1. Casting

2. Casting
Sand Casting is a process that has been around for over 5000 years. The process itself is fairly simple. A pattern is pressed into a sand mould to leave an impression. The pattern is then removed and the impression left behind is filled with a molten metal.

3. Pattern Design Broken Edges
Patterns are generally made from wood however they can be made from metal, plastic or any number of other materials.
When designing a pattern a number of things must be taken into consideration.
Square Pattern
1. All patterns must have a Taper (or Draft) this allows the pattern to be withdrawn cleanly from the mould. This should be between 2˚ & 5˚
Sharp Edges
Pattern
Tapered Pattern

4. Pattern Design
2. Sharp internal corners should be avoided as these will focus any stresses acting on the casting and can cause it to fracture
Weak Spot
Sharp Corners
If you leave any sharp internal edges
Use a wax fillet on internal corners
This can weaken the final design
For a stronger casting

5. Pattern Design
3. Patterns should be finished with paint or varnish and sanded with fine glass paper. This will help avoid the pattern absorbing moisture form the sand and distorting.
The varnish or paint will give the pattern a much finer finish and consequently the final casting will have a superior finish

6. Pattern Design Pattern Casting
Cooling has occurred before the mould cavity has filled
4. Avoid changes in section because this may cause differential cooling (one part of the casting cooling much faster than the rest) this can lead to internal stresses in the casting. Also try to avoid patterns that are extremely thin as the molten metal can often cool before it has flowed into all areas of the mould.

7. Pattern Design
5. Finally remember to make the pattern slightly larger than the required casting. This will allow for any machining and for the fact that as the molten metal cools it will contract.

8. Casting Metals
Aluminium is a lightweight, Non ferrous metal often used for casting . It is the most suitable metal for casting in the school workshop due to its low melting point (around 660˚C) Because the metal cools as it flows through the moulding box it is advisable to heat the metal to 760˚C before pouring.
Aluminium Ingots
Aluminium Lamp Aluminium Saucepan

9. Casting Metals
Brass (an alloy of Copper & Zinc) is often used for casting. This yellow, non ferrous metal has many uses, mainly due to its resistance to corrosion. Brass has a higher melting point (905˚C) than aluminium and thus is generally not used as a casting material in schools.
Brass Ornaments Brass Bell
Brass Ingots

10. Casting Metals
Cast Iron is a hard, ferrous metal often used by industry for casting.
Cast Iron melts at about 2270˚C and consequently is not used in the school workshop.
Cast Iron Gate Cast Iron Vice Cast Iron Fire place surround

11. The above casting equipment will be used
Cope
Riddle
Striking Off Bar
Bellows
Drag
Parting Powder
Vent Spike
Degassing Tablets
Gate Cutter
Rapping Iron
Draw Pin
Sprue Pins
Rammer
The above casting equipment will be used

12. The above Safety Equipment will be required
Casting Equipment
Full Face Mask
Leather Apron
Leather Gauntlets
The above Safety Equipment will be required

13. Casting
Pattern
Drag
Place the Drag face down on a board and sit the pattern in the centre

14. Casting Parting Powder
Lightly dust the pattern and board with some parting powder (chalk dust)

15. Casting
Carefully riddle some facing sand over the pattern until it is completely covered to a depth of 20mm

16. Use your fingers to lightly pack the sand around the pattern.
Casting
Use your fingers to lightly pack the sand around the pattern.

17. Casting
Rammer
Fill the rest of the moulding box and use a rammer to compact the sand.

18. Use a strike off bar to remove any surplus sand.
Casting
Strike Off Bar
Use a strike off bar to remove any surplus sand.

19. Carefully turn the drag over and place the cope on top.
Casting
Cope
Drag
Carefully turn the drag over and place the cope on top.

20. Again lightly dust with parting powder.
Casting
Parting Powder
Again lightly dust with parting powder.

21. Place the Sprue Pins in the box.
Casting
Sprue Pins
Place the Sprue Pins in the box.

22. Casting
Riddle more facing sand onto the underside of the pattern (about 20mm) Then fill the rest of the moulding box.

23. Casting
Again use a Rammer to pack the sand. Take care to pack around the Sprue Pins.

24. Fill the Cope to the top and use the Strike off bar to level the top
Casting
Fill the Cope to the top and use the Strike off bar to level the top

25. Carefully form a pouring cup around one of the Sprue pins
Casting
Pouring Cup
Carefully form a pouring cup around one of the Sprue pins

26. Gently remove the Sprue pins
Casting
Sprue Pins
Use a finger to round over any sharp corners
Gently remove the Sprue pins

27. Carefully separate the two halves of the moulding box
Casting
Pouring Cup
Carefully separate the two halves of the moulding box

28. Carefully cut the in and out gates
Casting
Out Gate
In Gate
In Gate
Carefully cut the in and out gates

29. Casting Draw Pin Draw Pin Rapping Iron
Screw the Draw Pin into the centre of the pattern and gently tap in all directions with a Rapping Iron

30. Carefully remove the pattern
Casting
Carefully remove the pattern

31. Casting
Use your finger to round over any sharp edges near the two gates then use the Bellows to blow away any grains of sand that have fallen into the mould

32. Carefully put the two halves of the moulding box back together
Casting
Carefully put the two halves of the moulding box back together

33. Casting
Vent Rod
Use the Vent Rod to make some holes part way through the sand on the top of the moulding box. This will help any excess gas escape

34. Casting
Carefully lift the completed moulding box and sit it in front of the crucible furnace

35. Casting
Heat the aluminium until it reaches the required temperature (750˚C) This can be checked with a Pyrometer

36. Casting
Add a Degassing Tablet, this will help remove any excess gas from the aluminium and drive any impurities to the surface

37. Carefully skim off the impurities on the surface of the aluminium
Casting
Carefully skim off the impurities on the surface of the aluminium

38. Casting
Carefully pour the molten aluminium down the runner stopping when the mould is full (when the molten metal rises up the riser)

39. Allow to cool (this will take a number of hours)
Casting
Allow to cool (this will take a number of hours)

40. When the casting has cooled open the moulding box

41. Carefully scrape the burnt sand into the bin
Casting
Carefully scrape the burnt sand into the bin

42. Remove the casting (trying not to mix the burnt sand with the rest)

43. Use a Hacksaw to cut off the runner & riser
Casting
Use a Hacksaw to cut off the runner & riser

44. Finally file off any excess with a Dreadnaught File
Casting
Dreadnaught File
Finally file off any excess with a Dreadnaught File

45. The End