Types of Pattern: -

1. Single piece or solid pattern:

If the object to be produced is simple in shape and size.
One of the surface of the pattern must be flat.
It is less expensive.
2. Split Piece pattern:
If the object to be produced is complex in shape and size, pattern cab be split along the parting
line and they can be removed from the cope and drag boxes separately.
3. Loose piece pattern:
If the pattern is having projection or undercut.
If the projections are complex, then we use plastic or wax and remove by heating.
4. Gated pattern: (small size and simple)
To produce number of cavities in mass production.
5. Match plate pattern: (small size and complex)
To produce complex shape of the object in mass production.
6. Sweep pattern:
To produce complex shape of 3D mould cavities.
7. Follow board pattern:
If the pattern is structurally weak there is a possibility of breaking of pattern due to ramming
force. To overcome this, follow board pattern is used.

Shell moulding:
Pattern: Made of metal.
Moulding material: Fine grain silica sand, phenolic resin (phenol formaldehyde or urea
formaldehyde), alcohol.
Uses: cylinder block of air cooled IC engine, rocker arms, valve plate of refrigerator.
Production rate is more.

Investment casting: (lost wax process)

Pattern: wax, plastic.
Slurry: Silica flour, ethyl silicate, water
Accuracy and surface finish is very high, can be used for mass production.
Expendable casting and mould can be used.
Uses: Gas turbine blades, jet engine parts, dentures, gold ornaments, medical implants.

Full moulding (Cavity less moulding, EPC and lost foam process)
Pattern: Plastic(polystyrene, foam, PVC, thermocol)
Uses: Motor casings, fittings, lock components.
Surface finish is more but less than investment casting.

CO2 moulding:
Similar to sand casting but added sodium silicate instead of water and clay.
Uses: Machine tool beds, engine block, gear box housing.
Centrifugal casting:
Uses: Hollow cylindrical pipes, gun barrels, cylinder liners, propeller shafts.
No gating element, so casting yield is 100%.
Used for hollow symmetrical objects only.
Due to centrifugal force and fast rate of cooling fine grain structure with high density can be
produced.

Semi centrifugal casting:

Uses: pulleys, wheels, spoked wheels.
Can be used to produce axis-symmetric object. Strength of material is more at outside and less
at inside.

Centrifuging:
To produce asymmetric object in mass production.
Axis of rotation of the mould doesnt coincide with the axis of the object.

Gravity die casting:

Uses: Piston used in automobile made up of Al.
Due to fast rate of cooling, fine grain structure developed in the casting which are having more
strength and hardness.

Hot and Cold chamber die casting:

Uses: Carburettors, crank cases, valve bodies, fuel injection pump parts and toilet fixtures.

Slush casting:
Uses: Thin casting, hollow thin casting, hollow statues, lamp shades, toys, decorative items, thin
ornaments.
No core is used for making thin and hollow thin castings.

Squeeze casting:
Uses: Brake shoe made up of Al, Bushes made of Brass and Bronze.
It is a combination of casting and forging.
Surface finish and accuracy of the object are very high.

Continuous casting:
Uses: Long length metallic bars, rods, blooms.
Production rate is very high.
To produce continuously large length of metallic object directly from the liquid metal.