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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