Fundamental of Metal Casting

Factors in casting operation

„ (1)Solidification
„ (2)Fluidity of molten metal
„ (3)Heat transfer
„ (4)Mold material
 Solidification
„ (1)Nucleation
-homogeneous
-heterogeneous
„ (2)Growth
-planar
-dendrite
 Solidification of metals
„ (1)Pure metals (fig.10.1-2)
-skin , shell , or chill zone of fine equiaxed
grains
-columnar grains
„ (2)Alloys(fig .10.3-4)
-chill zone
-columnar dendrites
-equiaxed zone (grains )
Cast Structures of Metals
Figure 10.1 Schematic illustration of
three cast structures of metals
solidified in a square mold: (a) pure
metals; (b) solid-solution alloys; and
(c) structure obtained by using
nucleating agents. Source: G. W.
Form, J. F. Wallace, J. L. Walker,
and A. Cibula.
 Preferred Texture
Development

Figure 10.2 Development of a preferred texture at a cool mold wall. Note that only
favorably oriented grains grow away from the surface of the mold.
 Alloy Solidification

Figure 10.3
Schematic illustration
of alloy solidification
and temperature
distribution in the
solidifying metal.
Note the formation of
dendrites in the
mushy zone.
 Solidification Patterns
Figure 10.4 (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting. Note
that after 11 min. of cooling, dendrites reach each other, but the casting is still mushy throughout. It
takes about two hours for this casting to solidify completely. (b) Solidification of carbon steels in
sand and chill (metal) molds. Note the difference in solidification patterns as the carbon content
increases. Source: H. F. Bishop and W. S. Pellini.
 Cast
Structures Figure 10.5
Schematic
illustration of three
basic types of cast
structures: (a)
columnar dendritic;
(b) equiaxed
dendritic; and (c)
equiaxed
nondendritic.
Source: D. Apelian.

Figure 10.6 Schematic illustration of cast

structures in (a) plane front, single phase, and (b)
plane front, two phase. Source: D. Apelian.
 Effects of cooling rates
„ (1)Slow cooling rates (order of 102K/s )
-coarse dendritic structure
„ (2)Faster cooling rates (order of 104K/s )
-finer with smaller dendrite arm spacing
„ (3)Faster cooling rates (order of
106 to 108K/s )
-amorphous
 Grain size of the cast alloy
decreases
„ (1)Strength and ductility increase
„ (2)Microporosity decreases
„ (3)Tendency to crack (hot tearing)
decreases
 Fluid flow
„ (1)Bernoulli's theorem
„ (2)Continuity law
„ (3)Flow characteristics
-turbulence or laminar flow
 Riser-Gated
Casting
Figure 10.7 Schematic illustration
of a typical riser-gated casting.
Risers serve as reservoirs,
supplying molten metal to the
casting as it shrinks during
solidification. See also Fig. 11.4
Source: American Foundrymen’s
Society.
 Fluidity of molten metal
A .Molten metal
„ (1)Viscosity

„ (2)Surface tension

„ (3)Inclusions

„ (4)Solidification pattern (freezing range )

Fluidity Test
Figure 10.8 A test method for fluidity
using a spiral mold. The fluidity index is
the length of the solidified metal in the
spiral passage. The greater the length of the
solidified metal, the greater is its fluidity.
 Fluidity of molten metal
B .Casting parameters
„ (1)Mold design

„ (2)Mold material and its surface

characteristics
„ (3)Degree of superheat

„ (4)Rate of pouring

„ (5)Heat transfer (fig.10.9)

 Temperature
Distribution

Figure 10.9 Temperature

distribution at the interface of the
mold wall and the liquid metal
during solidification of metals in
casting.
 Solidification time

