Copyright 1999 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES Casting

Transcription

1 Copyright 1999 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES Casting SCENE 1. CG: FBI warning white text centered on black to blue gradient SCENE 2. CG: disclaimer white text centered on black to blue gradient WARNING federal law provides severe civil and criminal penalties for the unauthorized reproduction, distribution or exhibition of copyrighted videotapes SME Always read the operating manual and safety information provided by the manufacturer before operating any casting equipment. Make sure all machine guards are in place, and follow all safety procedures when working with or near casting equipment. SCENE 3. tape 40, 01:00:00-01:00:12 SME logo, with music SCENE 4. tape 25, 01:01:00-01:01:45 fundamental series open, with music MUSIC UP AND UNDER THE FUNDAMENTAL MANUFACTURING PROCESSES VIDEO SERIES, EXAMINING THE TOOLS AND TECHNIQUES OF PRECISION MANUFACTURING. SCENE 5. program title: CG: Casting white text centered on black SCENE 6. tape 447, 14:23:31-14:23:40 casting being poured tape 450, 17:19:54-17:20:02 die casting being ejected THIS PROGRAM IS AN INTRODUCTION TO CASTING. CASTING IS THE SOLIDIFICATION OF MOLTEN METAL THAT IS POURED INTO A MOLD..., OR INJECTED INTO A DIE HAVING A CAVITY IN THE SHAPE OF THE DESIRED PART.

2 Copyright 1999 Society of Manufacturing Engineers SCENE 7. tape 418, 14:02:07-14:02:14 casting operation tape 419, 04:11:03-04:11:15 pan of just cast mill forms CASTING IS USED IN VIRTUALLY EVERY INDUSTRY SINCE ALL METALS CAN BE CAST. EVEN MILL FORMS, SUCH AS BAR AND PLATE ARE PRODUCED FROM CAST METAL. SCENE 8. tape 435, 03:22:00-03:22:14 casting of prototype tape 446, 13:26:20-13:26:30 production casting CASTING IS USUALLY THE QUICKEST WAY TO SHAPE METAL INTO A PART. BECAUSE OF THIS, CASTING IS USED BOTH FOR PROTOTYPING..., AS WELL AS PRODUCTION OF LARGE QUANTITY PARTS. SCENE 9. tape 435, 03:08:19-03:08:26 zoom out, castings surface tape 468, 00:00:50-00:00:58 GRAPHIC: cutaway of casting showing isotropic grain structure tape 468, 00:01:15-00:01:23 GRAPHIC: cutaway of wrought part showing directional properties tape 455, 23:24:42-23:42:53 part taken from casting mold CASTINGS TYPICALLY HAVE AN ISOTROPIC, OR UNIFORM, GRAIN STRUCTURE AND PROPERTIES, RATHER THAN THE DIRECTIONAL GRAIN STRUCTURE AND PROPERTIES OF WROUGHT METALS. HOWEVER, CASTINGS ONLY APPROACH THE FULL, OR THEORETICAL, DENSITY OF WROUGHT METALS. SCENE 10. tape 456, 02:27:54-02:28:04 casting being sealed with a resin or a metal additive tape 381, 01:50:08-01:50:17 parts in hot isostatic process SURFACE POROSITY OF CASTINGS CAN BE ELIMINATED BY SEALING WITH A RESIN OR A METAL. INTERNAL POROSITY CAN BE REDUCED BY ISOSTATIC PRESSING, IMPROVING THE CASTINGS' MECHANICAL PERFORMANCE. SCENE 11. tape 438, 04:03:49-04:04:10 pattern covered in sand CG, SUPER: Wood Plastic Metal tape 454, 22:09:59-22:10:22 investment casting during pour CG, SUPER: Wax Plastic Polystyrene Foam MANY CASTING PROCESSES UTILIZE PATTERNS. THESE ARE USED TO FORM THE CAVITY OF THE MOLD INTO THE SHAPE TO BE CAST. REUSABLE PATTERNS ARE MADE OF WOOD, PLASTIC, OR METAL.

3 Copyright 1999 Society of Manufacturing Engineers EXPENDABLE PATTERNS, SO CALLED BECAUSE THEY'RE CONSUMED IN THE MOLD MAKING PROCESS, OR BY THE POURED METAL DURING CASTING, ARE MADE OF WAX, PLASTIC, OR POLYSTYRENE FOAM, DEPENDING ON THE PROCESS. SCENE 12. tape 454, 22:23:44-22:23:51 pan of pattern tape 454, 22:20:57-22:21:04 pattern released from the mold tape 439, 05:16:34-05:16:54 wide of pattern being produced CG, super: Allowances For Finish Machining Location Of The Parting Line Details For Alignment Of Mold Halves Details For Metal Transfer Through The Mold PATTERNS ARE OVERSIZE TO ACCOMMODATE METAL SHRINKAGE DURING SOLIDIFICATION. THEY ARE GIVEN A TAPER, OR DRAFT, TO EASE RELEASE FROM THE MOLD. PATTERNS MAY ALSO INCLUDE ALLOWANCES FOR FINISH MACHINING, LOCATION OF THE PARTING LINE, DETAILS FOR ALIGNMENT OF MOLD HALVES, AND FOR METAL TRANSFER THROUGH THE MOLD. SCENE 13. tape 439, 05:06:21-05:06:40 core placed in mold tape 438, 04:15:28-04:15:33 core produced in core box tape 446, 13:02:41-13:02:50 cores produced on machine CORES ARE NEEDED TO CREATE THE RECESSES, UNDERCUTS AND INTERIOR CAVITIES THAT ARE OFTEN REQUIRED FOR CASTINGS. CORES ARE PRODUCED FROM VARIOUS MATERIALS USING A VARIETY OF PRODUCTION METHODS. --- TOUCH BLACK --- SCENE 14. tape 449, 16:15:08-16:15:15 casting process tape 468, 00:09:00-00:10:00 blue background CG: Casting Process Classifications: Expendable Mold/Reusable Pattern Expendable Mold/Expendable Pattern Permanent Mold/No Pattern CASTING PROCESSES CAN BE GROUPED INTO THREE CLASSIFICATIONS: EXPENDABLE MOLD/REUSABLE PATTERN PROCESSES, EXPENDABLE MOLD/EXPENDABLE PATTERN PROCESSES, AND PERMANENT MOLD/NO PATTERN PROCESSES. SCENE 15. tape 439, 05:04:51-05:05:00

