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Special Casting Process: Anil KR Garikapati

This document discusses different casting processes including die casting, centrifugal casting, and investment casting. It describes die casting machines and common die casting alloys and their properties. It explains that die casting uses permanent molds and can be gravity or pressure based. Centrifugal casting involves pouring molten metal into a rapidly rotating mold to distribute it evenly. There are three types: true, semi, and centrifuging. Investment casting, also called lost wax casting, allows for fine detail and casting of various metals by creating a ceramic mold from a wax pattern that is later melted out and replaced with molten metal.

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Anil Kumar Garikapati
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1K views

Special Casting Process: Anil KR Garikapati

This document discusses different casting processes including die casting, centrifugal casting, and investment casting. It describes die casting machines and common die casting alloys and their properties. It explains that die casting uses permanent molds and can be gravity or pressure based. Centrifugal casting involves pouring molten metal into a rapidly rotating mold to distribute it evenly. There are three types: true, semi, and centrifuging. Investment casting, also called lost wax casting, allows for fine detail and casting of various metals by creating a ceramic mold from a wax pattern that is later melted out and replaced with molten metal.

Uploaded by

Anil Kumar Garikapati
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Special casting process

Anil Kr Garikapati
Die casting
The mold used for making the casting is permanent ,
called die.
Depending on the way the metal is introduced into
the cavity the die casting is classified as,

GravityDie Casting

Pressure Die Casting


Die Casting Machine

 (a
)

Figure 11.24 (a) Schematic illustration of a cold-chamber die-casting machine. These


machines are large compared to the size of the casting because large forces are required
to keep the two halves of the dies closed.
Hot Chamber Machine

 (b)

800-ton hot-chamber die-casting machine, DAM 8005 (made in Germany in 1998). This is
the largest hot-chamber machine in the world and costs about $1.25 million.
Hot & Cold chamber machine
 (  (
a b
) )
Types of Dies
Properties and typical applications of
common die casting alloys
TABLE 11.4
Ultimate
tensile Yield Elongation
strength strength in 50 mm
Alloy (MPa) (MPa) (%) Applications
Aluminum 380 (3.5 Cu-8.5 Si) 320 160 2.5 Appliances, automotive components,
electrical motor frames and housings
13 (12 Si) 300 150 2.5 Complex shapes with thin walls, parts
requiring strength at elevated
temperatures
Brass 858 (60 Cu) 380 200 15 Plumbing fiztures, lock hardware,
bushings, ornamental castings
Magnesium AZ91 B (9 Al-0.7 Zn) 230 160 3 Power tools, automotive parts, sporting
goods
Zinc No. 3 (4 Al) 280 -- 10 Automotive parts, office equipment,
household utensils, building hardware,
toys
5 (4 Al-1 Cu) 320 -- 7 Appliances, automotive parts, building
hardware, business equipment
Source : Data from American Die Casting Institute
Centrifugal casting process
Centrifugal casting is the method of producing
castings by pouring the molten metal into a rapidly
rotating mould.
The metal is thrown out towards the casing by the
centrifugal force.
This method is chiefly used for castings having
hollow portions.
 Because of the centrifugal force ,a continues pressure
will be acting on the as it solidifies
C
E
N
T
R
I
F
U
G
A
L
CASTING
Classification of centrifugal casting

True centrifugal casting

Semi –centrifugal casting

Centrifuging
True Centrifugal Casting
Used for
hollow pipes,
tubes,
Hollow bushes , etc…
No core is required ,as the metal pushes outwards by
centrifugal action
The axis of rotation can be vertical or horizontal and
also any angle in between,
Semi -Centrifugal casting & centrifuging

Figure 11.28 (a) Schematic illustration of the


semi-centrifugal casting process. Wheels with
spokes can be cast by this process. (b)
Schematic illustration of casting by
centrifuging. The molds are placed at the
periphery of the machine, and the molten metal
is forced into the molds by centrifugal force.
INVESTMENT
CASTING:
Schematic illustration of
investment casting
(lost wax casting).
Castings by this method
can be made with fine detail
& from variety of metals
Investment Casting
of a Rotor

Figure 11.19 Investment casting of an integrally cast rotor for a gas turbine. (a)
Wax pattern assembly. (b) Ceramic shell around wax pattern. (c) Wax is melted out
and the mold is filled, under a vacuum, with molten superalloy. (d) The cast rotor,
produced to net or near-net shape. Source: Howmet Corporation.

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