MIME2650-Manufacturing
f Processes
Class 05: Fundamentals of Metal Casting
Reminders:
▪ Instructor: Dr. Ala Qattawi [Link]@[Link]
Start email title with MIME2650. Allow 1 business
day for a response.
▪ Office Hours: 12:30 pm- 1:30 pm M/W or by
appointment
▪ When have an online class instead of in person.
Students should watch the video of the recorded
class on Thinkific. Quizzes, assignments, and exams’
questions can and will include materials from the
online recorded class.
Read Blackboard ▪ Online class notes are pinned under the video.
Announcements before class ▪ Assignments will be available on Blackboard one
week before the due date; online submission via
Blackboard is the sole permitted submission option.
▪ Email/paper submissions will not be accepted or
assessed. Please start early.
▪ Read the syllabus to be aware of class setup and
expectations.
Jan 28, 2026 MIME2650 Attendance
The Slido app must be installed on every computer you’re presenting from
Metal Sand Casting Video
Recap:
Recap:
For a cast of volume 10 in^3 and molten metal flow of 2 in^3
/seconds. How long will be the filling time for this cast?
ⓘ Start presenting to display the poll results on this slide.
Solved Example-1
Pure copper is poured into a
sand mold.
The metal level in the pouring
basin is 10 in. above the metal
level in the mold, and the
runner is circular with a 0.4-in.
diameter. What are the velocity
and rate of the flow of the
metal into the mold? Is the flow
turbulent or laminar?
A typical riser-gated casting. Risers serve as reservoirs, supplying molten
metal to the casting as it shrinks during solidification.
Solved Example-1
Pure copper is poured into a sand
mold.
The metal level in the pouring
basin is 10 in. above the metal
level in the mold, and the runner
is circular with a 0.4-in. diameter.
A) What are the velocity and rate
of the flow of the metal into the
mold? B) Is the flow turbulent or
laminar if the density is 33.2
lb/in3 and the viscosity of the
molten metal at the pouring
tempreature is 25.4 lb.s/in?
2
Solved Example-1
Pure copper is poured into a sand
mold.
The metal level in the pouring
basin is 10 in. above the metal
level in the mold, and the runner
is circular with a 0.4-in. diameter.
A) What are the velocity and rate
of the flow of the metal into the
mold? B) Is the flow turbulent or
laminar if the density is 33.1
lb/in3 and the viscosity of the
molten metal at the pouring
tempreature is 25.4 lb.s/in?
2
Solved Example-1 Assuming the pressure does not change appreciably in the channel
and that there is no friction in the sprue, the flow is given by
Pure copper is poured into a
sand mold.
The metal level in the pouring
basin is 10 in. above the metal
Where the subscript 1 indicates the top of the sprue and 2 the
level in the mold, and the bottom. If we assume that the velocity at the top of the sprue is
runner is circular with a 0.4-in. very low (as would occur with the normal case of a pouring basin
diameter. What are the velocity on top of the sprue with a large cross-sectional area), then v1 = 0.
and rate of the flow of the Therefore, the velocity at the bottom of the sprue is
metal into the mold? Is the flow
turbulent or laminar?
1 Q = v2A(runner) = 87.9 in/s * π *(0.4/2)2 in2 = 11:0 in3/s
2
Solved Example-1 Is the flow turbulent or laminar? Density = 33.1 Ib/in3
Pure copper is poured into a Viscosity= 25.4 Ib/in -S
sand mold.
The metal level in the pouring
basin is 10 in. above the metal
level in the mold, and the
runner is circular with a 0.4-in.
diameter. What are the velocity
and rate of the flow of the
metal into the mold? Is the flow
turbulent or laminar?
2
Air entrainment and formation of dross in
metal casting is caused by
ⓘ Start presenting to display the poll results on this slide.
Dross is a mass of
solid impurities
floating on a molten
metal or dispersed in
the metal,
Solved Example-2
For the previous example,
what runner diameter
needed to ensure a
Reynolds number of 2000?