4 Copyright 1999 Society of Manufacturing Engineers sand casting process tape 453, 21:10:36-21:10:48 investment casting process tape 442, 08:04:10-08:04:17 die casting process CG, SUPER: Part Size Part Configuration Part Quantity Required Tolerances Metal Specified WHICH CASTING PROCESS TO CHOOSE DEPENDS ON PART SIZE, PART CONFIGURATION, PART QUANTITY, REQUIRED TOLERANCES, AND THE METAL SPECIFIED. --- FADE TO BLACK --- SCENE 16. CG: Expendable Mold/Reusable Pattern Processes white text centered on black SCENE 17. tape 448, 15:04:36-15:04:46 sand casting operation tape 468, 00:09:00-00:10:00 blue background CG: Expendable Mold/Reusable Pattern Processes Sand-Mold Casting Plaster-Mold Casting Ceramic-Mold Casting EXPENDABLE MOLD/REUSABLE PATTERN PROCESSES INCLUDE: SAND-MOLD CASTING, PLASTER-MOLD CASTING, AND CERAMIC-MOLD CASTING. SCENE 18. tape 446, 13:12:38-13:12:51 shell mold casting being broken out of mold ALTHOUGH PATTERNS CAN BE REUSED MANY TIMES, REMOVING THE CASTING FROM THE MOLD NECESSITATES BREAKING THE MOLD. THUS, MULTIPLE PARTS REQUIRE MULTIPLE MOLDS. SCENE 19. CG, SUPER: Sand-Mold Casting tape 452, 19:18:52-19:19:04 sand-mold casting operation tape 439, 05:10:23-05:10:39 large no-bake mold glued together SAND-MOLD CASTING, ALSO CALLED SAND CASTING, IS THE MOST COMMON CASTING PROCESS. IT IS APPLICABLE TO A GREAT VARIETY OF METALS AND THERE IS ESSENTIALLY NO LIMIT TO THE SIZE OF CASTING THAT CAN BE MADE. SCENE 20. tape 439, 05:25:03-05:25:11 pull back, castings tape 439, 05:21:01-05:21:10 CASTINGS MADE IN SAND MOLDS ARE NOT VERY PRECISE,

5 Copyright 1999 Society of Manufacturing Engineers castings pulled from mold BUT PRODUCTION COST IS GENERALLY LOWEST. ALTHOUGH THE MOLDS ARE EXPENDABLE, THE SAND CAN USUALLY BE RECONDITIONED FOR REUSE. SCENE 21. tape 451, 18:09:00-18:09:08 mold half built by packing sand about the pattern in a flask CG, SUPER: Flask SAND MOLDS, MADE IN HALVES, ARE BUILT BY TIGHTLY PACKING THE SAND AROUND THE PATTERN IN A FLASK. SCENE 22. tape 438, 04:12:02-04:12:11 wide of mold CG, SUPER: Cope Drag THE UPPER MOLD HALF IS CALLED THE 'COPE'..., AND THE LOWER HALF THE 'DRAG'. SCENE 23. tape 451, 18:11:56-18:12:10 sand mold being produced tape 468, 00:03:55-00:04:30 GRAPHIC: static, cross section of sand mold, add switcher effect highlighting the pouring basin, dissolve to switcher effect highlighting the sprue, dissolve to switcher effect highlighting the runner system, dissolve to switcher effect highlighting the gate THE MOLD INCLUDES ONE OR MORE RISERS, VENTING PROVISIONS, AND A SYSTEM FOR TRANSFERRING THE MOLTEN METAL TO THE MOLD CAVITY. THIS SYSTEM INCLUDES: A POURING BASIN, SPRUE, RUNNER SYSTEM, AND ONE OR MORE GATES. SCENE 24. tape 451, 18:06:28-18:06:38 compacted mold half separated from pattern ONCE THE SAND HAS BEEN COMPACTED, THE PATTERN AND MOLD HALF ARE SEPARATED, AND ANY LOOSE SAND IS BLOWN AWAY. SCENE 25. tape 451, 18:13:59-18:14:03 core inserted into mold tape 451, 18:14:20-18:14:29 mold halves aligned, closed together CORES, IF REQUIRED, ARE INSERTED INTO THE MOLD. ONCE THEY ARE SET, THE MOLD IS CLOSED BY ALIGNING THE COPE AND DRAG. THE MOLD IS THEN TRANSFERRED TO THE POURING STATION.

6 Copyright 1999 Society of Manufacturing Engineers SCENE 26. tape 451, 18:17:03-18:17:33 zoom out, casting metal flowing into mold, up in risers IN CASTING, METAL FLOWS FROM THE POURING BASIN THROUGH THE SPRUE, RUNNERS AND GATES TO THE MOLD CAVITY. VENT HOLES FORMED IN THE COPE AND DRAG, AND OFTEN IN THE CORES, PERMIT TRAPPED GASES TO ESCAPE. SCENE 27. AFTER FILLING THE MOLD, THE METAL ENTERS THE RISER OR RISERS, WHICH SERVE AS RESERVOIRS OF EXCESS METAL TO COMPENSATE FOR METAL SHRINKAGE DURING SOLIDIFICATION. SCENE 28. tape 448, 15:18:15-15:18:30 casting removed from mold tape 451, 18:20:24-18:20:36 runners and risers removed from casting ONCE COOLED, THE CASTING IS REMOVED FROM THE MOLD..., AND THE METAL IN THE RUNNERS AND RISERS SEPARATED FROM THE CASTING FOR RE-MELTING. SCENE 29. tape 451, 18:01:36-18:01:55 sand casting operation tape 468, 00:09:00-00:10:00 blue background CG: Green-Sand Molds No-Bake Molds Shell Molds CASTING IN SAND MOLDS IS CLASSIFIED BASED ON THE TYPE OF SAND USED AND VARIATIONS IN THE MOLD- MAKING PROCESS. THESE VARIATIONS INCLUDE CASTING IN: GREEN-SAND MOLDS, NO-BAKE MOLDS, AND IN SHELL MOLDS. SCENE 30. CG, SUPER: Green-Sand Mold Casting tape 449, 16:04:57-16:05:12 pattern being set in green-sand mold GREEN-SAND MOLDS ARE MADE FROM A FLEXIBLE MIXTURE OF SILICA SAND, CLAY AND WATER. THE SAND IS SAID