2
 volume 
= C  
 surface area 
Solidification
Time
Figure 10.10 Solidified skin on a
steel casting. The remaining
molten metal is poured out at the
times indicated in the figure.
Hollow ornamental and decorative
objects are made by a process
called slush casting, which is
based on this principle. Source: H.
F. Taylor, J. Wulff, and M. C.
Flemings.
 Shrinkage
„ (1)Dimensional changes
„ (2)Cracking
 Solidification Contraction for
Various Cast Metals
TABLE 10.1
Volumetric Volumetric
solidification solidification
Metal or alloy contraction (%) Metal or alloy contraction (%)
Aluminum 6.6 70%Cu–30%Zn 4.5
Al–4.5%Cu 6.3 90%Cu–10%Al 4
Al–12%Si 3.8 Gray iron Expansion to 2.5
Carbon steel 2.5–3 Magnesium 4.2
1% carbon steel 4 White iron 4–5.5
Copper 4.9 Zinc 6.5
Source: After R. A. Flinn.
 Defects
„ (1)Metallic projections
„ (2)Cavities
„ (3)Discontinuities
„ (4)Defective surface
„ (5)Incomplete casting
„ (6)Incorrect dimensions or shape
„ (7)Inclusions
„ (8)Porosity (fig .10.13-15)
 Hot Tears

Figure 10.11 Examples of hot tears in castings. These defects occur

because the casting cannot shrink freely during cooling, owing to
constraints in various portions of the molds and cores. Exothermic (heat-
producing) compounds may be used (as exothermic padding) to control
cooling at critical sections to avoid hot tearing.
 Casting Defects
Figure 10.12 Examples of common defects in castings. These defects can be minimized or eliminated
by proper design and preparation of molds and control of pouring procedures. Source: J. Datsko.
 Internal and External
Chills
Figure 10.13
Various types of
(a) internal and
(b) external chills
(dark areas at
corners), used in
castings to
eliminate
porosity caused
by shrinkage.
Chills are placed
in regions where
there is a larger
volume of metals,
as shown in (c).
Solubility of Hydrogen in
Aluminum
Figure 10.14 Solubility of hydrogen in
aluminum. Note the sharp decrease in
solubility as the molten metal begins to
solidify.
Metal-Casting Processes
 Introduction
„ (1)Metal casting processes
„ (2)Principles
„ (3)Advantages
„ (4)Limitations
Impact on the casting industry

„ (1)Mechanization and automation

„ (2)High quality with close tolerance
Casting Examples

Figure 11.2 Typical gray-

iron castings used in
automobiles, including
transmission valve body
(left) and hub rotor with
disk-brake cylinder (front).
Source: Courtesy of Central
Foundry Division of
General Motors
Corporation.

Figure 11.3 A cast

transmission housing.
 Major classification of casting
processes

„ (1)Expendable molds
- sand , plaster , ceramics , and similar
materials ,which are generally mixed
with various binder, bonding agent .
Major classification of casting
processes
„ (2)Permanent molds
-metals with adequate strength at
high temperature
„ (3)Composite molds
 Sand casting
„ (1)Process
„ (2)Sands
-silixca(SiO2)：naturally bonded
synthetic (preferred )
-grain shape and size affect mold
surface , strength , permeability
-clay (a cohesive agent)
 Steps in Sand
Casting

Figure 11.5 Outline of production steps in a typical sand-casting operation.

34
 Sequence of Operations for Sand Casting
(cont.)

Figure 11.11 (g) The flask is rammed with sand and the plate and inserts are removed. (g) The drag half is
produced in a similar manner, with the pattern inserted. A bottom board is placed below the drag and aligned
with pins. (i) The pattern, flask, and bottom board are inverted, and the pattern is withdrawn, leaving the
appropriate imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the
cope on top of the drag and buoyant forces in the liquid, which might lift the cope. (l) After the metal
solidifies, the casting is removed from the mold. (m) The sprue and risers are cut off and recycled and the
casting is cleaned, inspected, and heat treated (when necessary).
 Sand casting

„ (3)Three basic types of sand molds

-green sand：a mixture of sand, clay,
and water skin-dried (baked)-stronger,
better dimensional accuracy and
surface finish the least expensive
 Sand casting
-cold-box：organic and inorganic binder
+sand greater strength
more dimensional accuracy
more expensive
-no-bake mold (cold-setting):
a synthetic liquid resin + sand at room
temperature
 Sand casting
„ (4)Major component of sand casting(fig.11.4)
-flask , cope , drag , cheeks
-pouring basin or cup , sprue
-runner system , gates
-risers (blind and open)
-cores
-vents
 Sand Mold Features

Figure 11.4 Schematic illustration of a sand mold, showing various features.

