The Casting

Casting Processes

ver. 2

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Types of Parts Made

• • • • Engine blocks Pipes Jewelry Fire hydrants

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Complex, 3-D shapes

• • • • • • • Near net shape Low scrap Relatively quick process Intricate shapes Large hollow shapes No limit to size Reasonable to good surface finish

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011 3

Processes

• • • • • • • • Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum • • • • • • Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification • Slush • Continuous

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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

Metals processed by casting

• • • • • • Sand casting – 60% Investment casting – 7% Die casting – 9% Permanent mold casting – 11% Centrifugal casting – 7% Shell mold casting – 6%

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Breakdown of Castings

• Ingots for bulk deformation processing 85% • Cast to near net shape - 15%

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Ingots

• Iron or steel molds • Water-cooled molds • Continuous casting

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Shapes

• Permanent mold (cavity)

– die casting – hot chamber – cold chamber

• Expendable Molds

– – – – sand shell slurry investment

• lost wax • lost foam

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Shapes

• Centrifugal

– pipes – spinning

ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton © GIT 2011

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Capabilities

• Dimensions

– sand casting - as large as you like – small - 1 mm or so

• Tolerances

– 0.005 in to 0.1 in

• Surface finish

– die casting 8-16 micro-inches (1-3 mm) –...