Casting

Disclaimer: This is solely for teaching purpose, not to be shared.

 Pouring of Melt in a Pre-designed and
Pre-Fabricated Cavity [Mould]

 Mould may be Expendable- [ Advantages include

Flexibilities, complexities]
 Mould Materials Sand, Plaster, and Ceramic mixe
With bonding agent

 Mould May be Permanent[ Advantages include

Higher production rate]
Expendable Mould Process
 Sand Casting
 Shell Casting
 Plaster Casting
 Ceramic Casting
 Investment Casting

Permanent Mould Casting

 Low Pressure Permanent Mould Casting
 Vacuum Permanent Mould Casting
 Die Casting
 Squeeze Casting
 Centrifugal Casting [ True Centrifugal, Semi-centrifugal,
Centrifuging]
 Injection Moulding
 Compression Moulding
Steps in Sand Casting Process

 Pattern Making

 Mould Making

 Pouring System Design-Foundry Methoding

 Pouring and Solidification

 Fettling

 NDT

 Heat-treatment
 Steps in Sand Casting

Source: www.pcpolytechnique.com
 Pattern Materials

 Wood
 Metal
 Plastic
 Wax  Pattern Allowances
 Shrinkage Allowances
[Dimension, Material, Design, Temp.]
 Draft or Taper Allowances
 Distortion Allowances
 Machining Allowances

 Pattern Types
 Cope and Drag Pattern
 Split Pattern
 Gated Pattern
 Match-Plate Pattern
 Sweep Pattern
  Shrinkage Allowance:

 Liquid Shrinkage
 Solid Shrinkage

Source: www.pcpolytechnique.com
 Dimensional errors of castings can be divided into those due to
random causes and those due to pattern errors.

 Pattern errors occur when the mean of the resultant casting

feature is different from the specified feature size. When a new
pattern is being designed, the dimensional changes of the mould
and casting are estimated. These estimated changes are then
applied to the pattern as what is traditionally called the
shrinkage allowance or the shrink rule.

 PA allowance= (Pattern feature size-Casting feature size)/Casting

Feature size X100

 There are many highly interdependent physical processes

responsible for steel castings not having the same dimensions as
the pattern from which the moulds are made. Shrinkage of the
steel upon solidification and cooling to room temperature is the
primary reason for dimensional changes.

 Stresses develop and the resulting casting contraction depends

on the mechanical and physical properties of the sand and the
solidifying steel.
 The final dimensions of a steel casting are also strongly
influenced by volumetric changes of the mould and core sands.
The high pouring temperature of steel can cause significant
early heating and thermal expansion of the mould sand. When
the metal is mostly liquid it offers little resistance and the sand
can expand into the cavity. This expansion is arrested when
metal develops a solidified shell against the sand.

 Only linear shrinkage is taken into account. It depends on the

type of casting material, construction as well as the stability of
the mold during solidification and shrinkage.

 Solid shrinkage is influenced by four factors.

 Investment Casting: Free and Restricted Shrinkage

 The wax pattern and casting shrinkage of the H-shape
castings have been calculated using the following
relationships: 1. Wax shrinkage( WS) = Die dimensions - Wax
Pattern dimensions 2. Cast shrinkage(CS) = Wax pattern
dimensions- Casting dimensions 3. Total shrinkage(TS) = (WS)
+ (CS) = Die dimensions- Casting dimension
Effect of mould expansion on pattern allowances in
sand casting of steel
 For steel castings produced in sand moulds, the expansion of the sand and have a significant impact
on the final size and shape of the casting
 Unlike zircon sand, silica sand can undergo phase transformations with associated dimensional
changes in the temperature range seen in steel casting applications

THERMAL EXPANSION OF SILICA SAND

THEMAL EXPANSION OLIVINE SAND
 Draft Allowance

Source: www.pcpolytechnique.com
 Pattern Allowances

 Effect Of Moulding sand Expansion

 Shrinkage allowance Prediction

[ Prediction of Shrinkage allowance for
ir-regular shape]

 Prediction od Distortion allowance

 Geometry Dependent Pattern Allowance Model

 Finite Element..
 Moulding Methods

Source: www.pcpolytechnique.com
Sand Types-----Silica Sand, Zircon Sand, Olivin Sand

Sand Moulding Methods

 Based on Binder
 Natural Sand Moulding
 Synthetic Sand Moulding

 Based on Process….
 Green Sand
 Dry Sand  Binders
 Flask less  Sodium Silicate
 Vacuum Assisted  Organic
 3-D printing of sand mould -Binder Jetting Technology
Selective Laser Sintering
 Chemical Sand Moulding Process
 Shell Moulding
 Sodium Silicate Moulding
 No Bake Moulding
 Green Sand:
 Natural sand prepared as a mixture of silica sand with 18-30 %
clay and 6-8 % moisture.
 Fine, soft, light and porous.

 The name ‘Green sand’ employs for damped i.e. it contains

moisture and the mould made of this sand is used immediately
to pour the molten metal.
 Easily available and has low cost.

Source: www.pcpolytechnique.com
  Dry Sand:
 Green sand that has been dried or baked in between 250° to
550° in suitable oven after the making mould and cores, is
called dry sand.
 More strength, rigidity and thermal stability.

 Suitable for larger castings.

