Casting Mukul Gupta ID# M-L

Casting A manufacturing process used to solidify objects from their liquid form into various useful shapes by introducing a fluid melt into a mold. A manufacturing process used to solidify objects from their liquid form into various useful shapes by introducing a fluid melt into a mold. Four main elements Pattern Pattern Mold Mold Cores Cores the part the part

Subdivisions of Casting Expendable mold casting: Sand Casting Sand Casting Sand Casting Sand Casting Plaster casting (of metals) Plaster casting (of metals) Plaster casting (of metals) Plaster casting (of metals) Plaster casting (of plaster or concrete) Plaster casting (of plaster or concrete) Plaster casting (of plaster or concrete) Plaster casting (of plaster or concrete) Shell molding Shell molding Shell molding Shell molding Investment Casting Investment Casting Investment Casting Investment Casting Nonexpendable mold casting: Permanent Mold Casting Permanent Mold Casting Permanent Mold Casting Permanent Mold Casting Die Casting Die Casting Die Casting Die Casting Centrifugal casting Centrifugal casting Centrifugal casting Centrifugal casting Continuous casting Continuous casting Continuous casting Continuous casting

Cooling rate The rate at which a casting cools affects it microstructure, quality, and properties The rate at which a casting cools affects it microstructure, quality, and properties Slower Cooling: Increases the metal's grain size Increases the metal's grain size Resluting in a coarse microstructure Resluting in a coarse microstructure allows more gases and waste metal to escape, reducing the voids and inclusions that can weaken a casting allows more gases and waste metal to escape, reducing the voids and inclusions that can weaken a casting Faster Cooling: resulting in a fine microstructure with small grain and less alloy segregation resulting in a fine microstructure with small grain and less alloy segregation more trapped gases and inclusions more trapped gases and inclusions

Shrinkage The shrinkage caused by solidification can leave cavities in a casting, weakening it. The shrinkage caused by solidification can leave cavities in a casting, weakening it. Risers provide additional material to the casting as it solidifies Risers provide additional material to the casting as it solidifies Add Costs Add Costs Why does shrinkage occurs Metals are less dense as liquids than as solids, castings shrink as they cool Metals are less dense as liquids than as solids, castings shrink as they cool

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