 Sand casting
„ (5)Patterns
-wood , plastic , metal (table 11.2)
-depends on
size and shape of the casting
dimensional accuracy
quality
molding process
-parting agent
 General Characteristics of Casting
Processes

TABLE 11.2
Typical
Typical Weig ht (kg) surface Section thic kness (mm)
materials finish Shape Dimensional
Process cast Minimum Maximum (µm, Ra) Porosity* complexity* accuracy* Minimum Maximum
Sand All 0.05 No limit 5-25 4 1-2 3 3 No limit
Shell All 0.05 100+ 1-3 4 2-3 2 2 --
Expendable
mold
pattern All 0.05 No limit 5-20 4 1 2 2 No limit
Nonferrous
Plaster (Al, Mg, Zn,
mold Cu) 0.05 50+ 1-2 3 1-2 2 1 --
All
(High melting
Investment pt.) 0.005 100+ 1-3 3 1 1 1 75
Permanent
mold All 0.5 300 2-3 2-3 3-4 1 2 50
Nonferrous
(Al, Mg, Zn,
Die Cu) <0.05 50 1-2 1-2 3-4 1 0.5 12
Centrifugal All -- 5000+ 2-10 1-2 3-4 3 2 100
*Relative rating: 1 best, 5 worst.
Note : These ratings are only general; significant variations can occur, depending on the methods used.
 Sand casting
„ -one-piece patterns
simple shape and low quality production wood
-split patterns (two-piece)
cavity
-match-plate pattern (fig .11.6)
a popular type each half of one or more split
patterns large production
 Patterns for Sand Casting
Figure 11.6 A typical metal
match-plate pattern used in
sand casting.

Figure 11.7 Taper on patterns for

ease of removal from the sand mold.
 Sand casting
„ (6)Cores
-shell , no-bake , or cold-box processes
-core prints (fig.11.8)
-chaplets：metal supports for shifting
-core blowers
 Examples of Sand Cores and
Chaplets

Figure 11.8 Examples of sand cores showing core prints and chaplets to support cores.
 Sand casting
„ (7)Sand-molding machines
-jolting , squeezing ,
compacting(fig.11.7-8)
-vertical flask less molding (fig .11.9)
-impact molding
-vacuum molding (V process )
Squeeze Heads
Figure 11.9 Various
designs of squeeze heads for
mold making: (a)
conventional flat head; (b)
profile head; (c) equalizing
squeeze pistons; and (d)
flexible diaphragm. Source:
© Institute of British
Foundrymen. Used with
permission.
 Vertical Flaskless
Molding

Figure 11.10 Vertical flaskless molding. (a) Sand is squeezed between two halves of the pattern.
(b) Assembled molds pass along an assembly line for pouring.
 Sand casting
„ (8)Sand-casting operation(fig.11.10)
-molds
-gating system , risers.
-solidification
-surface of casting
-heat treatment
-finishing operations
 Sequence of Operations for Sand
Casting

Figure 11.11 Schematic illustration of the sequence of operations for sand casting. Source: Steel
Founders' Society of America. (a) A mechanical drawing of the part is used to generate a design for
the pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c)
Patterns have been mounted on plates equipped with pins for alignment. Note the presence of core
prints designed to hold the core in place. (d-e) Core boxes produce core halves, which are pasted
together. The cores will be used to produce the hollow area of the part shown in (a). (f) The cope half
of the mold is assembled by securing the cope pattern plate to the flask with aligning pins, and
attaching inserts to form the sprue and risers. (continued)
 Shell Molding
„ (1)Close tolerance and good surface finishing
Suited for nearly any metal
More economical
Casting with sharper corners , thinner section ,
smaller projection
High quality and complex shapes
Typical parts : gear housings , cylinder head ,
connecting rods ,high-precision
molding cores
Surface Roughness for Various Metalworking
Processes

