Unit-II Basic Metal Forming &

Casting Processes

Introduction to casting process

INTRODUCTION TO CASTING PROCESS
lecture plan
L19
 Casting: Pattern: Materials, types and

allowances. Type and composition of Molding

sands and their desirable properties.
L20
 Mould making with the use of a core. Gating

system. Casting defects & remedies.

L21
 Cupola Furnace. Die-casting and its uses.
Topics
 Pattern materials, pattern types and pattern
allowances.
 Type and composition of Molding sands and

their desirable properties.

 Mould making with the use of a core.
 Gating system
 Casting defects & remedies.
 Cupola Furnace.
 Die -casting and its uses.
INTRODUCTION
 Metal-Casting Processes
◦ First casting were made during 4000 – 3000 BC
◦ In time many casting processes have been developed
◦ Many parts can be made from castings
 Engine blocks
 Cameras
 Gun barrels
 Cook ware
 Etc
CASTING PRODUCTS
Pattern and casting
Difference between pattern and
casting
PATTERN, MOULD
Pattern, mould and casting
Pattern
A pattern may be defined as a model of
desired casting which when moulded in sand
forms an impression called mould. The mould
when filled with the molten metal forms
casting after solidification of the poured
metal.
 The quality and accuracy of casting depends

upon the pattern making.

Pattern materials
The pattern may be made
of wood, metal(cast iron,
brass, aluminium and alloy
steel.), plaster, plastics and
wax
Types of pattern
common types of patterns are as follows:
1.     solid or single piece patterns
2.     split or two/multiple piece patterns
3.     match plate pattern
4.     cope and drag pattern
5.     loose piece pattern
6.     gated patterns
7.     sweep pattern
8.     skeleton pattern
9.     shell pattern
10. segmental pattern
11. follow board pattern
12. lagged up pattern
13. left and right hand pattern
Fig.- types of pattern
Fig.- solid or single piece pattern
- it is made of single part.
Fig.- Split or two piece pattern
it is made of tow parts.
-for gears and pulleys
Fig.- multipiece pattern
-is made of more than two parts.
-for large and complex shapes
Fig.- Gated pattern and
where gate is part of pattern
- more than one gate is used.
Fig.- Skeleton pattern
for large pipes.
- outer body is made up wood and
Fig.- sweep pattern
for symmetrical shapes like cylinders
Fig.- segment pattern
for alloy wheel , etc.
Pattern allowances
A pattern is always made
larger than the required size
of the casting considering the
various allowances. These are
the allowances which are
usually provided in a pattern.
1. shrinkage or contraction allowance:
 The various metals used for casting

contract after solidification in the

mould. Since the contraction is
different for different materials,
therefore it will also differ with the
form or type of metal.
2: Draft allowance
 It is a taper which is given to all the vertical walls

of the pattern for easy and clean withdraw of the

pattern from the sand without damaging the
mould cavity. It may be expressed in millimeters
on a side or in degrees.
 The amount of taper varies with the type of

patterns. The wooden patterns require more

taper than metal patterns because of the greater
frictional resistance of the wooden surfaces.
3: Finish or machining allowance
 The allowance is provided on the pattern if

the casting is to be machined. This allowance

is given in addition to shrinkage allowance.
The amount of this allowance varies from 1.6
to 12.5 mm which depends upon the type of
the casting metal, size and the shape of the
casting. The ferrous metals require more
machining allowance than non ferrous
metals.
4: Distortion or camber allowance
 This allowance is provided on patterns used

for casting of such design in which the

contraction is not uniform throughout.
5: Rapping or shaking allowance
 This allowance is provided in the pattern to

compensate for the rapping of mould

because the pattern is to be rapped before
removing it from the mould.
Draft or taper allowance in pattern
FIG.- DRAFT OR TAPPER ALLOWANCE
Fig.- distortion or camber allowance
Moulding sand composition
The main ingredients of any molding sand are:
1. Base sand( Silica sand)
2. Binder,
3. Additive
4. Moisture
Sand
 Silica sand is most commonly used base sand. Other

base sands that are also used for making mold are
zircon sand, Chromite sand, and olivine sand. Silica
sand is cheapest among all types of base sand and it is
easily available.
 while the remainder helps in improving the plasticity.
Binder
 Binders are of many types such as:

 Clay binders,

 Organic binders and Inorganic binders

 Clay binders are most commonly used binding

agents mixed with the molding sands to provide

the strength. The most popular clay types are:
 Kaolinite or fire clay (Al O  2 SiO  2 H O) and
2 3 2 2
Bentonite (Al2O3 4 SiO2 nH2O)
 Of the two the Bentonite can absorb more water

which increases its bonding power.

