castingprocesses

8/19/2019 castingprocesses

1/31

Manufacturing, Engineering & Technology, Fifth Edition, by Serope

4hapter

Metal%4a0ting /roce00e0


2/31


Suary of 4a0ting /roce00e0


3/31


Typical 4a0t /art0

Figure . 5a6 Typical gray%iron ca0ting0 u0ed in autoobile0, including the tran0i00ion

valve body 5left6 and the hub rotor 7ith di0k%brake cylinder 5front6. Source8 4ourte0y of

4entral Foundry 9ivi0ion of :eneral Motor0 4orporation. 5b6 3 ca0t tran0i00ion hou0ing.

5c6 The /olaroid /94%$$$ digital caera 7ith a 3;*9 die%ca0t high%purity agne0iu

ca0e. 5d6 3 t7o%piece /olaroid caera ca0e ade by the hot%chaber die%ca0ting proce00.

Source: 4ourte0y of /olaroid 4orporation and 4hicago


4/31


4haracteri0tic0 of 4a0ting


5/31


/roduction Step0 in Sand%4a0ting

Figure . =utline of production 0tep0 in a typical 0and%ca0ting operation.


6/31


Sand Mold

Figure .' Scheatic illu0tration of a 0and old, 0ho7ing variou0 feature0.


7/31Manufacturing, Engineering & Technology, Fifth Edition, by Serope

/attern /late

Figure .( 3 typical etal atch%plate pattern u0ed in 0and ca0ting.


8/31Manufacturing, Engineering & Technology, Fifth Edition, by Serope

9e0ign for Ea0e of Reoval fro Mold

Figure . Taper on pattern0 for ea0e of reoval fro the 0and old


9/31


Sand 4ore0

Figure .+ E>aple0 of 0and core0 0ho7ing core print0 and chaplet0 to 0upport core0.


10/31


?ertical Fla0kle00 Molding

Figure .@ ?ertical fla0kle00 olding. 5a6 Sand i0 0AueeBed bet7een t7o

halve0 of the pattern. 5b6 300ebled old0 pa00 along an a00ebly line

for pouring. 5c6 3 photograph of a vertical fla0kle00 olding line. Source8

4ourte0y of 3erican Foundry Society.

(c)


11/31


SeAuence of

=peration0 for

Sand%4a0ting

Figure .) Scheatic illu0tration of the 0eAuence of operation0 for 0and ca0ting. 5a6 3

echanical dra7ing of the part i0 u0ed to generate a de0ign for the pattern. 4on0ideration0 0ucha0 part 0hrinkage and draft u0t be built into the dra7ing. 5b%c6 /attern0 have been ounted on

plate0 eAuipped 7ith pin0 for alignent. #ote the pre0ence of core print0 de0igned to hold the core

in place. 5d%e6 4ore bo>e0 produce core halve0, 7hich are pa0ted together. The core0 7ill be u0ed

to produce the hollo7 area of the part 0ho7n in 5a6. 5f6 The cope half of the old i0 a00ebled by

0ecuring the cope pattern plate to the fla0k 7ith aligning pin0 and attaching in0ert0 to for the 0prue

and ri0er0. 4ontinued on ne>t 0lide.


12/31


SeAuence of

=peration0 for

Sand%4a0ting,

4onCt.

5g6 The fla0k i0 raed 7ith 0and and rthe plate and in0ert0 are reoved. 5h6 The drag half i0

produced in a 0iilar anner 7ith the pattern in0erted. 3 botto board i0 placed belo7 the drag

and aligned 7ith pin0. 5i6 The pattern , fla0k, and botto board are invertedD and the pattern i07ithdra7n, leaving the appropriate iprint. 5j6 The core i0 0et in place 7ithin the drag cavity. 5k6

The old i0 clo0ed by placing the cope on top of the drag and 0ecuring the a00ebly 7ith pin0.