Figure 11.12 Surface roughness in casting and other metalworking processes. See also Figs. 22.14
and 26.4 for comparison with other manufacturing processes.
Dump-Box Technique
Figure 11.13 A common
method of making shell
molds. Called dump-box
technique, the limitations
are the formation of voids in
the shell and peelback
(when sections of the shell
fall off as the pattern is
raised). Source: ASM
International.
 Composite Molds

Figure 11.14 (a) Schematic illustration of a semipermanent composite mold. Source:

Steel Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. (b) A
composite mold used in casting an aluminum-alloy torque converter. This part was
previously cast in an all-plaster mold. Source: Metals Handbook, vol. 5, 8th ed.
 Shell Molding
„ (2)Process
-a mounted pat tern of a ferrous or aluminum at
175-370℃
-coated with a parting agent (silicone )
-sand + 2.5-4.0 % thermosetting resin binder
-sand mixture is blown over the heated pattern
-shell hardens around the pattern and is
removed from the pat tern
-assemble of the shell
 Shell Molding
„ (3)Characteristics of shell
-thickness depend on time , 5-l0mm
-a much lower permeability produce a
high volume of gas
 Shell Molding
„ (4)Composite molds
-two or more different materials and used in
shell molding and other casting processes
-complex shapes ex . impellers
-increase the strength of mold improve the
dimensional accuracy and finish reduce
overall costs and processing time
 Sodium Silicate Process
(CO2 Process)
„ -sand + 1.5-6 % sodium silicate
(waterglass) + CO2 gas
„ -used as cores
 Evaporative Pat tern Casting
(Lost Foam)
„ (1)Process
-polystryrene + 5-8 % pentane or PMMA,
polyalkylene carbonate placed at a
preheated AL die
-pattern coated with a water-base
refractory slurry, dried , and placed in a
flask
-sand + pattern
Expendable Pattern
Casting

Figure 11.15
Schematic
illustration of the
expendable
pattern casting
process, also
known as lost
foam or
evaporative
casting.
 Evaporative Pat tern Casting
(Lost Foam)
„ (2)Velocity of molten metal：0.1-1 m/s
„ (3)Advantages
-relatively simple process
-inexpensive flasks
Evaporative Pat tern Casting
(Lost Foam)
-complex shapes , various sizes , and
fine surface detail of inexpensive
polystyrene pattern
-minimum finishing and cleaning
operation
-economical for long production runs
-automation
 Evaporative Pat tern Casting
(Lost Foam)
„ (4)Typical parts
-cylinder heads , crankshafts , brake
components ,manifolds for automobiles
-machine bases
 Plastor-Mold Casting
„ (1)Process
-plaster + talc /silica flour + water
placed at patter within 15 min
-plaster mold dried at 120-260℃
-mold assembled and preheated to
about 120℃
-pouring
-shakeout
 Plastor-Mold Casting
„ (2)Pattern for plaster molding : Al alloys,
thermosetting plastic , brass , or zinc
alloys
„ (3)Increasing permeability
-Antioch process :
-dehydrated in a pressurized oven for 6-12
hrs, then dehydrated in air for 14 hrs
-foamed plaster
 Plastor-Mold Casting
„ (4)Characteristics
-Max. temperature：about 1200℃
-used only for Al , Mg , Zn , and some
Cu-base alloys casting
 Plastor-Mold Casting
-precision casting (Ceramic-mold ,
investment casting)
-high dimensional accuracy
-good surface finish
-weight less than 10 kg , typical range
of 125-250 g
 Plastor-Mold Casting
„ (5)Typical parts
-lock component
-gears
-valves
-fitting
-tooling
-ornaments
 Ceramic-Mold Casting
(cope-and-drag casting)
„ (1)Process
-slurry of fine-grained zircon , aluminum
oxide , fused silica , and bonding agent
poured into pattern
-green mold dried , burned off
-ceramic facings assembled into a complete
mold
-pouring
-shakeout
 Ceramic Molds
Figure 11.16 Sequence of operations in
making a ceramic mold. Source: Metals
Handbook, vol. 5, 8th ed.