7 Copyright 1999 Society of Manufacturing Engineers TO BE GREEN BECAUSE OF ITS MOISTURE CONTENT. SCENE 31. tape 448, 15:14:27-15:14:45 zoom in, green sand casting operation ALTHOUGH CASTING IN GREEN SAND MOLDS IS A VERSATILE PROCESS, THIN SECTIONS ARE DIFFICULT TO CAST BECAUSE THEY MAY BE ERODED BY THE MOLTEN METAL, OR THE METAL MAY COOL AND BECOME SOLID BEFORE FILLING THE SECTIONS. SCENE 32. tape 448, 15:20:24-15:20:45 cast part from green sand molds ALSO, PART TOLERANCES AND MACHINING ALLOWANCES MUST BE RATHER LIBERAL, VERY SMOOTH FINISHES ARE NOT ATTAINABLE, AND CERTAIN METALS CAN DEVELOP DEFECTS IF CAST IN MOLDS THAT CONTAIN MOISTURE. --- TOUCH BLACK --- SCENE 33. CG, SUPER: No-Bake Sand Mold Casting tape 439, 05:11:30-05:11:43 no-bake mold being produced NO-BAKE SAND MOLDS, ALSO KNOWN AS AIR-SET SAND MOLDS, ARE A MIXTURE OF SAND AND A RESIN BINDER. THIS MIXTURE IS PACKED AROUND A PATTERN AND SETS QUICKLY AT ROOM TEMPERATURE. SCENE 34. tape 439, 05:14:15-05:14:33 pouring of no-bake mold NO-BAKE SAND MOLDS ARE EXTREMELY STRONG, EROSION RESISTANT AND PROVIDE GOOD DIMENSIONAL ACCURACY AND CASTING FINISH. SCENE 35. tape 439, 05:20:17-05:20:28 no-bake molds shaken out tape 439, 05:28:59-05:29:07 tilt of reclamation unit CASTING SHAKEOUT IS EXCELLENT..., AND RECLAMATION OF THE BONDED SAND IS PRACTICAL, ALTHOUGH IT IS MORE COSTLY THAN WITH GREEN SAND.

8 Copyright 1999 Society of Manufacturing Engineers TOUCH BLACK --- SCENE 36. CG, SUPER: Shell-Mold Casting tape 447, 14:10:35-14:10:39 oven closing on pattern tape 447, 14:10:58-14:11:11 oven raising, box turned upside down tape 447, 14:11:31-14:11:42 box opening exposing shell mold, covered with oven SHELL MOLDS FOR SAND CASTING ARE PRODUCED BY HEATING A METAL PATTERN, AND THEN ROTATING IT UPSIDE DOWN. THIS EXPOSES THE PATTERN TO A MIXTURE OF FINE SILICA SAND AND A RESIN BINDER, SETTING A LAYER OF THE MIXTURE TO THE HEATED SURFACE OF THE PATTERN. SCENE 37. TO COMPLETE THE CURING PROCESS, THE COATED PATTERN IS COVERED AND BAKED. SCENE 38. tape 447, 14:10:11-14:10:18 shell stripped from pattern ONCE CURED, THE HARDENED SHELLS ARE REMOVED FROM THE PATTERN AND SERVE AS MOLD HALVES. SCENE 39. tape 447, 14:19:52-14:19:59 shell cores placed in drag tape 447, 14:20:06-14:20:19 adhesive applied to shell-mold drag, cope placed atop drag, secured SHELL CORES, WHICH ARE PRODUCED SIMILARLY, ARE PLACED WITHIN THE DRAG SIDE OF THE MOLD..., A BONDING ADHESIVE IS THEN APPLIED..., AND THE COPE SIDE OF THE MOLD IS ALIGNED AND SECURED, CREATING THE FINISHED SHELL-MOLD. SCENE 40. tape 446, 13:21:15-13:21:28 pan of shell molds THESE SHELL MOLDS CAN BE PRODUCED QUICKLY AND STORE WELL FOR EXTENDED PERIODS OF TIME. SCENE 41. tape 446, 13:18:19-13:18:42 shell-mold casting operation SHELL-MOLD CASTING IS A SEMI-PRECISION PROCESS, PERMITTING MORE INTRICATE SHAPES, CLOSER

9 Copyright 1999 Society of Manufacturing Engineers TOLERANCES AND SMOOTHER FINISHES THAN USING GREEN OR NO-BAKE MOLDS. SCENE 42. tape 446, 13:15:20-13:15:28 shell mold cast parts tape 467, 10:01:15-10:01:23 shell mold cast part tape 467, 10:02:25-10:02:35 shell mold cast part tape 467, 10:03:25-10:03:34 shell mold cast part THE SIZE OF PARTS THAT CAN BE CAST IN SHELL MOLDS IS LIMITED HOWEVER, WITH MOST CASTINGS WEIGHING LESS THAN 45 KILOGRAMS. --- TOUCH BLACK --- SCENE 43. CG, SUPER: Plaster-Mold Casting tape 435, 03:10:43-03:11:08 zoom in, casting in plaster mold CASTING IN PLASTER MOLDS IS A PRECISION PROCESS FOR ALUMINUM-ALLOY, LOW-LEAD-COPPER AND ZINC-ALLOY PARTS. FERROUS METALS ARE UNSUITABLE FOR PLASTER MOLD CASTING BECAUSE THE MOLDS CANNOT WITHSTAND THEIR HIGH MELTING TEMPERATURE. SCENE 44. tape 435, 03:13:49-03:14:00 zoom out, plaster molds and cores PLASTER MOLDS AND CORES ARE MADE LARGELY OF CALCIUM SULFATE, OR GYPSUM, AND WATER. SCENE 45. tape 435, 03:26:59-03:27:07 plaster mold being poured BESIDES CALCIUM SULFATE, OTHER MOLD INGREDIENTS MAY BE USED TO IMPROVE MOLDABILITY, REDUCE POROSITY, INCREASE STRENGTH AND/OR CONTROL CONTRACTION. SCENE 46. tape 434, 02:05:09-02:05:29 mixture poured over pattern THE MIXTURE, IN SLURRY FORM, IS POURED OVER THE PATTERN AND ALLOWED TO SET AND HARDEN. SCENE 47. tape 434, 02:06:06-02:06:13 pattern removed from plaster mold ONCE SET, THE MOLD IS SEPARATED FROM THE

