Metal Processes.

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Presentation transcript:

Metal Processes

CASTING

Shrinkage The cavity is usually made oversize to allow for the metal contraction as it cools down to room temperature. This is achieved by making the pattern oversize. To account for shrinking, the pattern must be made oversize by these factors, on the average. Metal Pattern Oversize Factor (each direction) Finish Allowance (smaller number for larger sizes) Min Wall mm (inches) Aluminium 1.08 - 1.12 0.5 to 1.0 % 4.75 (0.18) Copper alloys 1.05 - 1.06 2.3 (0.094) Grey Cast Iron 1.10 0.4 to 1.6 % 3.0 (0.125) Nickel alloys 1.05 N/A Steel 1.05 - 1.10 0.5 to 2 % 5 (0.20) Magnesium alloys 1.07 - 1.10 4.0 (0.157) Malleable Irons 1.06 - 1.19 0.6 to 1.6 %

First steps The pattern is place in the drag with its parting line down. The pattern is then dusted with parting dust. Parting dust is a powder that will not absorb moisture. This provides a barrier between the pattern and the moulding sand. The parting dust makes it easier to remove the pattern later in the process.

Filling with sand Ramming the sand

The finished article Pouring the metal http://www.youtube.com/watch?v=IrcNSgLZuFs

Useful websites www.wynndanzur.com www.dansworkshop.com www.almmc.com www.world-aluminium.org www.maycast.co.uk www.castmetalsfederation.com www.johnschwytzer.com

Defects Metallic projections Cavities Discontinuities There are seven basic types of defects that occur in casting: Metallic projections Cavities Discontinuities Defective surface Incomplete casting Incorrect dimensions/shape Inclusions Using the computers find the definitions for these terms

Modifying characteristics using heat Using the following terms below find out the definition and explain the advantages and disadvantages of each. Annealing Case hardening precipitation strengthening Tempering quenching

Metal processes Using the following terms below find out the definition and explain the advantages and disadvantages of each. And a supporting image for the process. Milling Turning Pressing Stamping