Casting
means
Foundry Engineering
Dawid Myszka
[email protected]
Casting into sand moulds
Casing
- outer shape
Casing
- internal shape
core
Casting Today
endoprosthesis of the hip joint
Casting production process
How it begins
Cave Mold in calcareous stone Mold of stone - hatchet dated on IX – VIII
from Races – Shamara in Asia age BC found archaeological position in
eastern Poland
How it begins
Copper head of man
(36x20x30 cm)
from 2000 year BC
How it begins
Bell ( musical tool) with four tigers
Chinese foundry of bells according to
poured off from bronze in period of rule
sources from 1630 year
of Late westerly Dynasty Czou
Main elements of mold
and gating system
Main elements of gating system
Main elements of gating system
Scheme of filing the mould
by liquid metal
Main sprue
Low preasure area
runner
Refined liquid metal stream
Main sprue
runner
Sprue base
Main elements of gating system
Produkcja odlewów na świecie
filters
Solidification
Solidification
Schematic metal contraction
during solidification:
a) liquid,
b) contraction of sigle
crystals appearing moment,
c) contraction durig
solidification,
d) contraction in solid state.
Solidification
Shrink cavity
Solidification
1. Casting
2. Riser
3. Shrink cavity
4. Solidified layers
5. Cutting line
bold
cooler
Solidification
• Partitioning of casting shape
• Casting modulus calculation
volume
heat transfer
surface area
Main elements of gating system
SIDE RISER (blind-type) TOP RISER (open-type)
Casting cavity
Main elements of gating system
connection connection connection
Film
Film
Film
ceramic/metal mould
Solidification
Crystalisation
a) Columnar crystals
b) Dendritic crystals
c) Equiaxed crystals
mould mould
liquid
Crystalisation
liquid
Smooth-walled Wall-harshly
cristalisation cristalisation
mould mould
liquid liquid
Volumetric Mixed
cristalisation cristalisation
Solidification
Solidification
Amount of alloying element B [%] Time [s]
Solidification
Phase diagrams
Grains structure of the casting materials
• Cast metals
Casting production
Casting production
Poland
Europe
World
ductile cast aluminium other
grey iron
iron steel alloys non-ferrous metal alloys
Casting production in Europe
Petal of graphite Branched crystal
of graphite
Cast Iron
Microstructures for an Iron-Carbon Alloy
Schematic illustration of the
microstructures for an iron-carbon
alloy of eutectoid composition
(0.77% carbon) above and below the
eutectoid temperature of 727°C
(1341°F).
pearlite
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Microstructure of Steel Formed from Eutectoid Composition
Microstructure of pearlite in 1080 steel formed from austenite of a
eutectoid composition. In this lamellar structure, the lighter regions are
ferrite, and the darker regions are carbide. Magnification: 2500x.
• Heat treatment of castings
What About Cooling Rates?
• Faster cooling gives “non-equilibrium
microconstituents”…
– Bainite
– Martensite
– And more!
• To know what microconstituents are present,
you must look at cooling curve diagrams
Microconstituents vs. Cooling Rate
• Pearlite: Layers of ferrite and Fe3C
Increasing Cooling Rate
– Course Pearlite
– Fine Pearlite
• Bainite: 200 – 500 C Transformation
• Martensite: Rapid Cooling
Slow Cooling
Time in region
indicates amount of
microconstituent!
Medium Cooling
Cooling Rate, R, is
Change in Temp /
Time °C/s
Fast Cooling
This steel is very
hardenable… 100%
Martensite in ~ 1
minute of cooling!
Film x 2
Phase Diagram for Aluminum-copper Alloy
and Obtained Microstructures
(a) Phase diagram for the aluminum-copper alloy system.
(b) Various microstructures obtained during the age-hardening process.
Effect of Time and Temperature on Yield Stress
The effect of again time and temperature on the yield stress of
2014-T4 aluminum alloy. Note that, for each temperature, there is
an optimal aging time for maximum strength.
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting process
• Special casting processes
Casting into sand moulds
mould
core
core
Sand casting process
Sand mould
Casting
Casting into sand moulds
Casting into sand moulds
Moulding
Casting into sand moulds
Moulding plate
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting process
• Special casting processes
Casting into sand moulds
Moulding and core mass can be classified depending on the
application and type:
• moulding mass used for casting of cast iron, steel and non-
ferrous metals,
• moulding mass for casting "wet" and "dry"mold ,
• moulding mass „near-patterns”, filling and uniform,
• moulding mass natural and synthetic,
• moulding mass for cores (cement, ceramics, etc.).
Cores are made of the core mass. They are made of quartz sands
with small additions of clays and binding materials. When filling the
mold with liquid metal the cores are in more difficult conditions than
the mold. The core sand should have better properties than the
molding sand, and therefore must be more durable and have
greater refractoriness. Moreover, these masses should be low gas-
forming, non-hygroscopic and easy to remove from the solidified
casting.
Casting into sand moulds
Casting into sand moulds
linear distortion of
sand
increase in linear dimensions
sand for moulds
and cores
Molding materials
Grain matrix materials – sands, water, molding clays
a. quartz sand
b. zircon sand
c. chromite sand
d. magnesite sand
e. aluminosilicate sand
f. corundum sand
g. coal sand
Molding materials
HYPOTHESIS
The strength of the mass
bond depends mainly on
the value of the electric
potentials created
between the binder
molecules, the oriented
water molecules and the
quartz grains
Sand grains
Molding materials
Masa formierska
Technological analysis
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting process
• Special casting processes
Gravity die casting
Gravity die casting
Gravity die casting base on making castings by pouring liquid
metal to metal molds. The molds are reusable forms.
