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Metal Casting Technology Overview

Casting is a manufacturing process where molten metal is poured into a mold and solidifies to form the desired shape. There are different types of casting processes depending on the material, with metals being the most common. The key steps in metal casting are melting the metal, pouring it into a mold, and allowing it to solidify. Casting allows for complex geometries and large parts to be produced. While it provides net and near net shape, disadvantages include potential limitations in mechanical properties and dimensional accuracy/surface finish depending on the process. Common casting applications include engine blocks, pumps, pipes, and small parts like jewelry.

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37 views11 pages

Metal Casting Technology Overview

Casting is a manufacturing process where molten metal is poured into a mold and solidifies to form the desired shape. There are different types of casting processes depending on the material, with metals being the most common. The key steps in metal casting are melting the metal, pouring it into a mold, and allowing it to solidify. Casting allows for complex geometries and large parts to be produced. While it provides net and near net shape, disadvantages include potential limitations in mechanical properties and dimensional accuracy/surface finish depending on the process. Common casting applications include engine blocks, pumps, pipes, and small parts like jewelry.

Uploaded by

Vijay Ganapathy
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd

EMU - Manufacturing Technology

METAL CASTING
Overview of Casting Technology
Solidification Processes
We consider starting work material is either a liquid or is
in a highly plastic condition, and a part is created
through solidification of the material
Solidification processes can be classified according to
engineering material processed:
Metals
Ceramics, specifically glasses
Polymers and polymer matrix composites (PMCs)
Classification of solidification processes.
Casting
Process in which molten metal flows by
gravity or other force into a mold
where it solidifies in the shape of the
mold cavity
The term casting also applies to the
part made in the process
Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
Capabilities and Advantages of Casting
Can create complex part geometries that can not be
made by any other process
Can create both external and internal shapes
Some casting processes are net shape; others are
near net shape
Can produce very large parts (with weight more
than 100 tons), like m/c bed
Casting can be applied to shape any metal that can
melt
Some casting methods are suited to mass
production
Can also be applied on polymers and ceramics
Disadvantages of Casting
Different disadvantages for different casting processes:
Limitations on mechanical properties
Poor dimensional accuracy and surface finish for some
processes; e.g., sand casting
Safety hazards to workers due to hot molten metals
Environmental problems
Parts Made by Casting
Big parts
Engine blocks and heads for automotive vehicles, wood
burning stoves, machine frames, railway wheels, pipes,
bells, pump housings
Small parts
Dental crowns, jewelry, small statues, frying pans
All varieties of metals can be cast - ferrous and
nonferrous
Overview of Casting Technology
Casting is usually performed in a foundry
Foundry = factory equipped for
making molds
melting and
performing the casting processhandling molten metal
cleaning the finished casting

Workers who perform casting are called foundrymen


The Pattern
A full-sized model of the part, slightly enlarged to
account for shrinkage and machining allowances in
the casting
Pattern materials:
Wood - common material because it is easy to work, but
it warps
Metal - more expensive to make, but lasts much longer
Plastic - compromise between wood and metal
Types of Patterns
Figure: Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) match-plate pattern
(d) cope and drag pattern

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