Lec 2 Fundamental of Casting 1

Mech.
Eng. Dept.
Lecture 2
16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Production Technology 2 Mech.
Eng. Dept.
Fundamentals of Metal
Casting
This lecture notes includes not all the study material,
it represent a guidelines for the covered topics.
** The study from the reference books is essential.
16MECH03C: Production Technology 2 Dr. Mohamed Zaky 2

Mech.
Eng. Dept.
Text Books
1.Manufacturing Engineering and Technology,
Serope Kalpakjian, Steven R. Schmid Pearson
Education, Seventh Edition.
2.Fundamentals-of-modern-manufacturing,
Mikell.P.Groover 4th-edition.
3.Foundry technology, Peter Beeley, Second edition

2001.

Mech.
Fundamentals of Metal Casting Eng. Dept.
1 Overview of Casting Technology

1.1 Casting Processes
1.2 Sand-Casting Molds
2 Heating and Pouring
2.1 Heating the Metal
2.2 Pouring the Molten Metal
2.3 Engineering Analysis of Pouring
2.4 Fluidity
3 Solidification and Cooling
3.1 Solidification of Metals
3.2 Solidification Time
3.3 Shrinkage
3.4 Directional Solidification
3.5 Riser Design
16MECH03C: Production Technology 2 Dr. Mohamed Zaky 4

Mech.
Casting Eng. Dept.
Processes of making cast product in moulds

formed in sand or some other materials.
Process in which molten metal flows by

gravity or other force into a mold where it
solidifies in the shape of the mold cavity.
The term casting also applies to the part

made in the process

Advantages of Casting Mech.
Eng. Dept.
1. Design advantages
Size up to 200 ton can be produced also size of few
grams in one step.
Complexity: simple and complex geometries curved
inside or outside can be produced.
Weight saving: Producing products in net shape or
near net shape.
Production of prototypes.
Wide range of cast properties.
Mech.
Advantages of Casting Eng. Dept.
2. Advantages of Casting Process

Low cost
Dimensional accuracy up to +_ 0.1mm tolerance
Versatility in Production: Jobbing work and /or mass
production.
3. Metallurgical advantages
Fibrous structure existing in rolled or forged product
is not existing in casting
Grain Size can be controlled through solidification
Density: highly dense material such as deformed can
be produced
Disadvantages of Casting Mech.
Eng. Dept.
The casting process sometimes is not cost effective if

small number of cast units are required
Some products may have defects such as internal
porosity, shrinkage and hot tear.
Some alloys or metals have very high melting points
that can not be produced by casting
Some alloys or metals have very low castability
Cast structures generally coarse
Usually the product have rough surface finish(Sand
casting)
Safety hazards to workers due to hot molten metals
Parts Made by Casting Mech.
Eng. Dept.
Big parts
Engine blocks and heads for automotive
vehicles, wood burning stoves, machine
frames, railway wheels, pipes, church bells,
big statues, pump housings
Small parts
Dental crowns, jewelry, small statues, frying
pans
All varieties of metals can be cast, ferrous and
nonferrous.
Mech.
Overview of Casting Technology Eng. Dept.
Casting is usually performed in a foundry

Foundry = factory equipped for making molds,
melting and handling molten metal,
performing the casting process, and cleaning
the finished casting
Workers who perform casting are called
foundrymen

Casting Process main steps Mech.
Eng. Dept.
1. Pattern Making
2. Core making
3. Mould Making
4. Melting and pouring
5. Machining and inspection

Mech.
Units of the Foundry Eng. Dept.
Pattern and corebox Core making Sand Station

making
Sand mixing
Melting Unit Moulding
Melting Charge Pouring
Bad Product Shakout of mould Old Sand
Good Product
Machining
Inspection
Final Good Product

Mech.
The Mold in Casting Eng. Dept.
Contains cavity whose geometry determines

part shape
Actual size and shape of cavity must be slightly oversized
to allow for shrinkage of metal during solidification and
cooling
Molds are made of a variety of materials, including sand,
plaster, ceramic, and metal

Mech.
The Mold in Casting Eng. Dept.

