MIE 441 FOUNDRY TECHNOLOGY Introduction to casting BY...

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MIE 441 – FOUNDRY TECHNOLOGY Introduction to casting BY KIMUTAI
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Introduction One of the oldest processes used to shape metals is the casting process (CP) which basically involves : 1. Pouring molten metal into a mold cavity 2. Allowing it to solidify (cool), and 3. Removing the part from the mold. Casting processes developed over the years can be classified into: 1. Expandable mold: sand, shell, expandable pattern, plaster, ceramic and investment . 2. Permanent mold: slush, pressure, die, centrifugal, squeeze, and semisolid. 3. Single crystal growing: single crystals for microelectronics, single-crystal turbine blades, and directional solidification.
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Introduction –Cont’ Casting processes are most often selected over other manufacturing methods, for the following reasons: 1. Casting can produce complex shapes with internal cavities or hollow sections. 2. Very large parts can be produced in one piece. 3. It can utilize materials that are difficult or uneconomical to process by other means. 4. Casting is competitive with other processes. Almost all metals can be cast in the final shape desired ( net-shape mfg), often with only minor finishing operations required. Important considerations in casting operations: 1. Flow of the molten metal into the mold cavity. 2. Solidification and cooling of the metal in the mold. 3. The influence of the type of mold material .
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Solidification of Metals After pouring molten metal into a mold, a series of events takes place during the solidification of the metal and cooling to room temperature.
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