1. SPECIAL MOULDING PROCESSES Hareesha N G Lecturer Dept. of Aeronautical Engineering

2. Steps involved in the process The mould is cleaned using wire brush or compressed air to remove dust and other particles from it. It is preheated to a temperature of 200 - 280°C by gas or oil flame and then the surface is sprayed with a lubricant. The lubricant helps to control the temperature of the die thereby increasing its life and also assist in easy removal of solidified casting. The mould is closed tightly and the liquid metal of the desired composition is poured into the mould under gravity. After the metal cools and solidifies, the mould is opened and the casting is removed. Gating and risering systems are separated from the cast part. The mould is sprayed with lubricant and closed for next casting. The mould need not be preheated since the heat in the previous cast is sufficient to maintain the temperature. Advantages Good surface finish and close dimensional tolerances can be achieved. Suitable for mass production. Occupies less floor space. Thin sections can be easily cast. Eliminates skilled operators. Disadvantages Initial cost for manufacturing moulds (dies) is high. Not suitable for steel and high melting point metals/alloys. Un-economical for small productions.

3. 10. PRESSURE DIE CASTING Pressure die casting often called 'Die casting' is a casting process in which the molten metal is injected into a 'die' under high pressures. The metal being cast must have a low melting point than the die material which is usually made from steel and other alloys. Hence, this process is best suitable for casting non-ferrous materials, although a few ferrous materials can be cast. The two basic methods of die casting include: a)Hot chamber die casting process b)Cold chamber die casting process.

4. 10.a. Hot chamber die casting process Figure shows a 'goose neck' type of hot chamber die casting machine. In this process, the dies are made in two halves: one half called the fixed die or 'stationary die’ while the other half called 'movable die’. The dies are aligned in positions by means of ejector pins which also help to eject the solidified casting from the dies. Figure: Hot chamber die casting (Submerged plunger type)

5. Steps involved in the process A pivoted cast iron goose neck is submerged in a reservoir of molten metal where the metal enters and fills the goose neck by gravity. The goose neck is raised with the help of a link and then the neck part is positioned in the sprue of the fixed part of the die. Compressed air is then blown from the top which forces the liquid metal into the die cavity. When the solidification is about to complete, the supply of compressed air is stopped and the goose neck is lowered back to receive the molten metal for the next cycle. In the meantime, the movable die half opens by means of ejector pins forcing the casting from the die cavity. The die halves close to receive the molten metal for the next casting. Hot chamber process is used for casting metals like zinc, tin, magnesium and lead based alloys. Figure: Hot chamber die casting (Goose neck or air injection type)

6. 10.b: Cold chamber Die Casting Process In hot chamber process, the charging unit (goose neck) rests in the melting chamber, whereas in cold chamber process, the melting chamber is separate and the molten metal is charged into the machine by means of ladles. Cold chamber process is employed for casting materials that are not possible by the hot chamber process. For example, aluminum alloys react with the steel structure of the hot chamber machine and as a result there is a considerable iron pick-up by aluminum. This does not happen in cold chamber process, as the molten metal has a momentary contact with the structure of the machine. Figure shows the cold chamber die casting machine Fig: cold chamber die casting machine The machine consists of a die, made in two halves: one half called the 'fixed die' or 'stationary die’ while the other half called 'movable die’. The dies are aligned in positions by means of ejector pins which also help to eject the solidified casting from the dies.

7. Steps involved in the process A cylindrical shaped chamber called 'cold chamber' (so called because, it is not a part of melting or charging unit unlike in hot chamber process) is fitted with a freely moving piston and is operated by means of hydraulic pressure. A measured quantity of molten metal is poured into the cold chamber by means of ladles. The plunger of the piston is activated and progresses rapidly forcing the molten metal into the die cavity. The pressure is maintained during the solidification process. After the metal cools and solidifies, the plunger moves backward and the movable die half opens by means of ejector pins forcing the casting from the die cavity. The cold chamber process is slightly slower when compared to the hot chamber process.

8. Advantages of Die casting process Process is economical for large production quantities. Good dimensional accuracy and surface finish. Thin sections can be easily cast. Near net shape can be achieved. Disadvantages High cost of dies and equipment. Not economical for small production quantities. Process not preferable for ferrous metals. Part geometry must allow easy removal from die cavity

9. 11. CONTINUOUS CASTING Continuous casting is a casting process in which the operation of pouring, solidification and withdrawal of casting from an open mould are carried out continuously. Figure shows a schematic of the process.

