Casting
• Casting is the processes in which the molten
metal is poured in to a mould or cavity (shape
of the product) and allow solidifying.
• Sand casting
• Shell moulding
• Precision casting (lost wax or Investment
casting)
• Permanent mould casting (gravity die casting)
• Centrifugal casting
Furnace
molten metal
finished mold half from the
process
Pressure Die Casting
Pressure Casting Dies
Typical Castings
Courtesy of The Enfield Foundry Co Ltd Courtesy of Saunders Valve Co Ltd
Courtesy of J W Singer Ltd Courtesy of Boosey and Hawkes Ltd
Sand Casting
Steps
• Pattern making
• Moulding
• Melting and pouring
• Solidification, mould removal
• Cleaning , finishing, Inspection
Pattern Types
• Solid /single piece pattern
• Split pattern or two piece pattern
• Gated Pattern
Basic Components of a mould
Pouring
cup
Parting
Line
(Runners and Gates)
• Cope: The upper part of a casting mold
• Drag: The lower part of a casting mold
• Sprue: Carries molten metal from the pouring cup to
the runners and controls the fluid flow.
• Runner: Passageways in the parting plane through
which molten metal flow is regulated before enter into
mould cavity. The runners distribute metal to the part.
• Gate: A transition from the runner to the cavity of the
part
• Riser: A reservoir of thermal mass where excess metal
will remain in a liquid state while the part cools. As the
cooling part shrinks, the molten metal in the riser will
feed or fill in the shrinkage. Risers can also be used to
collect impurities that rise in molten metal.
• Core: it is used for making hollow cavities in casting
Types of sands use for
moulding
• Facing sands
• Green sands
• parting sands
• Core sands
Moulding sand composition
• Sands (Silica grains): Up to 50 – 95% of SiO2
(fusion point 1450°C-1550°C).
• Clay: Contain 2 -15% of clay (fusion point 1750°C-
1787°C). Clay is binder or bond of sand.
• Water: Present in 2 – 8%
• Additives: Graphite (improve mouldability and
surface finish), wood flour (control expansion, improve
collapsibility & flow-ability), silica , etc.
• Green sand molding refers to a slightly wet condition
of the sand
Sand Casting Procedure
Drag is kept on flat board after spreading parting
sands
Place one half of the pattern & apply facing sands
over it. Pour green sand (backing sand) , ram it, vent
it & smooth sand surface by straight bar.
Turn drag upside down & place on the plate.
Place another part (Cope) in its position & proceed.
Place sprue rods (one is riser & other runner)
Place the core in position and use chaplet to support
it
Sand Casting Procedure
Cut the gates on the two sides of the mould & repair if
any corner has damaged.
Reverse the cope and place on top of the drag n
position
Pour molten material
After proper cooling shake the boxes manually or
using automatic vibrator to break the sand and take
away casting
Cut the runners and gates away
Send sands to another moulding
Core Making
Casting Defects
Blow Holes Wash
Misrun Cold Shut
Casting Defects
Porosity
heating or cooling certain areas to
maintain uniform cooling
Hot Tears
• Porosity developed can be eliminated by
changing the design