Figure 11.17 A typical ceramic

mold (Shaw process) for
casting steel dies used in hot
forging. Source: Metals
Handbook, vol. 5, 8th ed.
 Ceramic-Mold Casting
(cope-and-drag casting)
„ (2)Casting materials
-ferrous and other high-temperature
alloys
-stainless steels
-tool steels
 Ceramic-Mold Casting
(cope-and-drag casting)
„ (3)Characteristics
-good dimensional accuracy
-good surface finish
-intricate shapes
-expensive
-weight up to 700 kg
 Ceramic-Mold Casting
(cope-and-drag casting)
„ (4)Typical parts
-impellers
-cutters for machining
-dies for metalworking
-molds
 Investment Casting
(lost-wax process)
„ (1)Process
-mold to make pattern
-wax pattern
-pattern assembly (tree)
-slurry and stucco coating
-completed mold
-pattern melt out
-pouring molten metal
-shakeout
-casting
 Figure 11.18
Schematic
illustration of
investment
casting, (lost-
wax process).
Castings by this
method can be
made with very
fine detail and
from a variety of
metals. Source:
Investment Steel Founders'
Society of
America.
Casting
 Investment Casting
(lost-wax process)
„ (2)Characteristics
-casting high melting point a1loys
ex .ferrous and nonferrous metals
-good surface finish
-close tolerance
-little or no finishing operations
-intricate shapes
 Investment Casting
(lost-wax process)
„ (3)Typical parts
-gears
-cams
-valves
-ratchets
 Ceramic-Shell Investment
Casting
„ (1)Process
-wax or plaster pattern
-pattern dipped in ethyl silicate gel
-pattern dipped in a fluidized bed of fine
grained fused silica or zircon flour
-pattern dipped in coarser grain silica to
withdraw the thermal shock of pouring
-the rest of the procedure is similar to
lost-wax process
 Investment Casting of a
Rotor

Figure 11.19 Investment casting of an integrally cast rotor for a gas turbine. (a) Wax pattern
assembly. (b) Ceramic shell around wax pattern. (c) Wax is melted out and the mold is filled, under
a vacuum, with molten superalloy. (d) The cast rotor, produced to net or near-net shape. Source:
Howmet Corporation.
Investment and Conventionally Cast
Rotors

Figure 11.20 Cross-

section and
microstructure of two
rotors: (top)
investment-cast;
(bottom)
conventionally cast.
Source: Advanced
Materials and
Processes, October
1990, p. 25 ASM
International
 Ceramic-Shell Investment
Casting
„ (2)Economical process
„ (3)Precision casting of steels and high-
temperature alloy
 Vacuum Casting
„ (1)Process
- sand + urethane molded
- vacuum
- drawing the molten metal into the
mold cavity
 Vacuum-Casting Process

Figure 11.21 Schematic illustration of the vacuum-casting process. Note that the mold has a
bottom gate. (a) Before and (b) after immersion of the mold into the molten metal. Source:
From R. Blackburn, "Vacuum Casting Goes Commercial," Advanced Materials and
Processes, February 1990, p. 18. ASM International.
 Vacuum Casting
„ (2)Characteristics
-temperature of molten metal：liquids
temp.+ 55℃
-suitab1e for thin wall(1.75mm)complex
shapes
 Vacuum Casting
-casting of carbon and low- and high-
alloys steel part
-weight up to 70kg
-inexpensive production costs
(similar to green sand casting)
 Permanent-Mold Casting
„ (1)Mold material：cast iron, stee1,
bronze, graphite, refractory metal
alloys
„ (2)Core material ：oil -bonded or resin-
bonded sand ,plaster , graphite ,
gray iron, low-carbon steel
„ (3)Mo Id preheated to 150-200 ℃
 Permanent-Mold Casting
„ (4)Casting material ：A1 , Mg , Cu alloys ,
gray iron , steel
„ (5)Good surface finish , close tolerance ,
Uniform and good mechanical
properties
High production rates
 Permanent-Mold Casting
„ (6)Typi calparts：automobile piston ,
cylinder head connecting rods , gear
blanks
 Slush Casting
„ (1)Process
-pour molten metal into mold
-mold inverted
-remaining liquid metal is poured out
-hollow casting with thin walls
 Slush Casting
„ (2)Small production runs
„ (3)Typical parts：ornamental and
decorative objects and toys
„ (4)Casting material :Zn ,Sn ,Pb alloys
 Pressure Casting
„ (1)Process
-molten metal forced upward by gas
pres sure or vacuum into a graphite or
metal mold
 Pressure Casting