10. Steps involved in the process 1.The molten metal is continuously supplied from the ladle to the intermediate ladle called 'tundish' from where it is continuously poured into the mould at a controllable rate, keeping the level at a constant position. 2.The mould usually made of copper or graphite is open at the bottom and is water cooled so as to extract the heat of the metal causing its solidification. The shape of the mould corresponds to the shape of the desired casting. 3.The process is started by placing a dummy bar at the bottom of the mould upon which the first liquid metal falls. 4.The molten metal from the tundish enters the mould and takes the shape of the mould. The water cooled mould controls the cooling rate of the metal, so that it solidifies before it leaves the mould. 5.The metal after coming out of the mould is further cooled by direct water spray (or water with air) to complete solidification. 6.The solidified metal is continuously extracted (along with the dummy bar) by 'pinch rolls', bent and fed horizontally and finally cut to the desired length. 7.The dummy bar is initially placed at the bottom of the mould to receive the first liquid metal (since the bottom of the mould is open). It is later disconnected from the casting.

11. Advantages Sprue, runner, riser etc., are not used. Hence, no waste metal. This leads to 100 % casting yield*. Capable of producing in single operation, rods, sections and tubes with varying sizes and wall thickness. Process is automatic. Product has good consistent soundness. Mechanical properties are high Disadvantages Not suitable for small quantity production. Continuous and efficient cooling of moulds is required, else, center- line shrinkage develops. Requires large floor space. * Yield - Comparison of casting weight to the total weight of the metal poured into the mould.

12. 12. CENTRIFUGAL CASTING Centrifugal casting is a process in which the molten metal is poured and allowed to solidify in a revolving mould. The centrifugal force due to the revolving mould holds the molten metal against the mould wall until it solidifies. The material used for preparing moulds may be cast iron, steel, sand or graphite (for non-ferrous castings). The process is used for making castings of hollow cylindrical shapes. The various centrifugal casting techniques include: a)True centrifugal casting b)Semi-centrifugal casting and c)Centrifuge casting.

13. 12.a. True Centrifugal casting True centrifugal casting is used to produce parts that are symmetrical about the axis like that of pipes, tubes, bushings, liners and rings. The outside shape of the casting can be round, octagonal, hexagonal etc., but the inside shape is perfectly (theoretically) round due to radially symmetric forces. This eliminates the need for cores for producing hollow castings. Figure shows the true centrifugal process. Figure: True centrifugal process

14. Steps involved in the process 1.The mould of the desired shape is prepared with metal and the walls are coated with a refractory ceramic coating. 2.The mould is rotated about its axis at high speeds in the range of 300 - 3000 rpm. A measured quantity of molten metal is poured into the rotating mould. 3.The centrifugal force of the rotating mould throws the liquid metal towards the mould wall and holds the molten metal until it solidifies. 4.The casting cools and solidifies from its outer surface towards the axis of rotation of the mould thereby promoting directional solidification. 5.The thickness of the casting obtained can be controlled by the amount of liquid metal being poured. An inherent quality of true centrifugal castings is based on the fact that, the non- metallic impurities in castings being less dense than the metal, are forced towards the inner surface (towards the axis) of the casting due to the centrifugal forces. These impurities can be machined later by a suitable machining process (say boring operation). The mould may be rotated horizontally or vertically. When the mould is rotated about horizontal axis, a true cylindrical inside surface is produced; if rotated on a vertical axis, parabolic inside surface is produced. Cores and gating/risering systems are not required for this process.

15. 12.b. Semi-centrifugal casting Semi-centrifugal casting process is used to produce solid castings and hence, requires a core to produce hollow cavities. The process is used only for symmetrically shaped objects and the axis of rotation of the mould is always vertical. Gear blanks, sheaves, wheels and pulley are the commonly produced parts by this process. Figure shows the process to produce a wheel shaped casting.

16. Steps involved in the process The mould is prepared in the usual manner using cope and drag box. The mould cavity is prepared with its central axis being vertical and concentric with the axis of rotation. The core is placed in position and the mould is rotated at suitable speeds, usually less than true centrifugal casting process. The centrifugal force produced due to the rotation of the mould causes the molten metal to fill the cavity to produce the desired shape.