Mech.
Open and closed casting mold Eng. Dept.
Open mold, simply a closed mold, for more complex geometry,

container in the shape requires a gating system (passageway)
of the desired part leading into the cavity.
16MECH03C: Production Technology 2 15

Dr. Mohamed Zaky
Mech.
Two Categories of Casting Processes Eng. Dept.
1. Expendable mold processes uses an

expendable mold which must be destroyed to
remove casting
Mold materials: sand, plaster, and similar materials, plus
binders
2. Permanent mold processes uses a
permanent mold which can be used over and
over to produce many castings
Made of metal (or, less commonly, a ceramic refractory
material

Advantages and Disadvantages Mech.
Eng. Dept.
More intricate geometries are possible with

expendable mold processes.
Part shapes in permanent mold processes are
limited by the need to open the mold.
Permanent mold processes are more
economic in high production operations.

Heating the Metal Mech.
Eng. Dept.
Heating furnaces are used to heat the metal

to molten temperature sufficient for casting
The heat required is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired
temperature for pouring

Mech.
Heating the Metal Eng. Dept.
The heat energy required from the furnace is the sum of:
(1) the heat to raise 2) the heat of fusion (3) the heat to raise the
the temperature to to convert it from molten metal to the desired
the melting point solid to liquid temperature for pouring.
where H = total heat required to raise the temperature of the metal to the
pouring temperature, J ; density; g /cm3 ; Cs = weight specific heat for the
solid metal, J/g-C; Tm = melting temperature of the metal, C; To = starting
temperature - usually ambient, C; Hf = heat of fusion, J/g ; Cl= weight
specific heat of the liquid metal, J/g-C ;Tp = pouring temperature, C; and V =
volume of metal being heated, cm3.
Dr. Mohamed Zaky
Mech.
Pouring the Molten Metal Eng. Dept.
For this step to be successful, metal must flow

into all regions of the mold, most importantly
the main cavity, before solidifying
Factors that determine success
Pouring temperature
Pouring rate
Turbulence

Mech.
Fluidity of molten metal Eng. Dept.
Castability of different
metals and alloys
E= excellent, G = good,
F= fair, D= difficult
Spiral
A test method for fluidity using a spiral mold
mold. The fluidity index is the length of
the solidified metal in the spiral passage.
The greater the length of the solidified
metal, the greater is its fluidity.

Dr. Mohamed Zaky
Mech.
Fluidity of molten metal Eng. Dept.
Spiral fluidity test casting. (a) Standard fluidity spiral, (b)

arrangement of down-gate and pouring basin for standard
fluidity spiral Foundry Technology
Mech.
Variables influencing Fluidity Eng. Dept.
Temperature
Influence of superheat on fluidity: (a) pure metals (b) alloys

Foundry Technology
Mech.
Variables influencing Fluidity Eng. Dept.
Relationship
between
composition and
fluidity of leadtin
alloys

Mech.
Solidification and cooling Eng. Dept.
(a) Temperature as a function of time

for the solidification of pure metals. (b) Density as a
Note that the freezing takes place at a function of time
constant temperature.
Dr. Mohamed Zaky
Mech.
Alloy Solidification Eng. Dept.
Phase diagram for a copper - Cooling curve for a 50%Ni-50%Cu

nickel alloy system composition during casting.

Dr. Mohamed Zaky
Mech.
Cast Structures of Solidified Metals Eng. Dept.
Three cast structures of

metals solidified in a
square mold:
(a) pure metals;
(b) solid-solution alloys;
(c) structure obtained by
using nucleating
agents.

