Professional Documents
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Casting is a manufacturing process whereby the desired material is heated to the liquid state,
then introduced into a previously prepared mold cavity of proper design, and allowed to
solidify
Advantages of Casting
Easier to manufacture
Type of metal
Runners channels that carry the molten metal from the sprue to the mold cavity
Gate is the portion of the runner though which the molten metal enters the mold cavity
Risers serve as reservoirs to supply the molten metal necessary to prevent shrinkage
Types of casting
Expendable molds- molds made of sand, plaster, ceramics, or other materials
capable of withstanding high temperatures which are broken up and discarded
after a single use.
Permanent Molds- molds usually made of metal which maintain strength at high
temperatures and are used for making a large number of repeated castings.
Core
Cores allow features that could not be easily formed into a sand core.
Cores are made with techniques similar to those for making sand molds.
The cores may need structural support in the mold - these metal supports are called
chaplets.
The cores are added when the cavity are made, and they act as part of the mold during
casting, but they are rigid enough to allow internal features on parts.
Un professional management policies relating to the fixing of incentive plans and setting
up of production procedure, faulty organization and poor work discipline, or lack of
training.
Some casting processes are net shape; others are near net shape
Can produce very large parts
Disadvantages of Casting
Poor dimensional accuracy and surface finish for some processes; e.g., sand
casting
Environmental problems
Directional Solidification
To minimize damaging effects of shrinkage, it is desirable for regions of the casting most
distant from the liquid metal supply to freeze first and for solidification to progress from
these remote regions toward the riser(s)
Thus, molten metal is continually available from risers to prevent shrinkage voids
The term directional solidification describes this aspect of freezing and methods
by which it is controlled