10 Copyright 1999 Society of Manufacturing Engineers tape 435, 03:29:04-03:29:10 plaster mold placed in oven PATTERN..., AND BAKED TO REMOVE THE MOISTURE. SCENE 48. tape 435, 03:16:00-03:16:12 plaster mold incorporating chills THE MOLDS MAY INCORPORATE METAL INSERTS CALLED CHILLS TO SPEED SOLIDIFICATION AND ENHANCE THE STRENGTH OF THE CASTING IN LOCAL REGIONS. SCENE 49. tape 434, 02:16:25-02:16:38 casting in plaster mold PLASTER MOLDS HAVE LOW THERMAL CONDUCTIVITY SO CASTINGS TAKE LONGER TO SOLIDIFY THAN IN SAND MOLDS. SCENE 50. tape 434, 02:12:06-02:12:22 casting shaken out of plaster mold PLASTER MOLD CASTINGS ARE TYPICALLY SMALL, LESS THAN 45 KILOGRAMS BY WEIGHT, USUALLY MUCH LESS. BUT CAST SHAPES CAN BE EXTREMELY COMPLEX AND HAVE VERY THIN SECTIONS. --- TOUCH BLACK --- SCENE 51. CG, SUPER: Ceramic-Mold Casting tape 453, 21:01:14-21:01:33 ceramic mold casting operation CERAMIC-MOLD CASTING IS ALSO A PRECISION PROCESS AND IT IS SUITABLE FOR CASTING A WIDE RANGE OF FERROUS AND NONFERROUS METALS. SCENE 52. tape 454, 22:04:17-22:04:24 mold mixture being made tape 454, 22:26:55-22:27:03 mold mixture poured over pattern THE MOLD MIXTURE, IN SLURRY FORM, INCLUDES STABLE CERAMIC POWDERS, BINDERS AND GELLING AGENTS. IT IS POURED OVER A PATTERN AND SETS IN A FEW MINUTES TO A STRONG, SMOOTH AND RUBBERY GEL. SCENE 53. tape 453, 21:08:54-21:09:05

11 Copyright 1999 Society of Manufacturing Engineers mold stripped from pattern tape 453, 21:09:27-21:09:40 mold ignited, burning off binder volatiles ONCE THE MIXTURE SETS, THE PATTERN IS STRIPPED FROM THE MOLD..., AND THE MOLD IGNITED TO BURN OFF THE BINDER VOLATILES. SCENE 54. tape 454, 22:04:53-22:05:02 ceramic mold being poured with a chamotte backup THE MOLDS MAY BE ALL CERAMIC OR, TO REDUCE COST, A COMPOSITE MADE OF A CERAMIC FACING AND AN AGGREGATE MEDIA KNOWN AS CHAMOTTE. SCENE 55. tape 454, 22:25:17-22:25:22 ceramic mold cast part held, turned in hand tape 454, 22:25:52-22:25:56 ceramic mold cast part tape 454, 22:24:48-22:24:51 ceramic mold cast part tape 454, 22:26:42-22:26:46 ceramic mold cast part PARTS WEIGHING LESS THAN HALF A KILOGRAM TO SEVERAL THOUSAND KILOGRAMS CAN BE CAST TO COMPLEX SHAPES. --- FADE TO BLACK --- SCENE 56. CG: Expendable Mold/Expendable Pattern Processes white text centered on black SCENE 57. tape 453, 21:13:33-21:13:38 investment casting operation tape 468, 00:09:00-00:10:00 blue background CG: Expendable Mold/Expendable Pattern Processes Investment Casting Evaporative-Foam Casting EXPENDABLE MOLD/EXPENDABLE PATTERN PROCESSES INCLUDE: INVESTMENT CASTING, AND EVAPORATIVE-FOAM CASTING. SCENE 58. CG, SUPER: Investment Casting tape 459, 04:27:41-04:27:55 investment casting operation INVESTMENT CASTING IS A PRECISION PROCESS USING PRIMARILY CERAMIC SHELL MOLDS. SCENE 59. tape 459, 04:17:28-04:17:38 tilt of wax patterns INVESTMENT CASTING IS ALSO KNOWN AS THE LOST-WAX

12 Copyright 1999 Society of Manufacturing Engineers PROCESS BECAUSE WAX, A PRINCIPAL PATTERN MATERIAL, IS CONSUMED DURING THE MOLD MAKING PROCESS. SCENE 60. tape 459, 04:22:02-04:22:08 plastic pattern tape 459, 04:22:16-04:22:22 part produced from plastic pattern CONSUMABLE PLASTIC PATTERNS ARE ALSO USED. SCENE 61. tape 459, 04:13:30-04:13:38 injection molding of wax pattern INVESTMENT CASTING PATTERNS ARE MADE BY INJECTION MOLDING. SCENE 62. tape 459, 04:04:13-04:04:35 patterns manually assembled to tree THESE PATTERNS ARE ASSEMBLED ONTO A WAX POST CONNECTED TO A POURING CUP. THIS PATTERN ASSEMBLY, CALLED A TREE, USUALLY INCORPORATES COMPLEX RUNNER SYSTEMS TO ASSIST METAL FLOW IN THE INVESTMENT CASTING PROCESS. SCENE 63. tape 459, 04:06:51-04:07:08 tree being dipped for first time THE SHELL MOLD IS PRODUCED BY DIPPING THE PATTERN ASSEMBLY SEVERAL TIMES IN SLURRY AND ALLOWING IT TO DRY BETWEEN DIPS. SCENE 64. tape 459, 04:08:42-04:08:53 first coat covered in particles tape 459, 04:11:18-04:11:28 subsequent dip mixed with coarse particles THE FIRST SLURRY MIXTURE CONSISTS OF FINE PARTICLES FOR SMOOTHNESS. SUBSEQUENT DIPS ARE MIXED WITH COARSE PARTICLES TO QUICKLY BUILD-UP THICKNESS AND PROVIDE STRENGTH. SCENE 65. tape 459, 04:22:51-04:23:01 melt out process THE WAX IS REMOVED FROM THE MOLD BY MELT-OUT IN A FURNACE OR AUTOCLAVE.