Source: www.pcpolytechnique.com
Moulding Sand Properties
 Physical---Shape, Size, Size Distibution

 Chemical----Inertness

 Others—Refractoriness, Strength, Permeability

Adhesiveness, Cohesiveness, Collapsibility

 Moulding Sand Properties depends upon

Binder Content, Moister Content, Ratio..
1. Refractoriness:
 The ability of moulding sand to withstand high temperatures
without breaking down or fusing.
 The degree of refractoriness depends on SiO2 content and
shape & grain size of the particle.
 To enhance the proporty, sand should have lower percentage
of lime, magnesia, alkali, oxides of metals.
 Refractoriness is measured by Sinter point rather than its
melting point. ( At sintering temperature, the moulding sand
adheres to the casting)

Source: www.pcpolytechnique.com
2. Permeability:
Also referred as porosity, is the property of sand allow the escape
of any air, gases or moisture present or generated in the mould
when the molten metal is poured into it.
Liquid metals cause evolution of gases due to their reaction with
moulding sand ingredients.
Permeability is a function of:
1. Grain size
2. Grain shape
3. Moisture and clay contents in the moulding sand.
 3. Cohesiveness:
Also referred to as the strength of sand.
It is property of moulding sand by virtue which the sand grain par-
ticles interact and attract each other within the moulding sand.
Moulding sand should be capable of withstanding the compres-
sive and erosive force exerted by liquid metal while filling the cav-
ity.
Low strength mouldings result in defective castings.
It depends upon the grain size, sand particle shape and size,
moisture content and density,
strength inversely affect the porosity

Source: www.pcpolytechnique.com
 4. Flowability:
It is the ability of the sand to get compacted and behave like a
fluid.
It will flow uniformly to all portions of pattern when rammed and
distribute the ramming pressure evenly all around in all directions.
In general, flow ability increases with decrease in green strength,
an, decrease in grain size.
flow ability also varies with moisture and clay content.
It is also called as plasticity fluidity.

Source: www.pcpolytechnique.com
 5. Adhesiveness:
It is property of moulding sand to get stick or adhere with foreign
material such sticking of moulding sand with inner wall of mould-
ing box.
It helps the sand to retain the mould cavity and stay in the box.

Source: www.pcpolytechnique.com
 6. Collapsibility:
After solidification of the molten metal, the casting is required to
be removed from the mould.
If the moulding sand is easily collapsible, free contraction of the
metal as well as easy removal of the casting is possible.
If the sand is not collapsible, it will strongly adhere to the casting,
becoming very hard to separate after metal solidification.

Source: www.pcpolytechnique.com
DIFFERENT SAND MOULDING METHODS

 GREEN SAND MOULDING

 DRY SAND MOULDING

 SKIN-DRIED SAND MOULDING

 NO BAKE MOULDING PROCESS

 CO2 MOULDING PROCESS

 AIR-SET METHOD

 Vacuum molding
Vacuum molding (V-process) is a variation of the sand casting process for most ferrous and non-ferrous
metals,in which unbonded sand is held in the flask with a vacuum . The pattern is specially vented so
that a vacuum can be pulled through it. A heat-softened thin sheet (0.003 to 0.008 in (0.076 to 0.203 mm))
of plastic film is draped over the pattern and a vacuum is drawn (200 to 400 mmHg (27 to 53 kPa)). A
special vacuum forming flask is placed over the plastic pattern and is filled with a free-flowing sand. The
sand is vibrated to compact the sand and a sprue and pouring cup are formed in the cope. Another sheet
of plastic is placed over the top of the sand in the flask and a vacuum is drawn through the special flask;
this hardens and strengthens the unbonded sand. The vacuum is then released on the pattern and the
cope is removed. The drag is made in the same way (without the sprue and pouring cup). Any cores are
set in place and the mold is closed. The molten metal is poured while the cope and drag are still under a
vacuum, because the plastic vaporizes but the vacuum keeps the shape of the sand while the metal
solidifies. When the metal has solidified, the vacuum is turned off and the sand runs out freely, releasing
the casting.
CONTD:

he V-process is known for not requiring a draft because the plastic film has a certain degree of
lubricity and it expands slightly when the vacuum is drawn in the flask. The process has high
dimensional accuracy, with a tolerance of ±0.010 in for the first inch and ±0.002 in/in thereafter.
Cross-sections as small as 0.090 in (2.3 mm) are possible. The surface finish is very good, usually
between 150 and 125 rms. Other advantages include no moisture related defects, no cost for
binders, excellent sand permeability, and no toxic fumes from burning the binders. Finally, the
pattern does not wear out because the sand does not touch it. The main disadvantage is that the
process is slower than traditional sand casting so it is only suitable for low to medium production
volumes; approximately 10 to 15,000 pieces a year. However, this makes it perfect for prototype
work, because the pattern can be easily modified as it is made from plastic.

FLASK LESS MOULDING

 3-D PRINTING SAND MOULDING

 3D Printing of Sand Molds is a process by which molds of sand, used for casting of
metals, are prepared by means of additive layer manufacturing of sand and binder.
The process is also known as pattern-less mold making method, as no patterns are
required for the construction of the molds.
 A layer of sand is deposited and is selectively hardened in areas according to the
shape of the required mold by using binders. Binder is deposited using moveable
print head, having a multi-jet or single-jet nozzle. The process is repeated until the
entire mold is obtained by addition of layers one after the other. The loose sand
around the hardened part acts as support.

 Binder Jetting Technology

A 3D printer prints the mold from the CAD file fed into the system by depositing
successive layers (usually of thickness 0.3mm) of sand or metal powder on the bed. A
moveable print head passes over each layer and deposits the binder only in the areas
which need to be hardened, as per the CAD model[5]. Depending on the binder and the
material used, the 3D printed object may or may not require post processing.
 Selective Laser sintering
Selective Laser Sintering is another method to prepare pattern-less sand molds. Laser is
used as the source of heat energy for fusing sand and binding it[6]. EOS was pioneer of
this technology.
 Effect of Moulding Sand Properties on Cast Structure

 Effect of additive on Moulding Sand Properties

 Prediction of Moulding sand Properties

 Reclamation/Re-use

 Study of Casting Defects by varying Moulding sand Properties