Overview of Casting Processes and Molds
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ScribdTranslationsOverview of Casting Processes and Molds
Translated by
ScribdTranslationsIntroduction
Used since around 6 thousand years ago, the casting process continues to be
one of the manufacturing processes to produce very small parts to large parts
and complex. The casting process basically involves 3 steps: (a) pouring the metal
liquid in the mold pattern (b) let the piece solidify and (c) remove the part of
mold.
The most important considerations in casting processes are the following:
the flow of molten metal into the mold cavity
the solidification and cooling of the metal in the mold
influence of the type of mold material
The first metal smelting was done during the period between 4000 and 3000 years ago.
of Christ, using stone and metal molds for casting copper. Several casting processes
They have been developed over time, each with its own characteristics and applications.
to meet specific design requirements. A wide variety of parts and
components are created by the casting process, among which we can highlight
engine blocks, automotive components, agricultural and railway equipment,
household tools, jewelry, orthopedic implants, and a large number of components
for hydraulic turbines.
Casting processes are divided into 2 categories depending on what they are based on.
mold: (1) disposable mold and (2) permanent mold. Disposable molds have to
be destroyed to remove the cast piece. Since a mold must be made for each
foundry, the production rates in disposable molds are often limited by the
time required to make the mold more than the time it takes to make it in itself
piece.
However, for certain geometries, sand molds and casting can be
produced at rates greater than 400 pieces per hour.
In permanent molds, these are made of metal (or any other durable material)
and can be used as many times as desired to manufacture as many pieces as desired.
consequently, these processes have a natural advantage in terms of better ratios of
production.
The most commonly used mold during the casting process is the sand mold. Almost
All alloys can be melted using the sand mold. This allows for
they can use metals with a high melting point such as steels and titaniums. Their
versatility allows casting from very small pieces to very large pieces and its
production from small quantities to mass production.
In Table 1.1, we can observe a summary of the advantages and disadvantages of the different
most commonly used types of molds during the casting process.
Table 1.1 - Advantages and Limitations of the Most Common Molds.
TYPE OF MOLD ADVANTAGES LIMITATIONS
Almost any metal can be finished,
melted, there are no limits on the finished surface size
GREEN ARENA
of the piece, shape or weight, relatively low cost thick
of machining. broad tolerances.
Good dimensional accuracy and the size of the piece is
surface finish, high limited ratio, models y
DRY CAP
expensive equipment production.
Most metals can be models have little
melted, there are no size limits, strength and it can be expensive
FOR MODEL
forms of complex pieces. for small amounts
EVAPORATIVE
Shapes of complex pieces, good Limited to non-metals.
dimensional accuracy and ferrous finish, the size of the
superficial, low porosity the piece is limited just like
GYPSUM MOLD its production volume,
the time it takes to do
the mold is relatively
long.
Forms of complex parts, The size of the part is
close tolerances, limited good finish
CERAMIC MOLD
superficial
Shapes of complex parts, Limited part size,
excellent surface finish and almost expensive models as well
CASTING OF
any metal can be used that the molds and work
LOST WAX
Good surface finish and accuracy High-cost mold, size
dimensional, low porosity and a high complexity of the piece
MOLD
production ratio limited, not suitable for
PERMANENT
metals with a high melting point
fusion.
Excellent dimensional accuracy and high-cost injection.
surface finish, high size ratio of the limited piece,
CASTING BY
production generally limited to
INJECTION
non-ferrous metals, time
long delivery.
CASTING Long cylindrical or tubular pieces Equipment expensive
centrifuge with good quality, high ratio of limited piece shape.
production
1.- disposable molds: they are typically made of sand, plaster, ceramics, and materials.
similar and are generally mixed with various binders (binding agents) to
improved properties. A typical sand mold consists of 90% sand, 7% clay, and 3%
gua.
2.- permanent molds: they are made of metals that maintain their strength at high temperatures
temperatures. As their name implies, they are used repeatedly and are designed to
so that the cast piece can be easily removed and that the mold can be used for
the following process. Metal molds are better heat conductors than molds
non-metallic disposables; therefore, the solidification is subject to a higher rate of
cooling, which in turn affects the microstructure and the grain size.
3.- Composite Molds: they are made of 2 or more materials (such as sand,
graphite and metal) combining the advantages that each material offers. These molds have both
a permanent mold like a disposable one and are used in various casting processes
to increase the strength of the mold, control the cooling rates and optimize the
general economy of the casting process.
Figure 1.2
Figure 1.2 shows a schematic illustration of the sequence of operations for
the casting process using sand mold. It is observed how the process encompasses from
(a) the mechanical drawing of the part is used to generate the model design up to (m) where
the part is finished, cleaned, inspected and if necessary is subjected to a
thermal treatment to improve the specified properties.
Figure 1.3–shell molding: it was first developed in the 1940s and
has grown significantly as it can produce various types of parts with tolerances
close dimensions and a good surface finish at a low cost. Its applications
they encompass small mechanical parts that require high precision such as the heads of
cylinders to high-precision cores.
Figure 1.4–ceramic mold: it is similar to the plaster mold, except that this type of mold
use suitable refractory materials for high-temperature applications. The parts
The most common items produced with this mold are impellers and cutters for operations.
of machining. Parts weighing up to 700kg have been manufactured by this process.