Casting
Module 1
Casting is a manufacturing process in which a liquid material, usually metal or alloy, is
poured into a mold containing a hollow cavity of the desired shape and then allowed to
solidify. After solidification, the mold is removed, leaving a solid part that replicates the
shape of the mold.
Pattern Allowance:
Pattern allowance is the intentional dimensional modification made to a pattern in
casting to compensate for changes that occur during the casting process, such as
shrinkage, machining, and distortion.
Importance:
•Ensures the final casting has accurate dimensions.
•Compensates for metal solidification shrinkage.
•Accounts for machining allowance if finishing is needed.
•Prevents defective or undersized castings, improving quality and fit.
Types of Patterns in Casting:
[Link] Pattern: Single-piece, simple shapes without cores.
[Link] Pattern: Made in two or more parts for easy removal from mold.
[Link] and Drag Pattern: Divided into top (cope) and bottom (drag) halves of mold.
[Link] Plate Pattern: Cope and drag mounted on a single plate for mass production.
[Link] Pattern: Includes built-in gates and risers for metal flow.
[Link] Pattern: Rotating template used for large symmetrical castings.
[Link] Pattern: Framework pattern for very large castings to save material.
[Link] Pattern: Burns or melts away during molding (e.g., investment casting).
Centrifugal casting
Centrifugal casting is a process in which molten metal is poured into a rapidly rotating
mold, and centrifugal force distributes the metal uniformly along the mold walls.
Working Principle:
[Link] mold is rotated at high speed around its central axis.
[Link] metal is poured into the rotating mold.
[Link] to centrifugal force, the metal is pushed outward and spreads evenly along the
inner surface of the mold.
[Link] and lighter particles move toward the center and can be machined off later.
[Link] metal solidifies under pressure, forming a dense, fine-grained casting.
[Link] solidification, rotation is stopped and the casting is removed.
Types of Gate
In casting, mainly two types of gating systems are used
Top Gate: In a top gate system, the molten metal enters the mold from the
top. This type of gate allows for quick filling of the mold but can cause
turbulence, which may lead to defects like air entrapment or splashing.
Top Gate: Used in heavy castings such as large machine components where speed of filling
is important.
Bottom Gate: In a bottom gate system, the molten metal enters the mold from the bottom.
This method allows for a more gradual and controlled flow of metal, reducing turbulence
and preventing the entrapment of air or gas bubbles.
Bottom Gate: Ideal for castings requiring a high-quality surface finish, such as automotive
parts.
Investment Casting
Investment casting, also sometimes known as precision casting or lost wax casting, is one of
the most popular metal forming techniques.
Principle
• Investment casting is a precision casting process where a wax pattern is created and
then coated with a ceramic slurry to form a hard shell.
• After the ceramic shell dries, the wax is melted out (lost wax process), leaving a cavity in
the shape of the component.
• Molten metal is poured into this cavity, allowed to solidify, and the ceramic shell is
broken to remove the final casting.
• The principle is based on copying the exact details of the wax pattern, giving high
accuracy, smooth surface finish, and complex shapes without machining.
Applications of Investment Casting
1. Used for producing complex, thin-walled, and intricate components with high
dimensional accuracy.
2. Commonly used in aerospace (turbine blades, vane segments), automotive (precision
gears, cams), medical implants (prosthetic parts), and industrial valves and pump
components.
3. Suitable for high-melting-point alloys, such as superalloys, stainless steel, titanium,
and aluminum.
4. Used when near-net shape manufacturing is required to reduce machining.
Advantages of Centrifugal Casting
1. Produces high-density and porosity-free castings due to centrifugal pressure.
2. Excellent mechanical properties and fine-grained structure.
3. No need for risers or gating system → material and cost savings.
4. Suitable for hollow cylindrical parts without using cores.
5. Impurities move to the center, giving clean outer surfaces.
6. Good dimensional accuracy and surface finish.
Limitations of Centrifugal Casting
1. Limited mainly to cylindrical or axisymmetric shapes.
2. High initial cost due to special rotating equipment.
3. Not suitable for complex shapes or intricate details.
4. Uneven solidification may cause segregation near the center.
5. Requires careful control of speed and pouring temperature.
6. Center portion may need machining to remove impurities.
Comparison: Investment vs Slush casting
Investment casting: makes a solid part by creating a full ceramic cavity
from a lost wax pattern; used for precision, complex metal parts.
Slush casting: pours molten metal into a mold and pours out excess to
leave a hollow shell; mainly used for hollow thin-walled nonferrous parts
(e.g., decorative items), not for precision aerospace components.
Types of Allowances in Casting
[Link] Allowance
• Added to the pattern size to compensate for metal contraction during solidification and cooling.
[Link] Allowance
• A taper provided on vertical surfaces of the pattern to allow easy withdrawal from the mould.
[Link] Allowance
• Extra metal is added to the casting to allow for machining and finishing operations.
[Link] Allowance
• Given to patterns for shapes that may warp or bend during cooling (e.g., long, thin parts).
[Link] (Rapping) Allowance
• A small reduction in pattern size to compensate for the enlargement of the mould cavity when the
pattern is shaken or rapped for removal.
Note : The remaining topic notes have already been provided by Dr. Tirupati Sir