TUTORIAL 2 (ANSWER SCRIPT)
1) Describe the differences between expendable and permanent molds.
• An expendable mold means that the mold in which the molten metal solidities must be destroyed
in order to remove the casting. These molds are made out of sand, plaster, or similar materials,
whose form is maintained by using binders of various kinds.
• A permanent mold is one that can be used over and over to produce many castings. It is made of
metal that can withstand the high temperatures of the casting operation.
2) What is the difference between sand mold and shell mold casting
3) Name the type of materials typically used for permanent-mold casting prosesses.
Aluminum, magnesium, copper alloys, gray iron
4) Why are risers not as useful in die casting as they are in sand casting?
In sand casting, a riser is sized and located so that it provides molten metal to the die cavity to
compensate for metal shrinkage. In sand casting, the cooling rate is relatively low, so that the
cooling rate can be effectively manipulated by placement and size of a riser. In die casting, it is
essential that the cooling rate be high, or else the economic justification for tooling and
equipment cannot be made. Using risers would of course slow the cooling time, and therefore
they are economically undesirable. Further, the metals that are used in die casting will therefore
be ones that develop internal shrinkage porosity, but do not separate from the mold wall, so that
risers are not as necessary.
5) Why is the investment-casting process capable of producing fine surface detail on castings?
The mold in investment casting is produced by coating a wax pattern. The pattern itself can have
extremely good detail and surface finish, as it can be produced by die casting or even machining
or rapid prototyping and finishing operations. The mold is produced by coating the pattern with
ceramic slurry. The first layers can use a slurry with small particles that result in especially fine
reproduction of the surface detail. This can be carefully done, even with a fine paintbrush for
small detailed parts, ensuring good reproduction of the pattern. Subsequent layers can be
produced with thicker slurries with larger particles, or even slurries combined with dry particles,
in order to build the mold wall thickness.
6) What differences, if any, would you expect in the properties of castings made by permanent-mold
versus sandcasting processes?
Permanent-mold castings generally possess a better surface finish, closer dimensional tolerances,
more uniform mechanical properties, and more sound thinwalled sections than sand castings.
However, sand castings generally will be of more intricate shapes, larger overall sizes, and
(depending upon the alloy) lower in cost than permanent-mold casting.
7) Would you recommend preheating the molds used in permanent-mold casting? Would you
remove the casting soon after it has solidified? Explain your reasons.
Preheating the molds in permanent-mold casting is advisable in order to reduce the chilling effect
of the metal mold, which could lead to low metal fluidity. Also, the molds are heated to reduce
thermal damage (fatigue, shock) which may result from repeated contact with the molten metal.
Considering casting removal, the casting should be allowed to cool in the mold until there is no
danger of distortion or developing defects during shakeout. While this may be a very short period
of time for small castings, large castings may require an hour or more.
8) Describe the measures that you would take to reduce core shifting in sand casting.
Core shifting is reduced in a sand mold by core prints, chaplets, or both. Core prints (see Fig.
11.6 on p. 265) are recesses in the pattern to support the core inside the mold. If excessive
shifting occurs, chaplets may be used. Chaplets are small metal supports which act both as a
spacer for the core to assure proper core location and as an added support to resist shifting.
9) Describe your observation concerning the design changes shown in Fig. 12.1.
Several observations can be made regarding this figure. Figure 12.1a on p. 296 is further
emphasized in Fig. 12.2 on p. 296, and shows that hot spots can develop where the section
thickness changes abruptly or where corners exist. Figure 12.2b shows how deep cavities should
be located on one side of the casting to greatly simplify pattern design as well as removal of the
pattern from the sand mold. Due to large temperature gradients (which may form along flat
surfaces during cooling) warping may occur. The design of a mold with ribs and serrations
shown in Fig. 12.1d can reduce this effect and result in a more sound (not warped) casting. Ribs
may be used, for example, on steel flanges at the recessed portion in order to avoid warping of
both surfaces with which it is in contact.
10) In Fig. P12.33, the original casting design shown in (a) was resized and modified to incorporate
ribs in the design shown in (b). The casting is round and has a vertical axis of symmetry. What
advantages do you think the new design has as a functional part over the old one?
Fig. P12.33
There are a number of advantages, including the fact that the part thickness is more uniform, so
that large shrinkage porosity is less likely, and the ribs will control warpage due to thermal
stresses as well as increase joint stiffness. This redesign illustrates the recommendations given in
Figs. 12.1 and 12.2 on pp. 296.
11) An incorrect and a correct design for casting are shown in Fig. P12.34. Review the changes made
and comment on their advantages.
Fig. P12.34
The main advantage of the new part is that it can be easily cast without using an external core.
The original part requires two such cores because the shape is such that it cannot be obtained in
a sand mold without using cores.
12) Three sets of designs for die casting are shown in Fig. P12.35. Note the changes made to design 1
and comment on the reasons for then or them.
Fig. P12.35.
There are many observations, usually with the intent of minimizing changes in section thickness,
eliminating inclined surfaces to simplify mold construction, and to orient flanges so that they can
be easily cast.
13) Porosity that has developed in the boss of a casting is illustrated in Fig. P11.55. Show that the
porosity can be eliminated simply by repositioning the parting line of this casting.
Fig. P11.55
Note in the figure below that the boss is at some distance from the blind riser; consequently, the
boss can develop porosity as shown because of a lack of supply of molten metal from the riser.
The sketch below shows a repositioned parting line that would eliminate porosity in the boss.
Note that the boss can now be supplied with molten metal as it begins to solidify and shrink.