Types of Casting

Different Types of Casting Process
（1）Sand Moulding.
（2）Centrifugal casting.
（3）Die casting.
（4）Investment casting.
（5）Shell Moulding
Centrifugal Casting
The centrifugal casting method is the method to
produce pipes by pouring molten metal into a rapidly
spinning cylindrical mold in which centrifugal force
from the rotation exerts pressure on the molten metal.
In centrifugal casting molten metal is poured into a spinning
die, which can rotate on a vertical axis (vertical centrifugal casting)
or horizontal axis (horizontal centrifugal casting) depending on the
configuration of the part. Ring and cylinder type shapes are made
by vertical centrifugal casting while tubular shapes are made by
horizontal centrifugal casting. Either process can be used to
produce multiple parts from a single casting.
High centrifugal force applied to the molten metal in the
spinning die causes less dense material such as oxides and
impurities to “float” to the inner diameter (I.D.) where they
concentrate and are removed by machining. Solidification is
managed directionally under pressure from the outer diameter
(O.D.) to the I.D
Centrifugal casting is carried out as follows:
• The mold wall is coated by a refractory ceramic coating (applying
ceramic slurry, spinning, drying and baking).
• Starting rotation of the mold at a predetermined speed.
• Pouring a molten metal directly into the mold (no gating system is
employed).
• The mold is stopped after the casting has solidified.
• Extraction of the casting from the mold.
Advantages of Centrifugal casting process :
 Castings acquire high density, high mechanical strength and
fine grained structure
 Inclusions and impurities are lighter
 Gates and risers are not needed
 High output
 Formation of hollow interiors without cores
Disadvantages of Centrifugal casting process :
 An inaccurate diameter of the inner surface of the casting

 Not all alloys can be cast in this way.
Applications of Centrifugal casting process :
 For casting pipe, bushings, gears, flywheel etc.

Die Casting
Die casting is a process, in which the molten metal is
injected into the mold cavity at an increased pressure up to
30,000 psi (200 MPa).
The reusable steel mold used in the die casting process
is called a die.
Advantages of Die casting process :
High productivity.
Good dimensional accuracy.
Good surface finish: 2-100 µinch (0.5-2.5 µm) Ra.
Thin wall parts may be cast.
Very economical process at high volume production.
Fine Grain structure and good mechanical properties are
achieved.
Intricate shapes may be cast.
Small size parts may be produced.
Disadvantages of Die casting process :

 Not applicable for high melting point metals and alloys
(eg. steels)
Large parts can not be cast.
High die cost.
Investment (lost wax) Casting
Investment casting is an industrial process based on lost-
wax casting, one of the oldest known metal-forming techniques.
Investment casting is so named because the process invests
(surrounds) the pattern with refractory material to make a
mould, and a molten substance is cast into the mold.
Investment casting process
The investment casting process uses expendable patterns made of investment casting wax.
1. The wax patterns are commonly prepared by injection molding technology
which involves injection of wax into a prefabricated die having the same
geometry of the cavity as the desired cast part.
2. The wax patterns are then attached to a gating system (a set of channels
through which a molten metal flows to the mold cavity).
3. The next stage is the shell building - the wax assembly is immersed into
refractory ceramic slurry of hardening mixtures followed by drying. This
operation is repeatedly carried out resulting in formation of a solid ceramic
shell of 1/4” -3/8” (6mm – 9mm) thick.
4. The next stage is dewax. At this stage the assembly is heated in an autoclave
where the most of the wax is melted out. This operation is followed by burning
out the residual wax in a furnace.
5. The mold is then preheated to 1830°F (1000°C). Now the mold is ready for
filling with a molten metal.
6. Casting stage is conventional operation involving pouring a molten metal into
the shell through the gating system.
7. After the metal has solidified and cooled to a desired temperature, the shell is
broken and the castings are cut away from the gates and sprue.
8. The last stage is finishing carried out by sandblasting or machining.
Advantages of Investment casting process :
Excellent surface finish.
Tight dimensional tolerances.
Complex and intricate shapes may be produced.
Capability to cast thin walls.
Wide variety of metals and alloys (ferrous and non-ferrous) may
be cast.
Low material waste.
Disadvantages of Investment casting process :
 Individual pattern is required for each casting.

 Limited casting dimensions.
 Relatively high cost (tooling cost, labor cost).
Shell Moulding
Shell Mould Casting is a metal casting process similar
to sand casting, in that molten metal is poured into an
expendable sand-based mould. However, in shell mould
casting, the mould is a thin-walled shell created by
applying a sand-resin mixture around a pattern.
Shell Moulding Process
Advantages of Shell Moulding :
Good surface quality
Thin wall thickness and complex castings may be produced.
 better dimensional accuracy
Less manpower and molding skill requirements
Disadvantages of Shell Moulding :
 High production costs

 High pattern costs
 Size and weight limitation

Types of Casting

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Types of Casting

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Different Types of Casting Process

 An inaccurate diameter of the inner surface of the casting

Applications of Centrifugal casting process :

 For casting pipe, bushings, gears, flywheel etc.

Disadvantages of Die casting process :

Disadvantages of Investment casting process :

 Individual pattern is required for each casting.

Disadvantages of Shell Moulding :

 High production costs

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