Casting Processes. ver. 2
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1 Casting Processes ver. 2 1
2 Types of Parts Made Engine blocks Pipes Jewelry Fire hydrants 2
3 Complex, 3-D shapes Near net shape Low scrap Relatively quick process Intricate shapes Large hollow shapes No limit to size Reasonable to good surface finish 3
4 Processes Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous 4
5 Metals processed by casting Sand casting 60% Investment casting 7% Die casting 9% Permanent mold casting 11% Centrifugal casting 7% Shell mold casting 6% 5
6 Breakdown of Castings Ingots for bulk deformation processing - 85% Cast to near net shape - 15% 6
7 Ingots Iron or steel molds Water-cooled molds Continuous casting 7
8 Shapes Permanent mold (cavity) die casting hot chamber cold chamber Expendable Molds sand shell slurry investment lost wax lost foam 8
9 Shapes Centrifugal pipes spinning 9
10 Dimensions Capabilities sand casting - as large as you like small - 1 mm or so Tolerances in to 0.1 in Surface finish die casting 8-16 micro-inches (1-3 mm) sand casting micro-inches (10-25 mm) 10
11 Casting Steps quick route from raw material to finished product Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish 11
12 Melting Heat Furnace Atmosphere Raw material (charge) scrap, alloying materials Atmosphere Raw materials Air (oxygen), vacuum, inert gas (argon) Heating External - electric, gas, oil Internal - induction, mix fuel with charge steel making in blast furnace -mix coke with iron Furnace material refractory ceramics 12
13 Furnaces Blast furnace Basic Oxygen Furnace 13
14 Furnaces Electric Arc Furnace Oxygen-Fuel, Oxygen Lance Furnace 14
15 Furnaces Induction Furnace Electric Furnace 15
16 Sand Casting 16
17 Sand Casting 17
18 Sand Casting 18
19 Sand Casting Steps 19
20 20
21 Sand Cast Parts 21
22 Permanent Mold Casting 22
23 Low Pressure Casting 23
24 Die Casting (high pressure) 24
25 Die Casting Machine 25
26 Die Casting Cold chamber Hot chamber 26
27 Direct Squeeze Casting 27
28 Die Casting Part Example 28
29 Continuous Casting 29
30 30
31 31
32 32
33 Investment Casting 33
34 Vacuum Casting 34
35 Investment (top) and Conventional Castings 35
36 Lost Foam Casting 36
37 Lost Foam Castings 37
38 Centrifugal Casting horizontal sand-lined mold casting vertical 38
39 Centrifugal Casting 39
40 Pipe Casting Process 40
41 Directional Solidification 41
42 Casting Characteristics Table 5.6 Process Typical Weig ht (kg) materials cast Minimum Maximum Typical surface finish (micron, Ra) Porosity* Shape complexity * Section thickness (mm) Dimensional accuracy* Minimum Maximum Sand All 0.05 No limit No limit Shell All Expendable mold pattern All 0.05 No limit No limit Nonferrou Plaster s (Al, Mg, mold Zn, Cu) Investment All (High melting pt.) Permanent mold All Nonferrou s (Al, Mg, Die Zn, Cu) < Centrifugal All *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods use d. 42
43 Microstructure 43
44 Microstructure - Dendrites Finer structure at walls Grains / dendrites grow to center 44
45 Grains on Willie B s head 45
46 Microstructure - Dendrites 46
47 Fluidity 47
48 Casting Defects - Porosity 48
49 Casting Defects 49
50 Shrinkage TABLE 5.1 Volumetric solidification contraction (%) Volumetric solidification contraction (%) Metal or alloy Metal or alloy Aluminum %Cu 30%Zn 4.5 Al 4.5%Cu %Cu 10%Al 4 Al 12%Si 3.8 Gray iron Expansion to 2.5 Carbon steel Magnesium 4.2 1% carbon steel 4 White iron Copper 4.9 Zinc 6.5 Source: After R. A. Flinn. 50
51 Differential Cooling Transition between thicker and thinner sections can lead to porosity 51
52 Pipe Defect Due to shrinkage giving rise to a funnel-like cavity Solutions insulate top (glass wool) heat top (exothermic mixture - thermit) 52
53 Defects - Hot Tears 53
54 Chills 54
55 Car Rims Stamped Cast 55
56 Casting Defects - Porosity 56
57 Design Rules Summary Uniform wall thickness Flat parting lines Gradual thickness transitions Draft for removal tapers: 0.5 to 2 degrees Surface of mold gives surface of part 57
58 Sand Casting Rules 58
59 Casting costs TABLE 5.10 Cost* Process Die Equipment Labor Production rate (Pc/hr) Sand L L L M <20 Shell-mold L M M-H L M <50 Plaster L M M M H <10 Investment M H L-M H <1000 Permanent mold M M L M <60 Die H H L M <200 Centrifugal M H L M <50 * L, low; M, medium; H, high. 59
60 Process economics 60
61 61
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