Figure 11.22 (a) The bottom-pressure casting process utilizes graphite molds for the production of
steel railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated. (b)
Gravity-pouring method of casting a railroad wheel. Note that the pouring basin also serves as a
riser. Railroad wheels can also be manufactured by forging.
 Die Casting-two basic types
„ A. Hot-chamber process
(1)Pressure: max.35MPa average 15MPa
(2)Dies cooled by circulating water or oil
(3)Casting low-melting-point alloys: Zn ,
Sn , Pb
 Die-Casting Examples

(a) (b)

Figure 11 (a) The Polaroid PDC-2000 digital camera with a AZ91D die-cast, high purity
magnesium case. (b) Two-piece Polaroid camera case made by the hot-chamber die casting
process. Source: Courtesy of Polaroid Corporation and Chicago White Metal Casting, Inc.
 Die Casting-two basic types
„ B .Cold-chamber process
(1)Pressure: 20-70 MPa, max.150MPa
(2)Casting high-melting-point
alloys:A1,Mg ,Cu alloys
 Hot- and Cold-Chamber Die-
Casting

(a) (b)

Figure 11.23 (a) Schematic illustration of the hot-chamber die-casting process. (b) Schematic
illustration of the cold-chamber die-casting process. Source: Courtesy of Foundry Management
and Technology.
 Cold-Chamber Die-Casting Machine

(a)

Figure 11.24 (a) Schematic illustration of a cold-chamber die-casting machine.

These machines are large compared to the size of the casting because large forces
are required to keep the two halves of the dies closed.
 Hot-Chamber Die-Casting Machine
(b)

Figure 11.24 (b) 800-ton hot-chamber die-casting machine, DAM 8005

(made in Germany in 1998). This is the largest hot-chamber machine in the
world and costs about $1.25 million.
 Die Casting-two basic types
„ C. Characteristics
(1)Typical parts : carburetors, motors,
business machine ,hand tools ,toys
(2)Die casting dies
 Die-Casting Die Cavities
Figure 11.25 Various types of cavities in a die-casting die. Source: Courtesy of
American Die Casting Institute.

Figure 11.26 Examples of

cast-in- place inserts in die
casting. (a) Knurled
bushings. (b) Grooved
threaded rod.
Die Casting-two basic types
(3)High production rates
Good strength, dimensional accuracy
and surface finish
Complex shapes (wall thickness as
small as 0.5mIm)
Little or no finishing operations
Centrifugal Casting-three types
„ A. True centrifugal casting
(1)Mold material: steel, iron, graphite
coated with a refractory lining
(2)Pressure: max.150g
Centrifugal Casting Process

Figure 11.27 Schematic

illustration of the
centrifugal casting process.
Pipes, cylinder liners, and
similarly shaped parts can
be cast with this process.
 Properties and Typical Applications of
Common Die-Casting Alloys

TABLE 11.4
Ultimate
tensile Yield Elongation
strength strength in 50 mm
Alloy (MPa) (MPa) (%) Applications
Aluminum 380 (3.5 Cu-8.5 Si) 320 160 2.5 Appliances, automotive components,
electrical motor frames and housings
13 (12 Si) 300 150 2.5 Complex shapes with thin walls, parts
requiring strength at elevated
temperatures
Brass 858 (60 Cu) 380 200 15 Plumbing fiztures, lock hardware,
bushings, ornamental castings
Magnesium AZ91 B (9 Al-0.7 Zn) 230 160 3 Power tools, automotive parts, sporting
goods
Zinc No. 3 (4 Al) 280 -- 10 Automotive parts, office equipment,
household utensils, building hardware,
toys
5 (4 Al-1 Cu) 320 -- 7 Appliances, automotive parts, building
hardware, business equipment
Source : Data from American Die Casting Institute
Centrifugal Casting-three types
(3)Cylindrical parts:
diameter: 13mm-3m
length: 16m
wall thickness :6-125mm
(4)Typical parts: pipes, bushing, engine-
cylinder liners bearing rings, gun
barrels
Centrifugal Casting-three types
„ B .Semi centrifugal casting
(1)Casting parts with rotational
symmetry