13 Copyright 1999 Society of Manufacturing Engineers SCENE 66. tape 459, 04:25:46-04:26:05 mold fired before pouring THEN THE MOLD IS FIRED TO REMOVE MOISTURE, CURE THE CERAMIC AND TO PREHEAT IT FOR POURING. SCENE 67. BOTH FERROUS AND NONFERROUS METALS CAN BE INVESTMENT CAST. SCENE 68. tape 459, 04:18:45-04:18:54 mold being broken around casting ONCE THE METAL HAS SOLIDIFIED, THE MOLD IS BROKEN AND THE CASTING REMOVED. SCENE 69. tape 459, 04:25:08-04:25:20 investment casting operation THE MAIN ADVANTAGE OF INVESTMENT CASTING IS THE COMPLEXITY OF SHAPES THAT CAN BE CAST TO CLOSE TOLERANCES, THIN WALLS, AND SMOOTH FINISHES. SCENE 70. tape 459, 04:19:40-04:19:48 investment-cast part tape 459, 04:20:20-04:20:26 investment-cast part tape 459, 04:21:20-04:21:26 investment-cast part tape 459, 04:20:50-04:20:56 investment-cast part tape 459, 04:20:00-04:20:06 investment-cast part tape 459, 04:19:24-04:19:30 investment-cast part MOST INVESTMENT-CAST PARTS WEIGH LESS THAN FOUR AND A HALF KILOGRAMS. HOWEVER, PARTS WEIGHING OVER A HUNDRED KILOGRAMS ARE ALSO MADE. --- TOUCH BLACK --- SCENE 71. CG, SUPER: Evaporative-Foam Casting tape 455, 23:19:32-23:19:53 pouring metal into evaporative foam mold EVAPORATIVE-FOAM CASTING REFERS TO THE USE OF EXPENDABLE POLYSTYRENE-FOAM PATTERNS IN MOLDS MADE OF DRY, UNBONDED SAND. THE PROCESS IS ALSO KNOWN AS THE LOST-FOAM, OR EXPANDED-POLYSTYRENE PROCESS. SCENE 72. tape 455, 23:04:26-23:04:32

14 Copyright 1999 Society of Manufacturing Engineers pull back, single piece pattern tape 455, 23:03:23:00 still, complex pattern assembled from multiple pieces tape 455, 23:04:57-23:05:10 patterns grouped together THE PATTERN MAY BE A SINGLE PIECE..., OR, FOR COMPLEX SHAPES, AN ASSEMBLY OF MOLDED PIECES. PATTERNS ALSO CAN BE CLUSTERED IN GROUPS TO PRODUCE MULTIPLE PARTS AT A TIME. SCENE 73. tape 455, 23:08:38-23:08:48 pattern coated with slurry THE PATTERN IS COATED WITH A THIN, HIGH HEAT RESISTANT COATING, USUALLY SILICA. SCENE 74. tape 455, 23:14:13-23:14:26 sand being vibrated to compact it around pattern ONCE THE COATING IS DRY, THE PATTERN IS PLACED IN A FLASK AND SURROUNDED BY SAND, WHICH IS VIBRATED FOR COMPACTION AGAINST THE PATTERN. SCENE 75. tape 455, 23:23:29-23:23:51 pouring metal into evaporative foam mold CASTING THEN PROCEEDS WITH THE POURED METAL EVAPORATING THE POLYSTYRENE FOAM AND FILLING THE CAVITY FORMED BY THE PATTERN. SCENE 76. tape 468, 00:09:00-00:10:00 blue background CG: Single Flask Replaces Cope & Drag Cores Are Not Required Foam Patterns Are Light In Weight No Parting Line As-Cast Finish Is Smoother EVAPORATIVE-FOAM CASTING HAS SEVERAL ADVANTAGES OVER CONVENTIONAL SAND CASTING. THESE ADVANTAGES INCLUDE: A SINGLE FLASK REPLACES THE COPE AND DRAG, CORES ARE NOT REQUIRED, POLYSTYRENE-FOAM PATTERNS ARE LIGHT IN WEIGHT, THERE IS NO PARTING LINE, AND THE AS-CAST FINISH IS SMOOTHER. SCENE 77. tape 456, 01:02:30:00 still, lost foam part tape 456, 01:03:08:00 still, lost foam part tape 456, 01:03:58:00 SHAPES WITH COMPLEX EXTERNAL AND INTERNAL FEATURES CAN BE CAST IN VARIOUS IRONS, CARBON AND ALLOY

15 Copyright 1999 Society of Manufacturing Engineers still, lost foam part tape 455, 23:17:34-23:17:54 lost foam casting operation CG, SUPER: Various Irons Carbon & Alloy Steels Stainless Steel Aluminum Alloys Brass Bronze STEELS, STAINLESS STEEL, ALUMINUM ALLOYS, BRASS AND BRONZE. --- FADE TO BLACK --- SCENE 78. CG: Permanent Mold/No Pattern Casting Processes white text centered on black SCENE 79. tape 463, 07:27:05-07:27:35 machining of die tape 449, 16:17:16-16:17:26 permanent mold casting operation, mold being poured INSTEAD OF PATTERNS, THE SHAPE TO BE CAST IN PERMANENT MOLD/NO PATTERN CASTING PROCESSES IS MACHINED IN THE MOLD MATERIAL, USUALLY METAL OR GRAPHITE. MOLD COST IS HIGH BUT THE MOLD CAN BE REUSED THOUSANDS OF TIMES. SCENE 80. tape 468, 00:09:00-00:10:00 blue background CG: Permanent Mold/No Pattern Processes Permanent-Mold Casting Die Casting Centrifugal Casting PERMANENT MOLD/NO PATTERN CASTING PROCESSES INCLUDE: PERMANENT-MOLD CASTING, DIE CASTING, AND CENTRIFUGAL CASTING. SCENE 81. CG, SUPER: Permanent-Mold Casting tape 451, 18:24:17-18:24:38 permanent mold casting mold opening, ejecting part CG, SUPER: Uniform Shapes Close Tolerances Smooth Finishes PERMANENT MOLD CASTING IS A SEMI-PRECISION PROCESS WHICH, BECAUSE OF THE CHILLING EFFECT OF THE MOLDS, CAN PROVIDE SUPERIOR MECHANICAL PROPERTIES. IN ADDITION, PERMANENT MOLD CASTING CAN PRODUCE UNIFORM SHAPES, CLOSE TOLERANCES AND SMOOTH FINISHES.

