Casting Processes
Expendable mold
Permanent Mold
Cross section of mold
Plaster
Ceramics
Evaporative pattern
Shell
Investment
Sand casting
Basic Steps
3) Pouring Techniques
4) Solidification Process
2) Melting Process
5) Mold Removal
1) mold cavity is produced
6) Cleaning,finishing and inspection operation
Sprue
Riser
Runner
Mold Cavity
Draft
Defects
Moulding Materials
Pouring Materials
Shrinkage Materials
Metallurgical
Gas
Air inclusion
Blow holes
Pin hole porosity
Cut and Washes
Metal penetration
Fusion
Run Out
Rat Tail and Buckles
Mis run
Cold shut
Slag inclusion
Hot Tear
Hot Spot
Pattern materials
Metal
Hard plastic
Wood
Sand Requirement
Collapsibility
Permeability
Cohesiveness
Refractoriness
Method of packing sand
Hand Ramming
Molding Machine
Mold Materials
Steel
Bronze
Graphite
Gray cast iron
Alloy cast iron
Frequently cast metal
Lead and its alloy
Magnesium and its alloy
Copper and its alloy
Aluminum and its alloy
Steel or iron ( mold : Graphite)
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Advantages
Disadvantages
Reusable molds
Good Surface finish
Little finish machining
Consistent dimension
Near net shapes
Directional solidification
High mold cost
Molds are not permeable
Limited to lower melting temperature alloy
Limited mold complexity
Types of permanent mold
Die
Centrifugal
Pressure
Squeeze
Slush
Semisolid
Hot chamber
Cold Chamber
Advantages
Very large parts can be produced
Difficult materials shape can be produced
Produce complex shapes with internal cavities
Economically competitive with other manufacturing processes