Casting : Introduction

•Metal casting is one of the oldest manufacturing methods.

•Casting was started about 5000 B.C in ancient Mesopotamia

and ancient Egypt.
•Initially ancient weapons included the spear, javelin, the bow
and arrow, were manufactured by CASTING
•Hand-to-hand weapons such as swords, maces, axes, and
knives.
•In ancient times the casting was also done to make domestic
items like pottery, utensils, jewellaries etc.
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Casting : Introduction

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 Casting : Introduction

•Casting is a manufacturing process in which a liquid(molten)

material is poured into a mould.
•Mould contains a hollow cavity of the desired shape, and then
allowed to solidify.
•The solidified part is also known as a casting, which is released
or broken out of the mould to complete the casting process.
•Casting was also used during stone age as cast tools like arrow
heads, spear heads .
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 Spear head Casting
• A wax model was created of spear head shape for its casting.

• The wax model was compacted all around with the

moisturized sand.
• After compacting the sand, heating is done.

• The wax after heating is drained out of the sand compaction.

• Thereafter, molten metal i.e iron, bronze is poured into the

cavity formed.
• And finally after sufficient dwell time the sand mold is broken
or removed from the solidified metal casted as SPEAR.
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Spear head Casting

5
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 Why Casting ?
• A job of 5m diamet
er and 10m length.
• A job with a hole of
2m diameter, mad
e
of very hard mater
ial.
• Parts of very
complicated shape
s.
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 Requirement for Casting?

1. Cavity of desired shape-

Mould

2. Molten metal

3. Proper channel to fill

the molten metal

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 Have you seen any similar process before?

• What do we control?
1. Size & shape of mold ca
vity

2. Mixture composition

3. Temperature

4. Cooling time/heating
time

5. Carefully remove it
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 Examples
• The Jaivana cannon, located
at the Jaigarh Fort in Jaipur,
is the largest wheeled
cannon ever casted.
• It was casted in 17th century
1720, Jaivana- 50 tons canno
n was built at Jaipur.

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Examples

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Examples

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EXAMPLES- PLOUGHING

Plough were developed in

233 B.C in China for
Agriculture purpose
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 Examples- Automobile
Engine head
Crank Casing

Alloy
Wheels

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Casting : Aircraft

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Casting : Machine parts

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 Sand Casting Production Sequence

Production sequence in sand casting, including

pattern‑making and mould making.

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 Steps in Sand Casting

1. Pour the molten metal into sand

mold

2. Allow time for metal to solidify

3. Break up the mold to remove

casting

4. Clean and inspect casting

5. Heat treatment of casting is

required to improve
metallurgical properties

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Heat treatment of castings

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 Sand Mold Preparation

• The mold(flask) 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.
• The shape of the patterns is
identical to the shape of the part
needed.

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Sand mold

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 Sand mold
• A funnel shaped cavity; the top
of the funnel is the pouring
cup.
• The cone-shape 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.
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 Sand Mold Preparation

• The cavity in the sand mold

is formed by packing sand
around a pattern, then
separating the mold into two
halves and removing the
pattern.
• If casting is to have internal
surfaces, a core must be
included in mold.
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Terms used in castings

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