lecture_6_-_fundamentals_of_metal_casting_-_ch_10.20110203.4d4af0f3b750d8.99216388

Lecture_6_-_fundamentals_of_metal_casting_-_ch_10.20110203.4d4af0f3b750d8.99216388

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ME 350 – Lecture 6 – Chapter 10 FUNDAMENTALS OF METAL CASTING: Overview of Casting Technology Heating and Pouring Solidification and Cooling
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The Casting Industry 14 million pounds of castings are produced every year The most common materials cast are gray iron, ductile iron, aluminum alloys, and copper alloys 35% of the market is in automotive and light truck manufacturing Castings are used in applications ranging from agriculture to railroad equipment and heating and refrigeration
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Capabilities and Advantages of Casting Can create complex part geometries Can create both external and internal shapes Some casting processes are net shape; others are near net shape Can produce a wide variety of sized parts: Large parts: e ngine blocks, wood burning stoves, railway wheels, pipes, church bells, statues, etc. Small parts: d ental crowns, jewelry, small statues, frying pans
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Limitations of Casting 1. Limitations on mechanical properties (heat treating, alloy segregation, etc.) 2. Poor dimensional accuracy and surface finish for some processes; e.g., sand casting 3. Safety hazards to workers due to hot molten metals
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Two Categories of Casting Processes 1. Uses a mold which is destroyed to remove casting: expendable mold processes Mold materials: sand, plaster, and similar materials, plus binders 2. Uses a mold which can be used over and over: permanent mold processes Made of metal (or, less commonly, a ceramic refractory material
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Sand Casting Mold
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Sand Casting Mold Terms Mold consists of two halves: Upper half of mold: Cope Bottom half of mold: Drag Mold halves are contained in a box, called: Flask The two halves separate at the: Parting line Gating system consists of: Horizontal tube openings through which metal travels to the main cavity: Runner Vertical tube opening of varying diameter designed to control metal flow velocity: Downsprue , Topmost opening designed to minimize splash and turbulence: Pouring cup
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Riser Reservoir in the mold which acts as a source of liquid metal during solidification to: compensate for shrinkage of the part In order to satisfy its function, the riser must be designed to freeze (before or after) the main casting
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Use of a Core in the Mold Cavity The mold cavity provides the external surfaces of the cast part In addition, a casting may have internal
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