16 Copyright 1999 Society of Manufacturing Engineers SCENE 82. tape 456, 02:08:19-02:08:34 permanent mold CG, SUPER: Gray Iron Carbon Steel Hot-Work Tool Steels Graphite PERMANENT MOLDS ARE USUALLY MADE OF GRAY IRON, CARBON STEEL, HOT-WORK TOOL STEELS OR GRAPHITE. SCENE 83. tape 457, 03:07:15-03:07:38 permanent mold releasing casting CG, SUPER: Aluminum Alloys Copper Alloys Magnesium Alloys Lead Alloys Zinc Alloys Gray Iron PERMANENT-MOLD CASTING IS SUITABLE FOR CASTING MANY NONFERROUS METALS, INCLUDING ALUMINUM, COPPER, MAGNESIUM, LEAD, AND ZINC ALLOYS. SOME GRAY IRON ALSO CAN BE CAST. SCENE 84. tape 456, 02:06:16-02:06:27 manual permanent mold operation tape 457, 03:01:22-03:01:48 automated permanent mold operation PERMANENT-MOLD CASTING CAN BE PERFORMED MANUALLY..., OR AUTOMATICALLY FOR LARGE PRODUCTION RUNS. SCENE 85. PERMANENT MOLDS ARE TYPICALLY PREHEATED AND MAINTAINED AT REQUIRED TEMPERATURE FOR CASTING. THIS HELPS FACILITATE METAL FLOW AND REDUCES THERMAL DAMAGE TO THE MOLD. SCENE 86. tape 456, 02:03:51-02:04:01 vertically oriented permanent mold process, mold opened tape 456, 02:20:12-02:20:30 horizontally oriented permanent mold process, mold closed and tilted THE PARTING LINE OF THE MOLD MAY BE ARRANGED VERTICALLY TO EASE REMOVAL OF THE CASTING. BUT SINCE SOME METALS ARE BETTER CAST IN HORIZONTAL MOLDS, TILTING MECHANISMS CAN REPOSITION THE MOLD VERTICALLY AFTER POURING. SCENE 87. ONCE POURED, THE CASTING IS COOLED BY AUXILIARY

17 Copyright 1999 Society of Manufacturing Engineers HEATING AND COOLING SYSTEMS. SCENE 88. tape 457, 03:05:58-03:06:04 c.u. metal core in the mold tape 456, 02:18:15-02:18:24 sand or plaster core placed in mold before closing tape 456, 02:18:32-02:18:41 closed mold being poured CORES USED FOR PERMANENT MOLD CASTING CAN BE METAL, OPERATING IN THE MOLD..., OR MADE OF SAND OR PLASTER AND PLACED IN THE MOLD BEFORE IT IS CLOSED. IF SAND OR PLASTER CORES ARE USED, THE PROCESS IS CALLED SEMIPERMANENT MOLD CASTING. SCENE 89. tape 458, 00:12:45-00:12:59 3 shots, insert placed in mold and cast INSERTS ARE ALSO USED TO VENT, COOL OR HEAT SELECTIVE SECTIONS OF THE CASTING, OR TO BE CAST IN PLACE FOR SPECIAL FEATURES. SCENE 90. tape 456, 02:04:42-02:04:49 zoom in, surface of mold being coated tape 456, 02:05:04-02:05:15 surface being coated with another lubricant INTERNAL MOLD FEATURES ARE COATED TO PROLONG MOLD LIFE, CONTROL METAL SOLIDIFICATION AND EASE CASTING RELEASE. COATINGS ARE CLASSIFIED AS INSULATIVE OR LUBRICATING. SOME COATINGS CAN PROVIDE BOTH QUALITIES. --- TOUCH BLACK --- SCENE 91. CG, SUPER: Die Casting tape 442, 08:18:36-08:18:52 die casting operation DIE CASTING IS A RAPID, HIGH PRODUCTION PROCESS FOR SIMPLE OR COMPLEX, OFTEN THIN-WALL, PRECISION PARTS. CASTINGS ARE USUALLY SMALL TO MODERATE IN SIZE AND CAST OF NONFERROUS METALS. SCENE 92. tape 450, 17:19:56-17:20:04 molten metal injected into die on horizontal machine tape 465, 01:21:04-01:21:12 THE MOLTEN METAL IS FORCED UNDER HIGH PRESSURE

18 Copyright 1999 Society of Manufacturing Engineers die casting on vertical machine INTO THE DIE OF A HORIZONTAL..., SOMETIMES VERTICAL, DIE CASTING MACHINE. SCENE 93. tape 445, 12:16:03-12:16:13 die opening, showing both stationary and movable platen, part ejected ONE DIE HALF IS ATTACHED TO A FIXED PLATEN..., THE OTHER DIE HALF TO A MOVABLE PLATEN. SCENE 94. tape 440, 06:09:18-06:09:24 single part removed from die tape 443, 09:01:56-09:02:01 multiple parts removed from die DIE-CASTING CAN PRODUCE A SINGLE PART..., OR MULTIPLE PARTS IN A SINGLE METAL CHARGE, ALSO CALLED A SHOT. SCENE 95. tape 442, 08:01:29-08:01:38 cold-chamber die casting machine tape 468, 00:09:00-00:10:00 blue background CG: Hot-Chamber Machine Cold-Chamber Machine THE TWO PRINCIPAL TYPES OF DIE CASTING MACHINES ARE: THE HOT-CHAMBER MACHINE, AND THE COLD-CHAMBER MACHINE. SCENE 96. tape 445, 12:04:22-12:04:36 hot-chamber die casting machine CG, SUPER: Hot-Chamber Machine THE HOT-CHAMBER MACHINE IS USED MAINLY FOR DIE- CASTING ZINC AND OTHER METALS OF LOW-MELTING TEMPERATURE. HOWEVER, IT IS ALSO USED TO DIE-CAST MAGNESIUM. SCENE 97. tape 441, 07:11:06-07:11:25 zoom in, holding furnace and injection system THE MACHINE'S SHOT END HAS A HOLDING POT WHICH IS A RESERVOIR FOR THE MOLTEN METAL, AND AN INJECTION SYSTEM FOR TRANSFERRING THE METAL TO THE DIE. SCENE 98. tape 442, 08:07:37-08:07:48 c.u., zoom out plunger descending then rising tape 442, 08:08:34-08:08:44 plunger descending THE PLUNGER END OF THE INJECTION SYSTEM AND THE LOWER PORTION OF THE TRANSFER PIPE ARE SUBMERGED