Dr. Mohamed Zaky
Shrinkage of a cylindrical casting duringMech.
SHRINKAGE solidification and cooling Eng. Dept.
(0) Starting level of molten

metal immediately after
pouring;
(1) Reduction in level caused
by liquid contraction during
cooling;
(2) Reduction in height and
formation of shrinkage
cavity caused by
solidification shrinkage;
(3) Further reduction in
height and diameter due to
thermal contraction during
cooling of the solid metal.
For clarity, dimensional
reductions are exaggerated
in sketches.

Dr. Mohamed Zaky
Mech.
Shrinkage in metals and alloys Eng. Dept.

Dr. Mohamed Zaky
Mech.
Pattern Making Eng. Dept.
A. Requirements
1. The type and form of material to be used
2. The type of pattern to suit the method of moulding
3. The need for corebox
4. Constructional details, the need for loose pieces and
coreprint
5. The value of allowance to be used
6. The method of gating and feeding to be allowed
7. The need of various foundry aids

Pattern Making Mech.
Eng. Dept.
B. Pattern Materials
The selection of pattern materials depends on
factors such as:
Service requirements such as quantity, quality
and intricacy of casting, minimum thickness
desired, degree of accuracy and finish
requirements
The possibility of design change
Type of moulding process
Possibility of repeated orders
Eng. Dept.
B. Requirements of Pattern Materials
1. Easily worked, shaped and joined
2. Light in weight for facility in handling and working
3. Strong, hard, durable (high strength to weight)
4. Resistance to wear and abrasion, to corrosion and
to chemical actions
5. Dimensional stability and unaffected by variation in
temperature and humidity
6. Available at low cost
7. Can be repaired or even re-used
8. Having ability to take a good surface finish
Eng. Dept.
Pattern Materials
1.Wood
2.Metals
3.Plasters
4.Plastic and rubbers (polymers)
5.Expandable Pattern (Waxes, polystyrene
foam and mercury)
6.Old castings

Eng. Dept.
Pattern Allowance
1.Contraction allowance (Liquid- Liquid
contraction, liquid-solid contraction and
solid-solid contractions)
2.Machining allowance
3.Draft or taper allowance
4.Rapping and shake allowance

Example Mech.
Eng. Dept.
Calculate the pattern dimensions for the following

cast to be made from plain carbon steel that having
contraction allowance of 21mm/1000mm and
machining allowance of 4mm.
L= 200 mm
W= 150 mm
D = 80 mm

Mech.
Eng. Dept.
End of Lecture 1

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Mech.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

** The study from the reference books is essential.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky 2

3.Foundry technology, Peter Beeley, Second edition

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

1 Overview of Casting Technology

16MECH03C: Production Technology 2 Dr. Mohamed Zaky 4

Processes of making cast product in moulds

Process in which molten metal flows by

The term casting also applies to the part

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

2. Advantages of Casting Process

The casting process sometimes is not cost effective if

Casting is usually performed in a foundry

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

4. Melting and pouring

5. Machining and inspection

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Pattern and corebox Core making Sand Station

Melting Unit Moulding

Melting Charge Pouring

Bad Product Shakout of mould Old Sand

Final Good Product

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Contains cavity whose geometry determines

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Open mold, simply a closed mold, for more complex geometry,

16MECH03C: Production Technology 2 15

1. Expendable mold processes uses an

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

More intricate geometries are possible with

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Heating furnaces are used to heat the metal

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

For this step to be successful, metal must flow

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

16MECH03C: Production Technology 2 21

Spiral fluidity test casting. (a) Standard fluidity spiral, (b)

Influence of superheat on fluidity: (a) pure metals (b) alloys

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

(a) Temperature as a function of time

Phase diagram for a copper - Cooling curve for a 50%Ni-50%Cu

16MECH03C: Production Technology 2 26

Three cast structures of

16MECH03C: Production Technology 2 27

(0) Starting level of molten

16MECH03C: Production Technology 2 28

16MECH03C: Production Technology 2 29

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

Calculate the pattern dimensions for the following

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

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