Solved Example-3
A- For the sprue described in
example-1, How long will a 15
in3 casting take to fill with such
a runner? (i.e., filling time),
D=0.4 in
B- For the sprue described in
example-2, How long will a 15
in3 casting take to fill with such
a runner? (filling time),
D=1.746 in
Solved Example-3
A- For the sprue described in
example-1, How long will a 15
in3 casting take to fill with such
a runner? (i.e., filling time),
D=0.4 in
B- For the sprue described in
example-2, How long will a 15
in3 casting take to fill with such
a runner? (filling time),
D=1.746 in
Solved Example-3
A- For the sprue described in
example-1, How long will a 15
in3 casting take to fill with such
a runner? (i.e., filling time),
D=0.4 in
B- For the sprue described in
example-2, How long will a 15
in3 casting take to fill with such
a runner? (filling time),
D=1.746 in
Parameters affecting Metal Casting
• Molten Metal Fluidity
• Heat Transfer : i.e., mold material &
temperature.
• The solidification and cooling :
solidification time is a function of the
volume of a casting and its surface
area ( Chvorinov’s Rule):
FIGURE 10.10 Temperature distribution at the interface of the mold wall and the liquid metal during the
solidification of metals in casting.
Solidification time and grain development
in metal casting depends on
ⓘ Start presenting to display the poll results on this slide.
Chvorinov’s Rule: Solidification Time
C : a constant that reflects (1) the mold material, (2) the metal
properties (including latent heat), and (3) the temperature .
n : a parameter that has value between 1.5 and 2, but usually is
taken as 2.
• A large solid sphere will solidify and cool to ambient temperature
at a much SLOWER rate than will a smaller solid sphere. The
reason for this is that the volume of a sphere is proportional to
the cube of its diameter, and the surface area is proportional to
the square of its diameter.
• Molten metal in a cube-shaped mold will solidify FASTER than
in a spherical mold of the same volume
Solidification Time The effects of mold geometry and elapsed time on skin
thickness and shape
• Skin thickness increases
with elapsed time,
• Skin is thinner at internal
angles (location A in the
figure) than at external
angles (location B).
• Location B is caused by
slower cooling at internal
angles than at external FIGURE 10.11 Solidified skin on a steel casting. The remaining molten metal is
angles. poured out at the times indicated in the figure. Hollow ornamental and decorative
objects are made by a process called slush casting, which is based on this principle.
Solidification Time-Example 4
Three metal pieces being cast have the same volume, but different shapes:, one a cube,
one is a sphere, and the other a cylinder with its height equal to its diameter. Which
piece will solidify the fastest, and which one the slowest? Assume that n = 2.
Solidification Time-Examples
Three metal pieces being cast
have the same volume, but
different shapes:, one a cube,
one is a sphere, and the other
a cylinder with its height
equal to its diameter. Which
piece will solidify the fastest,
and which one the slowest?
Assume that n = 2.
Solidification Time-Examples
Three metal pieces being cast
have the same volume, but
different shapes:, one a cube,
one is a sphere, and the other
a cylinder with its height
equal to its diameter. Which
piece will solidify the fastest,
and which one the slowest?
Assume that n = 2.
Solidification Time-Examples
Three metal pieces being cast
have the same volume, but
different shapes:, one a cube,
one is a sphere, and the other
a cylinder with its height
equal to its diameter. Which
piece will solidify the fastest,
and which one the slowest?
Assume that n = 2.
Solved Example-Handwritten Answer
Solved Example-5
A cylinder with a diameter of 2.0
in. and a height of 3 in. solidifies
in three minutes in a sand-
casting operation. What is the
solidification time if the cylinder
height is doubled?
Solved Example-5
A cylinder with a diameter of 2.0
in. and a height of 3 in. solidifies
in three minutes in a sand-
casting operation. What is the
solidification time if the cylinder
height is doubled?