• Application for serial production, high volume of medium
and small castings, primarily from non-ferrous alloys, to a
lesser extent with the iron.
• The molds are made of:
– pearlitic gray iron castings -to-ferrous metals and small thin-walled cast
iron castings,
– alloyed gray iron casting all non-ferrous alloys and iron,
– ductile iron casting mainly medium-sized cast iron and steel,
– carbon steel casting large cast iron or cast steel,
– low-alloy steel for medium and large castings of aluminum and iron.
Gravity die casting
The molds with metal cores and sand: a) the molds with metal split core, b) the
mold to cast iron sand cores, c) the mold with four cores metal
Gravity die casting
Conformal cooling
classical cooling chanels
Conformal cooling
Conventional proces of casting in the metal die without cooling
- time of the perticular operations in seconds
Conventional proces of casting in the metal die with cooling
- time of the perticular operations in seconds
Conformal cooling proces of casting in the metal die
- time of the perticular operations in seconds
Gravity die casting
Advantages of gravity die casting:
• high accuracy and dimensional stability of castings,
• good smoothness and purity of the casting surface,
• the ability to obtain a thin wall castings,
• high efficiency of the process,
• elimination of flasks, storage and transport,
• easy mechanization and automation of the process.
Disadvantages gravity die-casting:
• limited use for casting certain alloys, in particular iron,
• limited size and shape of the casting,
• the high cost of the mold.
Characteristic features of selected foundry processes
Weight of castings produced using different casting processes
Process Weight of casting
Sand moulds For several grams, no upper limit
For several grams up to 100 kg,
Gravity die castings rare to 1000 kg
Characteristic features of selected foundry processes
The surface roughness of castings produced using different
casting processes
Mean roughness of surface
Process
Ra, μm
Iron alloys: 8...20
Sand moulds Non-ferrous alloys: 4...10
Aluminium alloys: 4...6
Gravity die castings Copper alloys: 3...5
Iron alloys: 5...9
Characteristic features of selected foundry processes
Economic production quantity of castings produced using
different casting processes
Economic batch size,
Proces
number of parts
Sand moulds any
Castings simple: more than 400
Gravity die castings Castings complicated: over 1000
Characteristic features of selected foundry processes
Metals using for various casting processes
Process Types of alloys
Most alloys (without the zirconium and
Sand moulds titanium alloys)
Aluminum alloys, magnesium, less copper,
Gravity die castings zinc, tin and lead and iron (usually cast
iron)
Casting
means
Foundry Engineering
Dawid Myszka
[email protected]
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting process
• Special casting processes
Preasure die casting
COLD - CHAMBER
TECHNOLOGY
It is mostly used in casting machines for the manufacture of
aluminum alloy, and the re - magnesium.
HOT - CHAMBER
TECHNOLOGY
It is mostly used in casting machines
for the manufacture of zinc alloy, and magnesium.
Preasure die castings
Preasure die casting
The advantages of preasure die casting:
• very high dimensional accuracy,
• very small roughness,
• the possibility of obtaining castings having very thin walls,
• very large reduction or elimination of machining,
• improved mechanical, chemical and physical properties of castings,
• less weight of raw castings,
• very high performance.
The disadvantages of preasure die casting:
• the high cost of machinery and equipment,
• long pre-production,
• limited size and weight of castings,
• difficulties in casting casting with thicker walls (may porosity)
• restricting the use of certain alloys (mainly zinc alloy, aluminum,
magnesium)
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting process
• Special casting processes
Investment
casting
Lost wax process in the past
Principles of casting technology using wax.
I – Technology for small objects used in India and Central Asia around 3000 BCE:
1 – Wax model, 2 – Model covered with clay, 3 – Mold cavity filled with molten metal,
4 – Breaking the mold, 5 – Finished casting.
II – Technology used in Greece around 500 BCE: 1 – Clay prototype, 2 – Divided clay
mold, 3 – Mold cavity coated with a layer of wax, 4 – Wax model with a clay core.
Lost wax process in the past
Drawing reconstructive (a) and section by
through form ( b) of statue Buddy from
Nara
Investment casting process
Investment casting process
Investment casting
blades for aircraft engines
Investment casting
Nickel-based casting alloys
Additionaly 6 wt.% rhenium content,
relatively high refractory element level
(W+Ta + Re+Mo), and low level of
chromium employment
Investment casting process
Advantages of the process:
• getting the greatest dimensional accuracy and surface smoothness,
• replacing expensive forgings and machining through precision castings,
• the possibility of obtaining castings with very complex shapes, impossible to do by
other methods,
• possibility of making any alloy casting (in mass production and high volume most
often used to cast steel, especially alloy? less cast iron and copper alloys and
aluminum alloys exceptionally)
• thin-walled castings can be achieved.
Disadvantages of the process:
• process difficult to mechanization and automation,
• reduced mass of the casting, generally to 1 to 2 kg to 10 kg uniquely.
Base casting processes
• Sand casting process
• Gravity die casting process
• Preasure die casting process
• Investment casting proces
• Special casting methods
Special casting methods
• Directional casting
• Continuous casting
• Centrifugal casting
• Metallic foams
Continous casting
Continous casting
Continous casting
Continous casting
Continous casting
Continous casting
