Presented by:

Paidpilli Mahesh kumar 08120034

Aurobindo Mahanty 08120013

Nirvesh Biswas 08120029

CASTING SINCE ABOUT 4000 BC

Ancient Greece; bronze statue casting circa 450BC Iron works in early Europe, e.g. cast iron cannons from England circa 1543

ALUMINUM CASTING
Casting is a fast way to produce the desired shape.
Three steps are involved in a Aluminum casting process: 1) Heating Al metal till it becomes molten 2) Pouring molten Al metal into a mould 3) Allowing the molten Al to cool and solidify in the shape of the mould.

USES
Al castings are used in areas like:

Some cast components include:

Transportation Aerospace Defense Mining Construction Domestic household.

Engine blocks Suspension parts for automobiles & fluid flow components like valves, pumps, pipes, and fittings.

PROPERTIES
Non ferrous metal like aluminum is lighter than steel and has density one third of that of steel.
Aluminum has a lower density of 2.7 gm/cc compared to 7.8 gm/cc of steel. Aluminum and aluminum alloys are lightweight with good Corrosion resistance Ductility Strength.

The greater use of aluminum can decrease vehicle weight, improve its performance and reduce fuel costs.
Pure aluminum possesses relatively poor casting features and for this reason castings are prepared from aluminum alloys

ALUMINUM ALLOYS
The main alloying elements are silicon, copper, magnesium, zinc, etc.
Aluminum silicon alloys have Corrosion resistance properties Fluidity increases with silicon addition Aluminum copper alloys have Strength Hardness Heat treatable Good machinability.

MELTING FURNACE

MELTING FURNACES
Crucible

furnace Induction furnace

CRUCIBLE FURNACE
Crucible furnaces are used for melting and holding small batches of non-ferrous alloys

Crucible furnaces are the oldest type of melting furnaces. A refractory crucible filled with the metal is heated through the crucible wall. There are two main types of crucible furnace: Electricity resistance furnaces, Gas (oil) fired furnaces. In the gas fired furnaces heat is provided by a burner directed to the crucible.
In the resistance furnaces electric heating elements are used as a source of heat.

PREPARATION OF CRUCIBLE
Crucible used is of clay graphite & silicon carbide Silicon carbide is popular in industry because of high strength & high heat conductivity Pitches and resins are used as binder After crucible prepared they are fired Crucible should be stored in dry area because if moisture pick up by crucible it can crack on heating

CRUCIBLE FURNACE

RESISTANCE FURNACE

INDUCTION FURNACE
Induction furnaces are widely used for melting non-ferrous and ferrous alloys.
There are two types of induction furnaces: coreless induction furnaces and channel induction furnaces: Coreless induction furnace

CORELESS INDUCTION FURNACE

Coreless induction furnace consists of: A water cooled helical coil made of a copper tube A crucible installed within the coil Supporting shell equipped with trunnions on which the furnace may tilt. Alternating current passing through the coil induces alternating currents in the metal charge loaded to the crucible. These induced currents heat the charge. When the charge is molten, electromagnetic field produced by the coil interacts with the electromagnetic field produced by the induced current. The resulted force causes stirring effect helping homogenizing the melt composition and the temperature

DROSSING:

It is the formation of Al oxide on the surface of molten metal

Control: By fast melting Metal is protected from products of combustion GAS ADSORBTION: Al alloys can absorb harmful quantities of hydrogen gas Causes :porosity Control: Fluxing: Solid flux(Zncl) Gaseous flux (nitrogen) GRAIN REFINEMENT: Chilling Addition(boron ,titanium)

INDUCTION FURNACE

POURING MOLTEN LIQUID

CASTING PROCESS OF ALUMINIUM

CASTING PROCESSES
Aluminum/alloys can be cast by several processes: 1) Sand Casting 2) Centrifugal casting 3) Investment casting 4) Continuous casting

SAND CASTING
Sand casting is an important process for casting molten aluminum alloys It can be used to prepare castings of any shape and size. Molten metal is poured into a mould cavity formed out of sand (natural or synthetic).

The sand cavity is formed by using a wooden pattern.

The upper part of sand mould box is called cope and lower part is called drag. The pattern is made slightly oversize to allow for the metal contraction as it cools down. The liquid flows into the gap between the two parts, called the mold cavity. The metal from the sprue and risers is cut from the rough casting. The riser is a reservoir of liquid metal to supply a contracting, cooling casting with make-up metal. It is used to prevent internal or external voids due to shrinkage.

PATTERN

PATTERN INSIDE DRAG

TOOLS

SAND ADDED IN DRAG

SAND RAMMING

BOX FILLED AND EXCESS SAND REMOVED

COPE AND DRAG

EXCESS SAND REMOVED FROM DRAG

GATING CUT IN DRAG

RISER MADE IN COPE

FINAL COPE & DRAG

PREHEATING OF BOXES

Al CHARGED IN FURNACE

MOLTEN Al

FINAL PREHEATING BEFORE POURING

MOLTEN Al REMOVED FROM THE FURNACE

MOLTEN Al IN THE CRUCIBLE

DROSS REMOVED

TEMPERATURE MEASURE

POURING

CASTING REMOVED FROM THE BOXES

FINAL CASTING

CASTING DEFECT
In Aluminum casting

CLASSIFICATION OF CASTING DEFECTS

Surface Defects Blow, Scar, Blister, Drop, Scab, Penetration, Buckle Internal Defects Blow holes, Porosity, Pin holes, Inclusions, Dross Visible Defects Wash, Rat tail, Swell, Mis run, Cold shut, Hot tear, Shrinkage/Shift

SURFACE DEFECTS
Blow is relatively large cavity produced by gases which displace molten metal from convex surface. Scar is shallow blow generally occurring on a flat surface.

A scar covered with a thin layer of metal is called blister. These are due to improper permeability or venting. Sometimes excessive gas forming constituents in moulding sand.
Drop is an irregularly-shaped projection on the cope surface caused by dropping of sand.

SURFACE DEFECTS
A scab when an up heaved sand gets separated from the mould surface and the molten metal flows between the displaced sand and the mold. Penetration occurs when the molten metal flows between the sand particles in the mould. These defects are due to inadequate strength of the mold and high temperature of the molten metal adds on it.

Buckle is a v-shaped depression on the surface of a flat casting caused by expansion of a thin layer of sand at the mould face.

INTERNAL DEFECTS

The internal defects found in the castings are mainly due to trapped gases and dirty metal. Gases get trapped due to hard ramming or improper venting. These defects also occur when excessive moisture or excessive gas forming materials are used for mould making

INTERNAL DEFECTS
Blow holes are large spherical shaped gas bubbles Porosity indicates a large number of uniformly distributed tiny holes.

Pin holes are tiny blow holes appearing just below the casting surface.
Inclusions are the non-metallic particles in the metal matrix, Lighter impurities appearing the casting surface are dross.

VISIBLE DEFECTS

Insufficient mould strength, insufficient metal, low pouring temperature, and bad design of casting are some of the common causes.

Wash is a low projection near the gate caused by erosion of sand by the flowing metal.

Rat tail is a long, shallow, angular depression caused by expansion of the sand.

Swell is the deformation of vertical mould surface due to hydrostatic pressure caused by moisture in the sand.

VISIBLE DEFECTS
Misrun and cold shut are caused by insufficient superheat provided to the liquid metal.

Hot tear is the crack in the casting caused by high residual stresses. Shrinkage is essentially solidification contraction and occurs due to improper use of Riser.

Shift is due to misalignment of two parts of the mould or incorrect core location.

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