Scribd Logo
Upload

Welcome to Scribd!

  • 378 views

    Chapter 7 - Casting Process

    Uploaded by

    Ijal Haizal
    The document discusses different casting processes including sand casting, lost wax/investment casting, and pressure die casting. Sand casting uses molds made of sand and can produce components of various sizes and metals at low cost. Lost wax/investment casting uses wax patterns to form molds and is suitable for producing small, complex parts. Pressure die casting forces molten metal into steel molds under high pressure, allowing for complex shapes and smooth surfaces in materials with low melting points like aluminum.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Chapter 7 - Casting Process

    Uploaded by

    Ijal Haizal
    378 views34 pages
    The document discusses different casting processes including sand casting, lost wax/investment casting, and pressure die casting. Sand casting uses molds made of sand and can produce components of various sizes and metals at low cost. Lost wax/investment casting uses wax patterns to form molds and is suitable for producing small, complex parts. Pressure die casting forces molten metal into steel molds under high pressure, allowing for complex shapes and smooth surfaces in materials with low melting points like aluminum.

    Original Description:

    eee

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses different casting processes including sand casting, lost wax/investment casting, and pressure die casting. Sand casting uses molds made of sand and can produce components of various sizes and metals at low cost. Lost wax/investment casting uses wax patterns to form molds and is suitable for producing small, complex parts. Pressure die casting forces molten metal into steel molds under high pressure, allowing for complex shapes and smooth surfaces in materials with low melting points like aluminum.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    378 views34 pages

    Chapter 7 - Casting Process

    Uploaded by

    Ijal Haizal
    The document discusses different casting processes including sand casting, lost wax/investment casting, and pressure die casting. Sand casting uses molds made of sand and can produce components of various sizes and metals at low cost. Lost wax/investment casting uses wax patterns to form molds and is suitable for producing small, complex parts. Pressure die casting forces molten metal into steel molds under high pressure, allowing for complex shapes and smooth surfaces in materials with low melting points like aluminum.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 34
    At a glance
    Powered by AI
    The key takeaways are that there are different casting processes like sand casting, lost wax casting, and pressure die casting. Casting involves pouring molten material into molds to create components. Factors like mold design, cooling rates, and defects are important to consider.

    The different types of casting processes discussed are sand casting, lost wax/investment casting, and pressure die casting.

    Some advantages of sand casting are that it can produce parts in any size with a low cost mold and for almost all metals. Some disadvantages include possible defects like sand inclusions, misruns, and porosity from gas.

    CHAPTER 7 : CASTING PROCESS

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    CONTENTS
    1 2

    Sand Casting

    Lost Wax / Investment Casting Pressure Die Casting

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    CASTING PROCESS
    a method of producing a device or component a production process in which the materials needed, heated until molten and then poured into molds and allowed to solidify by cooling its own before being released for the machine to be cleaned or re can be categorized according to how filling molten metal into a mold and the mold material types used

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    can produce complex components or complicated very small-sized goods until sized items can be produced economically

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    BASIC ASPECTS CASTING PROCESS


    1. MOLD CAVITY (CAVITY) -Space filled with molten metal mold must be able to withstand the pressure or weight of the molten metal is filled into it 2. SMELTING PROCESS - Must be able to produce molten material at the desired temperature 3. POURING TECHNIQUE -should use appropriate techniques space, cavity or passage to remove air and gas during casting shall be provided

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    BASIC ASPECTS CASTING PROCESS


    4. SOLIDIFICATION PROCESS -Consideration in relation to the contraction and cooling rates should be noted when designing the mold -designs that do not fit the mold caused a range of defects 5. REMOVING THE CAST METAL -Can be removed easily, especially when using the permanent mold 6. CLEANING, INSPECTION AND TESTING -To ensure it is of high quality or meet the specifications

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    SAND CASTING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    SAND CASTING
    The most popular casting process since time immemorial to the present a mold produced by compacting molding sands This mold is divided into two or more parts called "COPE" and "DRAG" a feed system that involves the construction of a feed channel (runner), gate (gate) and risers (riser) was built in the mold casting hollow (hollow castings) can be made by placing a core (core) in the mold