„ C .Centrifuging
 Semicentrifugal Casting

Figure 11.28 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes
can be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are
placed at the periphery of the machine, and the molten metal is forced into the molds by centrifugal
force.
 Squeeze Casting
„ (1)Combination of casting and forging
„ (2)Fine microstructure Good mechanical
proper ties
„ (3)Typical parts: automotive whee1,
mortar bodies
 Squeeze-Casting

Figure 11.29 Sequence of operations in the squeeze-casting process. This process combines the
advantages of casting and forging.
 Casting Techniques for
Single-Crystal Components
„ (1)Convent ional casting of turbine
blades
-ceramic casting:
polycrystalline structure (fig.10.1c)
poor resistant to creep and cracking
 Casting Techniques for
Single-Crystal Components
„ (2)Directionally solidified blades
-columnar grains
-better resistant to creep
„ (3)Single-crystal blades
-best resistant to creep and thermal
shock
 Casting Techniques for
Single-Crystal Components
„ (4)Single-crystal growing
-crystal pulling (Czochralski process )
Si, Ge ingots: dia.50-150 mm
length 1m
-floating zone method
 Single Crystal Casting of Turbine
Blades
Figure 11.30 Methods of casting turbine blades: (a) directional solidification; (b) method to
produce a single-crystal blade; and (c) a single-crystal blade with the constriction portion still
attached. Source: (a) and (b) B. H. Kear, Scientific American, October 1986; (c) Advanced
Materials and Processes, October 1990, p. 29, ASM International.

(c)
 Single Crystal Casting

Figure 11.31 Two methods of

crystal growing: (a) crystal
pulling (Czochralski process)
and (b) the floating-zone
method. Crystal growing is
especially important in the
semiconductor industry.
Source: L. H. Van Vlack,
Materials for Engineering.
Addison-Wesley Publishing
Co., Inc., 1982.
Melt Spinning
Figure 11.32 Schematic
illustration of melt-spinning to
produce thin strips of
amorphous metal.
 Types of Melting
Furnaces

Figure 11.33 Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.
 Inspection of Castings
„ (1)Destructive tests
„ (2)Nondestructive tests
 TABLE 11.1
Process Advantages
Sand Almost any metal cast; no limit
to size, shape or weight; low
tooling cost.
Shell mold Good dimensional accuracy and
surface finish; high production
rate.
Expendable pattern Most metals cast with no limit
to size; complex shapes
Summary of
Plaster mold Intricate shapes; good
dimensional accu- racy and
finish; low porosity.
Casting Ceramic mold Intricate shapes; close
tolerance parts; good surface
Processes
finish.
Investment Intricate shapes; excellent
surface finish and accuracy;
almost any metal cast.
Permanent mold Good surface finish and
dimensional accuracy; low
porosity; high production rate.
Die Excellent dimensional accuracy
and surface finish; high
production rate.
Centrifugal Large cylindrical parts with
good quality; high production
rate.
Limitations
Some finishing required;
somewhat coarse finish; wide
tolerances.
Part size limited; expensive
patterns and equipment
required.
Patterns have low strength and
can be costly for low quantities
Limited to nonferrous metals;
limited size and volume of
production; mold making time
relatively long.
Limited size.
Part size limited; expensive
patterns, molds, and labor.
High mold cost; limited shape
and intricacy; not suitable for
high-melting-point metals.
Die cost is high; part size
limited; usually limited to
nonferrous metals; long lead
time.
Equipment is expensive; part
shape limited.
118