed the solidification
shrinkage
• If casting is to have internal surfaces, a core must be included in the
mould
 MELTING AND CASTING

• The molten metal of correct composition prepared in a suitable furnace is

referred to as melting
• When molten, it is taken into a ladle and poured into the mould
• The mould is then allowed to cool down so that the liquid metal solidifies
• The castings are finally extracted by breaking the mould. This operation
is known as shake out.
 FETTLING

• Fettling refers to all operations necessary to the removal of

sand and oxide scale adhered to the casting surface, core and
excess metal (fins and other projections, gating system,
feeder) from the casting.
 TESTING AND INSPECTION

• Finally, before the casting is dispatched from the foundry, inspection and testing of the
casting is carried out to ensure that it is flawless and conforms to the desired
specifications.
• In case any defects or shortcomings are observed, salvage and rectification of castings
are carried out to save the casting.
• Proper and thorough quality control scheme is followed to analyse and determine the
caused of these defects, so as to prevent their reoccurrence. The production process
then has to be corrected accordingly
Flow diagram of a casting process
 ADVANTAGES OF METAL CASTING PROCESS

Process Advantages
Design advantages
• Size
• Production of prototypes
• Complexity
• Weight saving
• Versatility in casting
alloys
• Design versatility Metallurgical advantages
• Shape and intricacy • Uniform/isotropic properties
• Material composition • Grain size
• Tooling costs • Density
• The cast structure
• Flexibility of the
process
DISADVANTAGES OF METAL CASTING
PROCESS

• Rough surface finish and dimensional

accuracy
• Lack of directional properties
• Unable to produce complex structures
• Unable to use refractory materials
• Presence of casting defects
• Historical development
_Book Foundry Technology by Peter Beeley
• Reference books
_Principles of Foundry technology by P L Jain
_Foundry Technology by Peter Beeley
_Castings by J. Campbell