17. 12.c. Centrifuging Process In true and semi centrifugal process, the axis of the mould/cavity coincide with the axis of rotation. Where as in centrifuging process, the axis of the mould cavity does not coincide with the axis of rotation. The mould is designed with part cavities located away from the axis of rotation. Hence, this process is suitable for non-symmetrical castings. Figure shows the centrifuging process.

18. Steps involved in the process 1.Several mould cavities are arranged in a circle and connected to a central down sprue through gates. 2.The axis of the down sprue is common to the axis of rotation of the mould. 3.As the mould is rotated, the liquid metal is poured down the sprue which feeds the metal into the mould cavity under centrifugal force. 4.The rotational speed depends on a number of factors such as, the moulding medium (sand, metal or ceramic), size of the casting, type of metal being poured and the distance of the cavity from the central axis (sprue axis). 5.Centrifuging is done only about a vertical axis.

19. 13. SQUEEZE CASTING Squeeze casting or squeeze forming or liquid metal forging is a combination of casting and forging process. Figure shows the sequence of operations involved in the process.

20. Steps involved in the process 1.The process makes use of two dies: bottom die and top die, cast and machined in such a way that upon mating leaves a cavity similar to the shape of the desired casting. Refer figure (a). 2. The bottom die is preheated to around 200 - 250°C with the help of a torch and sprayed by a water based graphite lubricant to facilitate easy removal of casting after solidification. Refer figure (b).

21. 3. Measured quantity of molten metal is poured into the bottom die as shown in figure (c). As the metal starts solidifying, pressure is applied to the top die causing it to move rapidly towards the bottom die. 4.This causes the molten metal to get squeezed and fill the mould cavity. Refer figure (d). The squeezing pressure is applied until solidification is completed. 5.The casting is ejected by operating the lift pin provided in the bottom die, and the die is then made ready for the next cycle. Refer figure (e) Squeeze casting is commonly used for casting aluminum and magnesium alloys. Cores can be used in this process to produce holes and recesses.

22. Advantages Metals which have poor fluidity characteristics can be cast by this process. Shrinkage and gas porosity will be less due to the applied pressure during solidification. Enhanced mechanical properties because of the fine grain structure caused by rapid solidification. Good surface finish. Disadvantages Process is costlier. Manufacturing of dies to accurate dimensions involves complex processes. Accurate metering of molten metal is a slight difficult problem. Un-economical for small quantity production.

23. 14. SLUSH CASTING Slush casting is a process in which hollow castings are produced without the use of cores. The process is not preferred to produce objects for engineering use, instead, it is used to make objects like statues, toys, lamp base, candle sticks and others, where only the external features of the object are important. Refer figure (c).

24. Steps involved in the process In this process, the molten metal is poured in a metallic mould and permitted to remain in the mould for a short interval of time. Refer figure (a). Solidification begins at the mould walls, as they are relatively cool and then progresses inward. When a shell of desired thickness is formed, the mould is inverted and the metal which is still in the liquid state is drained off. Refer figure (b). The thickness of the shell obtained depends on the time for which the metal was allowed to remain in the mould and also the thermal conductivity of the mould. When the mould halves are separated, a hollow casting with good features on its external surfaces, but variable wall thickness is, obtained as shown in figure (c). Advantages Process is inexpensive. Hollow castings can be made without using cores. Disadvantages Process is used for art and decorative work only. Only low melting point alloys with narrow freezing ranges can be used.

25. 15. THIXOCASTING PROCESS Thixocasting, although similar to squeeze casting, is a more refined process in which the casting material, for example, aluminum alloy is subjected to a heating treatment to prepare a semi-molten material having solid and liquid phases co-existing therein. The semi-molten material is injected into a cavity whose shape resembles to the shape of the desired product and rapidly compressed at very high pressures. This is a high potential technology bringing together quality metallurgy, advanced mechanical properties and excellent dimensional precision. The yield strength of the part made by thixocasting is around 220 MPa compared to a maximum of 140 MPa, that obtained by a pressure die casting process. It is therefore used in the manufacture of light weight parts especially in automobiles that are subjected to severe stresses.