19 Copyright 1999 Society of Manufacturing Engineers IN THE MOLTEN METAL. WHEN THE PLUNGER RISES, A CHARGE OF METAL ENTERS THE PIPE THROUGH A SUBMERGED PORT. WHEN THE PLUNGER DESCENDS, IT CLOSES THE PORT AND DRIVES THE CHARGE INTO THE DIE, FORMING THE PART. SCENE 99. CG, SUPER: Cold-Chamber Machine tape 450, 17:02:12-17:02:22 cold-chamber die casting machine THE COLD-CHAMBER MACHINE IS USED PRIMARILY TO DIE- CAST THE HIGHER TEMPERATURE ALUMINUM, MAGNESIUM, AND COPPER ALLOYS. SCENE 100. tape 444, 11:14:40-11:15:08 zoom in from ladle system to pouring of shot IN THE COLD-CHAMBER MACHINE, THE CHARGE IS SUPPLIED BY LADLE OR FEED SYSTEM FROM AN EXTERNAL FURNACE SOURCE. THE PLUNGER AND METAL-TRANSFER PIPE ARE NOT SUBMERGED IN THE MOLTEN METAL. SCENE 101. THE CHARGE IS POURED AHEAD OF THE PLUNGER FACE THROUGH A PORT IN THE PIPE. AS THE PLUNGER ADVANCES, IT CLOSES THE PORT AND DRIVES THE MOLTEN METAL INTO THE DIE. SCENE 102. tape 450, 17:08:39-17:08:48 casting released WHEN THE METAL HAS SOLIDIFIED, THE CASTING IS RELEASED AND THE CYCLE REPEATS. SCENE 103. tape 450, 17:18:00-17:18:13 casting being trimmed in trim die ONCE RELEASED, THE EXCESS METAL IS TRIMMED FROM THE CASTING. --- TOUCH BLACK ---

20 Copyright 1999 Society of Manufacturing Engineers SCENE 104. CG, SUPER: Centrifugal Casting tape 461, 05:18:45-05:19:07 semi-centrifugal casting operation tape 461, 05:20:57-05:21:10 casting pulled from semicentrifugal mold CENTRIFUGAL CASTING IS THE SOLIDIFICATION OF MOLTEN METAL UNDER THE CENTRIFUGAL FORCE GENERATED BY A RAPIDLY ROTATING PERMANENT OR EXPENDABLE MOLD. THE HIGH FORCE TYPICALLY RESULTS IN DENSER CASTINGS THAN ARE PRODUCED IN STATIC MOLDS. VIRTUALLY ALL METALS CAN BE CENTRIFUGALLY CAST. SCENE 105. tape 461, 05:05:42-05:05:50 semi-centrifugal casting operation tape 468, 00:09:00-00:10:00 blue background CG: True Centrifugal Casting Semi-Centrifugal Casting THERE ARE SEVERAL TYPES OF CENTRIFUGAL CASTING METHODS, INCLUDING: TRUE CENTRIFUGAL CASTING, AND SEMI-CENTRIFUGAL CASTING. SCENE 106. CG, SUPER: True Centrifugal Casting tape 460, 01:01:20-01:01:27 2 shots, pouring metal, mold turning tape 460, 01:05:10-01:05:12 mold turning after pouring, glowing red, loop image tape 460, 01:03:13-01:03:17 2 shots, tubes tape 460, 01:03:20-01:03:32 2 shots, tubes IN TRUE CENTRIFUGAL CASTING, METAL IS POURED INTO A MOLD ROTATED IN THE HORIZONTAL OR VERTICAL PLANE ABOUT ITS CENTRAL AXIS. THIS METHOD IS USED TO PRODUCE LARGE-DIAMETER TUBE, BIMETAL TUBE, AND ROLLS OF VIRTUALLY ANY WALL THICKNESS AND LENGTH. SCENE 107. tape 460, 01:21:46-01:21:52 zoom out, true centrifugal molds standing on end tape 460, 01:00:24-01:00:29 zoom out, man cleaning inside of tube OUTSIDE DIAMETER AND LENGTH ARE CONTROLLED BY THE MOLD, INSIDE DIAMETER IS CONTROLLED BY THE AMOUNT OF METAL POURED. SCENE 108. CG, SUPER: Semi-Centrifugal Casting tape 461, 05:09:15-05:09:35 semi-centrifugal casting operation IN SEMI-CENTRIFUGAL CASTING, THE MOLD SURROUNDS THE CASTING AND CONTROLS THE SHAPE BEING CAST. THE MOLD TYPICALLY ROTATES HORIZONTALLY, AND THE METAL