Moisture
 Clay acquires its bonding action only in the

presence of the required amount of moisture.

When water is added to clay, it penetrates the
mixture and forms a microfilm, which coats the
surface of each flake of the clay. The amount
of water used should be properly controlled.
 This is because a part of the water, which coats

the surface of the clay flakes, helps in bonding,

Moulding sand and properties of
moulding sand
 The moulding is a process of making a cavity or
mould out of sand by means of a pattern. The
molten metal is poured into the moulds to produce
casting.
Properties of moulding sand
1: porosity or permeability
 It is the property of sand which permits the steam

and other gases to pass through the sand mould.

The porosity of sand depends upon its grain size,
grain shape, moisture and clay components are the
moulding sand. If the sand is too fine, the porosity
will be low.
2: Plasticity
 It is that property of sand due to which it

flows to all portions of the moulding box or

flask. The sand must have sufficient plasticity
to produce a good mould.
: 3. Adhesiveness
 It is that properties of sand due to it adheres

or cling to the sides of the moulding box.

4: Cohesiveness
 It is the property of sand due to which the

sand grains stick together during ramming. It

is defined as the strength of the moulding
sand.
5: Refractoriness
 The property which enables it to resist high

temperature of the molten metal without

breaking down o r fusing.
6.Collapsibility
 The molding sand should also have collapsibility so that

during the contraction of the solidified casting it does not

provide any resistance, which may result in cracks in the
castings. Besides these specific properties the molding
material should be cheap, reusable and should have good
thermal conductivity.
7. Green Strength
 The molding sand that contains moisture is termed as

green sand. The green sand particles must have the

ability to cling to each other to impart sufficient strength
to the mold. The green sand must have enough strength
so that the constructed mold retains its shape.
Types of moulding sand
1: Green sand
  The sand in its natural or moist state is called green sand. It is also called

tempered sand. It is a mixture of sand with 20 to 30 percent clay, having total

amount of water from 6 to 10 percent. The mould prepared with this sand is
called green sand mould, which is used for small size casting of ferrous and
non-ferrous metals.
2: Dry Sand
 The green sand moulds when baked or dried before pouring the molten metal

are called dry sand moulds. The sand of this condition is called dry sand. The
dry sand moulds have greater strength, rigidity and thermal stability. These
moulds used for large and heavy casting.
3: Loam Sand
 A mixture of 50 percent sand grains and 50 percent clay is called loam sand.

It is used for loam moulds of large grey iron casting.

4: Facing Sand
 A sand which is used before pouring the molten metal, on the surface is

called facing sand. It is specially prepared sand from silica sand and clay.
5: Backing or Floor Sand
 A sand used to back up the facing sand and not used next to the pattern is

called backing sand. The sand which have been repeatedly used may be
employed for this purpose. It is also known as black sand due to its colour.
6: System Sand
 A sand employed in mechanical sand preparation and handling system is

called system sand. This sand has high strength, permeability and
refractoriness.
7: Parting Sand
 A sand employed on the faces of the pattern before the moulding is called

parting sand. The parting sand consists of dried silica sand, sea sand or burnt
sand.
8: Core Sand
 The cores are defined as sand bodies used to form the hollow portions or

cavities of desired shape and size in the casting. Thus the sand used for
making these cores is called core sand. It is sometimes called oil sand. It is
the silica sand mixed with linseed oil or any other oil as binder.
Sand casting mould
Gating system components
Pouring cup or basin
Sprue
Runner
Gate
Riser
GATING SYSTEM- 2D VIEW
GATING SYSTEM- 3D VIEW
SAND CASTING
 SAND CASTING STEPS
 Placing a pattern having the shape
of the desired casting in to the sand
to make an imprint
 Incorporating a gating system
 Filling the resulting cavity with
molten metal
 Allow the metal to cool
 Break away the sand mold
CORE, CORE PRINT, MOULD
Casting defects
Casting defects
1: Mould shift
 It results in a mismatching of the top and the bottom parts of

the casting , usually at the parting line.