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    suitable for producing cast various forms for almost all metals in any size with a low cost mold defects that may occur: Inclusion sand - Less messy mold grafting Cool cover - Casting at a temperature that is too low hot tearing - Inappropriate mold design porosity gas - The result of steam when there is moisture, low permeability mold and chemical reactions.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    SAND MOLDING
    - Sand must be able to meet four basic requirements: Refractory nature To maintain shape when compacted in a mold Permeability Realibility -Most of the casting operation using silica sand (SiO2) and red sand -It is unable to resist high temperatures, has a range of sizes and a large range of grain shape

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    - It also can be used repeatedly in a long time but do not have the feature to maintain good form - To obtain the required quality, clay is mixed up to 30% of the total weight of the mixture - Total mixed clay is different depending on the type and use of sand molds

    CHAPTER 7: CASTING PROCESS

    EQUIPMENT SAND CASTING

    JF302 MATERIAL TECHNOLOGY 1

    1. SAND mold - consisting of 85% silica sand, clay 8% and 7% water. 2. Mold box, a container used for making molds in it. Box mold comprising mold box above (Cope) and the mold box (Drag). It is made of wood or metal. 3. PATTERN - is a model or replica products made according to the original product in the form of castings. Made of wood, metal, plastic, wax and plaster. 4. CORE - to produce a mold cavity mold on the inside of casting products. Made of plaster, metal or ceramic. 5. BELLOWS - used to produce wind to produce grains of sand are on the ronggan mold or mold.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    6. BAR roller - used to smooth sand in the top or bottom of the mold box. Made of steel. 7. Spatula - for mold finishing work such as repairing a damaged mold, groove metal flow, make additions or penguarangan on the mold. 8. Casting spoon - used to repair minor damage to the mold cavity and groove metal flow. 9. Ram - used to compact the sand when making molds. Made of wood or metal. 10.WIRE vents - ventilation is used to produce pores in order to produce heat and gas contained with in the mold.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    11.DUST BAGS - filled with the powder to be sprinkled separation between the surface of the mold box up or down. 12.SPRUE - is used to form the inlet and outlet of the molten metal. 13.RISERS SCREW PATTERN - used to draw out the pattern from the sand. 14.DIPPER PROP - to remove the prop or impurities that float on the surface of the molten metal. 15.TOOL PENYAHGAS - to remove gases trapped in the molten metal.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP PROCESSING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    LOST WAX / INVESTMENT CASTING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    CANDLE CASTING LOST / INVESTMENT


    Have unique characteristics and can produce complex components Can produce components with very small tolerances Using this type of aggregate and binder molding the same Has two variants, namely by using the shell mold and techniques

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEPS PROCESSING
    STEP 1 Patterns generated using paraffin wax-like, beeswax, and resin acrawax Wax pattern is dipped into the concentrated heat-resistant coating material to produce a smooth surface on the inside of the mold wall

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 2 Pattern wax coated heat-resistant material is placed into a container of metal mold Melting material (material hardener and silica sand) poured into a mold and allowed to harden former in overall container mold for forming mold

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 3 Wax mold is heated in a furnace at a temperature range of 100 C to 200 C Candlestick patterns are melting and flowing out to produce a mold cavity.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 4 Mold is removed from the furnace and reversed Molten metal is poured into the mold cavity When the molten metal has solidified, casting products may be released.

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEPS PROCESSING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    PRESSURE DIE CASTING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    PRESSURE DIE-CASTING
    for materials that have a low melting temperature carried out by means of injection of a liquid metal into metal molds under pressure action high pressure 0.7MPa - 700MPa used to force molten metal into the mold cavity higher cooling rate can produce a uniform crystal structure with fine grain

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    properties such as strength and yield point is better mold made of special steel and are known as die suitable to produce large-scale can produce complex-shaped and have a smooth surface finish Examples such as automotive components, toys, jewelry and household goods

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEPS PROCESSING
    STEP 1 Molten metal is inserted into the chamber

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 2 Piston pushed in molten metal into the die cavity

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 3 Core released and die manufacturers moving back

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEP 4 Pin pusher will push out of the die casting products

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEPS PROCESSING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    STEPS PROCESSING

    CHAPTER 7: CASTING PROCESS

    JF302 MATERIAL TECHNOLOGY 1

    COMPARATIVE CASTING METHODS


    Sand casting Any Pressure Die Casting Based alloy Cu, Zn, Al Very Good Wax Casting Any

    Alloy / metal can be poured / processed Comparative mechanical properties surface finish Possibility to form complex shapes

    Medium

    Good

    Medium Good

    Very Good Very Good

    Very Good Very Good

    You might also like