21 Copyright 1999 Society of Manufacturing Engineers IS USUALLY POURED THROUGH A CENTRAL GATE. CORING IS REQUIRED IF THE SHAPE IS HOLLOW. --- FADE TO BLACK --- SCENE 109. CG: Review white text on black tape 63, 12:00:15-12:03:49 review music LET'S REVIEW THE MATERIAL CONTAINED IN THIS VIDEOTAPE. SCENE 110. tape 447, 14:23:31-14:23:40 casting being poured tape 450, 17:19:54-17:20:02 die casting being ejected CASTING IS THE SOLIDIFICATION OF MOLTEN METAL THAT IS POURED INTO A MOLD..., OR INJECTED INTO A DIE HAVING A CAVITY IN THE SHAPE OF THE DESIRED PART. SCENE 111. tape 435, 03:08:19-03:08:26 zoom out, castings surface tape 468, 00:00:50-00:00:58 GRAPHIC: cutaway of casting showing isotropic grain structure tape 468, 00:01:15-00:01:23 GRAPHIC: cutaway of wrought part showing directional properties CASTINGS TYPICALLY HAVE AN ISOTROPIC, OR UNIFORM, GRAIN STRUCTURE AND PROPERTIES, RATHER THAN THE DIRECTIONAL GRAIN STRUCTURE AND PROPERTIES OF WROUGHT METALS. SCENE 112. tape 435, 03:22:00-03:22:14 casting of prototype tape 446, 13:26:20-13:26:30 production casting CASTING IS USUALLY THE QUICKEST WAY TO SHAPE METAL INTO A PART. BECAUSE OF THIS, CASTING IS USED BOTH FOR PROTOTYPING..., AS WELL AS PRODUCTION OF LARGE QUANTITY PARTS. SCENE 113. tape 438, 04:03:49-04:04:10 pattern covered in sand CG, SUPER: Wood Plastic Metal tape 454, 22:09:59-22:10:22 investment casting during pour CG, SUPER: Wax Plastic MANY CASTING PROCESSES UTILIZE PATTERNS. THESE ARE USED TO FORM THE CAVITY OF THE MOLD INTO THE SHAPE TO BE CAST. REUSABLE PATTERNS ARE MADE OF WOOD, PLASTIC,

22 Copyright 1999 Society of Manufacturing Engineers Polystyrene Foam OR METAL. EXPENDABLE PATTERNS, SO CALLED BECAUSE THEY'RE CONSUMED IN THE MOLD MAKING PROCESS, OR BY THE POURED METAL DURING CASTING, ARE MADE OF WAX, PLASTIC, OR POLYSTYRENE FOAM, DEPENDING ON THE PROCESS. SCENE 114. tape 439, 05:06:21-05:06:40 core placed in mold tape 438, 04:15:28-04:15:33 core produced in core box tape 446, 13:02:41-13:02:50 cores produced on machine CORES ARE NEEDED TO CREATE THE RECESSES, UNDERCUTS AND INTERIOR CAVITIES THAT ARE OFTEN REQUIRED FOR CASTINGS. CORES ARE PRODUCED FROM VARIOUS MATERIALS USING A VARIETY OF PRODUCTION METHODS. SCENE 115. tape 449, 16:15:08-16:15:15 casting process tape 468, 00:09:00-00:10:00 blue background CG: Casting Process Classifications: Expendable Mold/Reusable Pattern Expendable Mold/Expendable Pattern Permanent Mold/No Pattern CASTING PROCESSES CAN BE GROUPED INTO THREE CLASSIFICATIONS: EXPENDABLE MOLD/REUSABLE PATTERN PROCESSES, EXPENDABLE MOLD/EXPENDABLE PATTERN PROCESSES, AND PERMANENT MOLD/NO PATTERN PROCESSES. SCENE 116. tape 451, 18:17:03-18:17:33 zoom out, casting metal flowing into sand mold, up in risers CG, SUPER: Sand-Mold Casting tape 435, 03:10:43-03:11:08 zoom in, casting in plaster mold CG, SUPER: Plaster-Mold Casting tape 453, 21:01:14-21:01:33 ceramic mold casting operation CG, SUPER: Ceramic-Mold Casting EXPENDABLE MOLD/REUSABLE PATTERN PROCESSES INCLUDE: SAND-MOLD CASTING..., PLASTER-MOLD CASTING..., AND CERAMIC-MOLD CASTING. SCENE 117. tape 453, 21:10:36-21:10:48 investment casting process CG, SUPER: Investment Casting tape 455, 23:19:32-23:19:53 pouring metal into evaporative foam mold EXPENDABLE MOLD/EXPENDABLE PATTERN PROCESSES INCLUDE:

23 Copyright 1999 Society of Manufacturing Engineers CG, SUPER: Evaporative-Foam Casting INVESTMENT CASTING..., AND EVAPORATIVE-FOAM CASTING. SCENE 118. tape 449, 16:17:16-16:17:26 permanent mold casting operation, mold being poured CG, SUPER: Permanent-Mold Casting tape 442, 08:18:36-08:18:52 die casting operation CG, SUPER: Die Casting tape 461, 05:18:45-05:19:07 semi-centrifugal casting operation CG, SUPER: Centrifugal Casting PERMANENT MOLD/NO PATTERN CASTING PROCESSES INCLUDE: PERMANENT-MOLD CASTING..., DIE CASTING..., AND CENTRIFUGAL CASTING. --- FADE TO BLACK --- SCENE 119. CG: credit roll white text on black, fade up mid-screen Produced By: The Society Of Manufacturing Engineers Executive Producer: Steven Bollinger Producer/Director/Cameraman: Jerome T. Cook Written By: John A. Vaccari Graphics By: Jerome T. Cook Dennis Summers Equipment Access Provided By: BarronCast, Inc. Bimac Corporation Brillcast, Inc. Cascade Die Casting Group, Inc. Hackett Brass Foundry

24 Copyright 1999 Society of Manufacturing Engineers Hiler Industries Kuhlman Casting Company MacDonald Industrial Products Metalloy Corporation Northfield Manufacturing, Inc. Reliable Castings Corporation Ross Aluminum Foundries Willard Industries, Inc. Video Footage Provided By: Aurora Metals Ladish Co., Inc. THT Presses, Inc. Technical & Editorial Consulting: Donald Blair, Talbot Associates, Inc. Duncan Talbot III, Talbot Associates, Inc. Production Assistance Provided By: Steve Bollinger Veronica Morris Julie Moyer Lance Rosol Video Editing: Communicore Visual Communications SCENE 120. CG: disclaimer white text centered on black Some machinery in this program had safety equipment removed to allow better recording of certain processes. Always read the safety information provided in the manufacturers' manual before machine operation. SCENE 121. tape 40, 01:00:00-01:00:12 SME logo