METALLURGY DEPARTMENT
Casting Processes
Investment
Sand Casting Casting
For large parts For smaller more
precision parts
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METALLURGY DEPARTMENT
Sand Casting Process Steps
Casting Patternmaking
Sand fills flask over Flask over patterns Wood patterns are
pattern & pattern constructed
removed
Metal is cast into
cavity left by
patterns
Part is left after sand
shaken out
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METALLURGY DEPARTMENT
Close-Up View of the Sand Casting Process
Two halves of
mold contain
cavities
cope
dr
a
Cores fit in the cavities of the mold
g
Assembled molds
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METALLURGY DEPARTMENT
Some examples of Cast
Components
API 6A PSL3 requires
components to be
Notice the surface roughness which forged. PSL 1 & 2 can
is the result of the hot metal
contacting with the sand mold. be cast.
Gate valve casting
Choke valve casting
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METALLURGY DEPARTMENT
The role of Feeders & Risers in Casting
Technology
Risers compensate for the metal shrinkage during Feeders are designed to minimize turbulence
solidification. during casting.
The part being cast is cylindrical in shape, but the liquid metal
flow in these examples are radically different.
Which is a better design?
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METALLURGY DEPARTMENT
Solidification of Castings
Note the pores
Freezing of metal is not uniform and dendrites throughout the
form following the cooling gradients. Dendrites structure.
look like Christmas trees.
Grey is liquid
Pores can arise from
the last metal freezing
between the
dendrites.
tal
ifie d me
solid
e is
Whit
Porosity & Non-uniform chemistry is one of the challenges of
the casting process
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METALLURGY DEPARTMENT
Ingot Solidification
Finer
equiaxed
Fine grains grains in
Longer
fast cooling slowest
at wall columnar cooling area.
grains as
cooling rate
slows.
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METALLURGY DEPARTMENT
Investment Casting Process
1. Pattern creation - The wax
patterns are typically injection
molded into a metal die and
are formed as one piece.
2. Mold creation - This
"pattern tree" is dipped into a
slurry of fine ceramic
particles, coated with more
coarse particles, and then
dried to form a ceramic shell
around the patterns and
gating system.
3. Pouring - The mold is
preheated in a furnace to
approximately 1000°C
(1832°F) and the molten metal
is poured from a ladle into the
gating system of the mold,
filling the mold cavity.
4. Cooling - After the mold
has been filled, the molten
metal is allowed to cool and
solidify into the shape of the
final casting.
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METALLURGY DEPARTMENT
Example of Investment Cast Parts
used in Compressors & Valves
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METALLURGY DEPARTMENT
Centrifugal Casting
LOW ALLOY STEELS
• Plain Carbon
• Ni-Cr, Ni-Cr-Mo
STAINLESS STEELS
Austenitic (300 series)
• CF8,The directional
CF3 (304, 304L)
solidification
• CF8M, CF3M (316, 316L)
improves
Martensitic (400 series)
properties
• CA15, CA40 (420)
• CA6NM (410)
Precipitation Hardened Alloys
• CB7Cu-1 (17-4PH)
• CB7Cu-2 (15-5PH)
Duplex Stainless Steel
• CD4MCu
• 2205 (CD3MN)
Heat Resistant Alloys
• HF, HF Mod, HH, HK, HP, HP Mod, HU, etc.
IRONS• Gray Irons• Ductile IronsNICKEL BASED ALLOYS• Hastelloy
X, C, S• Inconel 600, 625COBALT BASED ALLOYS• Stellite 6
equivalent• N-155 Heat Resistant AlloysVARIOUS PROPRIETARY
ALLOYS
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METALLURGY DEPARTMENT
Continuous Casting Process to produce bar
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METALLURGY DEPARTMENT
Typical Problems with Castings
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METALLURGY DEPARTMENT
Cameron use of Forgings/Castings
Forgings Castings
Almost all subsea
equipment Large valve applications
Better properties because All castings have some
of hot work pores & internal
imperfections
Rough surface finish
Better surface finish because of casting process
Easier to inspect with NDE More difficult to inspect
surface & volumetric with established NDE
methods techniques
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METALLURGY DEPARTMENT
Mechanical Properties determined from
Keel Keel Blocks
block is
cast from Test specimens removed from Keel
the same Block
heat as
the
casting
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