2: Swell
 It is an enlargement of the mould cavity by molten metal

pressure resulting in localized or general enlargement of the

casting.
3: Fins and Flash
 These are thin projections of the metal not intended as a part of

casting. These usually occurs at the parting line of the mould.

4: Sand Wash
 It usually occurs near the in the gates as rough lumps on the

surface of a casting.
5: Shrinkage
 It is a crack or breakage in the casting on the surface of the

work piece, which results from un equal contraction of the

metal during solidification.
6: Hot Tear
 It is an internal or external ragged discontinuously in the

metal casting resulting just after the metal has solidified.

7: Sand Blow or Blow Hole
 It is smooth depression on the outer surface of the casting

work piece.
8: Honeycombing or Slag holes
 These are smooth depression on the upper surface of the

casting. They usually occur near the ingates.

9: Scabs
 These are patches of sand on the upper

surface of the casting component.

10: Cold Shut and Misruns
 These happens when the mould cavity is not

completely filled by the molten and

insufficient material or metal.
11: Run-outs and Bust-outs
 These permit drainage of the metal from the

cavity and result in incomplete casting.

Casting defects
 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. Die casting is a
highly productive method of casting parts with
low dimensions tolerance and high surface quality.
 The following parts are manufactured by die
casting method: automotive connecting rods,
pistons, cylinder beds, electronic
enclosures,toys,plumbing fittings. 
Cold chamber die casting
Gravity Die casting video
Hot chamber die casting
Hot chamber die casting
Advantages and disadvantages of die casting

Advantages of die casting:

 High productivity.
 Good dimensional accuracy.

 Good surface finish: 2-100 µinch (0.5-2.5 µm) R .

a
 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:

 Not applicable for high melting point metals and alloys (eg. steels)

 Large parts can not be cast.

 High die cost.
 Too long lead time.
 Some gases my be entrapped in form of porosity.
Cupola furnace
 Cupola furnaces are tall, cylindrical furnaces
used to melt iron and ferrous alloys in foundry
operations. Alternating layers of metal and
ferrous alloys, coke, and limestone are fed into
the furnace from the top. A schematic diagram
of a cupola is shown in Figure . This diagram of
a cupola illustrates the furnace's cylindrical
shaft lined with refractory and the alternating
layers of coke and metal scrap. The molten
metal flows out of a spout at the bottom of the
cupola.
Description of Cupola

 The cupola consists of a vertical cylindrical steel sheet and lined inside with
acid refractory bricks. The lining is generally     thicker in the lower
    portion of the cupola as the temperature are higher than in upper portion
 There is a charging door through which coke, pig iron, steel scrap and flux

is charged
 The blast is blown through the tuyeres
 These tuyeres are arranged in one or more row around the periphery of

cupola
 Hot gases which ascends from the bottom (combustion zone) preheats the

iron in the preheating zone

 Cupolas are provided with a drop bottom door through which debris,

consisting of coke, slag etc. can be discharged at      the end of the melt
 A slag hole is provided to remove the slag from the melt
 Through the tap hole molten metal is poured into the ladle
 At the top conical cap called the spark arrest is provided to prevent the

spark emerging to outside

Operation of Cupola

 The cupola is charged with wood at the bottom. On the

top of the wood a bed of coke is built.
 Alternating layers of metal and ferrous alloys, coke,
and limestone are fed into the furnace from the top.
 The purpose of adding flux is to eliminate the
impurities and to protect the metal from oxidation.
 Air blast is opened for the complete combustion of
coke.
 When sufficient metal has been melted that slag hole is
first opened to remove the slag.
 Tap hole is then opened to collect the metal in the
ladle.
Figure – cupola furnace
Figure – cupola furnace