Casting Processes

ver. 2

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Types of Parts Made

Engine blocks Pipes Jewelry Fire hydrants Fi h d t

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Complex, 3-D Complex 3 D shapes

Near net shape p Low scrap Relatively quick process Intricate shapes Large hollow shapes No limit to size Reasonable to good surface finish
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Processes
Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Metals processed by casting

Sand casting 60% Investment casting 7% g Die casting 9% Permanent mold casting 11% Centrifugal casting 7% Shell mold casting 6%

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Breakdown of Castings
Ingots for bulk deformation processing 85% Cast to near net shape - 15%

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Ingots
Iron or steel molds Water-cooled molds Water cooled Continuous casting

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

Shapes
Permanent mold (cavity)
die casting hot chamber cold chamber ld h b

Expendable Molds
sand shell slurry investment
lost wax lost foam

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

Shapes
Centrifugal
pipes spinning

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

Capabilities
Dimensions
sand casting - as large as you like small - 1 mm or so

Tolerances
0 005 in to 0 1 in 0.005 0.1

Surface finish
di casting 8 16 micro-inches (1 3 m) die ti 8-16 i i h (1-3 ) sand casting - 500 micro-inches (10-25 m)
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Casting Steps
quick route from raw material to finished product

Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Melting
Raw material (charge)
scrap alloying materials scrap,
Heat

Furnace Atmosphere

Atmosphere Heating

Raw materials

Air (oxygen), vacuum inert gas (argon) (oxygen) vacuum, External - electric gas oil electric, gas, Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron mix

Furnace material
refractory ceramics
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Furnaces

Blast furnace

Basic Oxygen Furnace

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Furnaces

Electric Arc Furnace

Oxygen-Fuel, Oxygen Lance Furnace

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

Furnaces

Induction Furnace

Electric Furnace

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Sand Casting g

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Sand Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Sand Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Sand Casting Steps

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Sand Cast Parts

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Permanent Mold Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Low Pressure Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Die Casting ( g p g (high pressure) )

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Die Casting Machine

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Die Casting

Cold chamber

Hot chamber

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Die Casting Part Example

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Continuous Casting

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Investment Casting C ti

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Investment (top) and Conventional Castings

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Lost Foam Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Lost Foam Castings

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Centrifugal Casting

horizontal

sand-lined mold g casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

vertical
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Centrifugal Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Pipe Casting Process

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Squeeze Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Directional Solidification

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Vacuum Casting

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Casting Characteristics
Table 5.6 Typical materials cast
All All

Weig ht (kg)

Process
Sand Shell Expendable E pendable mold pattern

Minimum
0.05 0.05

Maximum
No limit 100+

Typical surface finish (micron, Ra)

5-25 1-3

Section thickness (mm) Shape complexity Dimensional * accuracy*

1-2 2-3 3 2

Porosity*
4 4

Minimum
3 2

Maximum
No limit --

All Nonferrou Plaster s (Al, Mg, mold Zn, Cu) All (High melting Investment pt.) Permanent mold All Nonferrou s (Al Mg (Al, Mg, Die Zn, Cu) Centrifugal All

0.05

No limit

5-20

No limit

0.05

50+

1-2

1-2

--

0.005 0.5

100+ 300

1-3 2-3

3 2-3

1 3-4

1 1

1 2

75 50

<0.05 50 1-2 1-2 3-4 1 -5000+ 2-10 1-2 3-4 3 *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods used.

0.5 2

12 100

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Microstructure

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Microstructure - Dendrites

Finer structure at walls Grains / dendrites grow to center

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Grains on Willie Bs head Bs

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Microstructure - Dendrites

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Fluidity

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Casting Defects - Porosity

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Casting Defects

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Shrinkage
TABLE 5.1 Volumetric solidification contraction (%) 6.6 6.3 3.8 2.53 4 4.9 Volumetric solidification contraction (%) 4.5 4 Expansion to 2.5 4.2 45.5 6.5

Metal or alloy Aluminum Al4.5%Cu Al12%Si Carbon steel 1% carbon steel Copper Source: After R. A. Flinn.

Metal or alloy 70%Cu30%Zn 90%Cu10%Al Gray iron g Magnesium White iron Zinc

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Differential Cooling
Transition between thicker and thinner sections can lead to porosity p y

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Pipe Defect
D t shrinkage giving rise t Due to h i k i i i to a funnel-like cavity Solutions
insulate top (glass wool) heat top (exothermic mixture thermit)

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Defects - Hot Tears

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Chills

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Design Rules Summary

Uniform wall thickness Flat parting lines Gradual thickness transitions D ft for removal Draft f l
tapers: 0.5 to 2 degrees

Surface of mold gives surface of part

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Sand Casting Rules

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Casting costs
TABLE 5.10 Cost Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M *L l L, low; M medium; H hi h M, di H, high. Equipment L M-H M L-M M H H Labor L M LM LM MH H LM LM LM Production rate (Pc/hr) <20 20 <50 <10 <1000 <60 <200 <50

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006

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Process economics

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