The fla0k0 the are 0ubjected to pre00ure to counteract buoyant force0 in the liAuid, 7hich ight lift

the cope. 5l6 3fter the etal 0olidifie0, the ca0ting i0 reoved fro the old. 56 The 0prue and

ri0er0 are cut off and recycled, and the ca0ting i0 cleaned, in0pected, and heat treated 57hen

nece00ary6. Source8 4ourte0y of Steel FounderC0 Society of 3erica


13/31


Shell%Molding /roce00

Figure .* The 0hell%olding proce00, al0o called dump-box techniAue.


14/31


SeAuence of =peration0 in Making a 4eraic Mold

Figure .$ SeAuence of operation0 in aking a

ceraic old. Source8 Metals Handbook, ?ol. , )th ed.


15/31


E>pandable%/attern 4a0ting /roce00

Figure . Scheatic illu0tration of the e>pandable%pattern ca0ting proce00, al0o

kno7n a0 lo0t%foa or evaporative ca0ting.


16/31


Figure . 5a6 Metal i0 poured into old for lo0t%foa ca0ting of a +$%hp. '%cylinder

arine engineD 5b6 fini0hed engine block. Source8 4ourte0y of Mercury Marine.

5b65a6

Evaporative /attern 4a0ting of an Engine "lock


17/31


!nve0tent 4a0ting /roce00

Figure .' Scheatic illu0tration of inve0tent ca0ting 5lo0t%7a>6 proce00.

4a0ting0 by thi0 ethod can be ade 7ith very fine detail and fro a variety

of etal0. Source8 4ourte0y of Steel FounderC0 Society of 3erica.


18/31


!ntegrally 4a0t Rotor for a :a0 Turbine

Figure .( !nve0tent ca0ting of an integrally ca0t rotor for a ga0 turbine.

5a6 pattern a00ebly. 5b6 4eraic 0hell around 7a> pattern. 5c6

i0 elted out and the old i0 filled, under a vacuu, 7ith olten 0uperalloy.

5d6 The ca0t rotor, produced to net or near%net 0hape. Source8 4ourte0y of

o7et 4orporation.


19/31


4opari0on of !nve0tent%4a0t and

4onventionally 4a0t Rotor0

Figure . 4ro00%0ection and icro0tructure of t7o rotor08 5top6

inve0tent%ca0tD 5botto6 conventionally ca0t. Source8 Advanced

Materials and Processes, =ctober **$, /. . 3SM !nternational.


20/31


?acuu%4a0ting

Figure .+ Scheatic illu0tration of the vacuu%ca0tin proce00. #ote that

the old ha0 a botto gate. 5a6 "efore and 5b6 after ier0ion of the old

into the olten etal. Source8 3fter R. "lackburn.


21/31


ot%4haber 9ie%4a0ting

Figure .@ Scheatic illu0tration of the hot%chaber die%ca0ting proce00.


22/31


4old%4haber 9ie%4a0ting

Figure .) Scheatic illu0tration of the cold%chaber die%ca0ting proce00.

The0e achine0 are large copared to the 0iBe of the ca0ting, becau0e high

force0 are reAuired to keep the t7o halve0 of the die0 clo0ed under pre00ure.


23/31


24/31


Type0 of 4avitie0 in 9ie%4a0ting 9ie

Figure .* ?ariou0 type0 of cavitie0 in a die%ca0ting die.

Source: 4ourte0y of 3erican 9ie 4a0ting !n0titute.


25/31


4entrifugal%4a0ting /roce00

Figure .$ 5a6 Scheatic illu0tration of the centrifugal%ca0ting proce00. /ipe0,

cylinder liner0, and 0iilarly 0haped part0 can be ca0t 7ith thi0 proce00. 5b6 Side

vie7 of the achine.


26/31


Seicentrifugal 4a0ting and 4a0ting by 4entrifuging

Figure . 5a6 Scheatic illu0tration of the 0eicentrifugal ca0ting proce00.


27/31


SAueeBe%4a0ting

Figure . SeAuence of operation0 in the 0AueeBe%ca0ting proce00.

Thi0 proce00 cobine0 the advantage0 of ca0ting and forging.


28/31


Method0 of 4a0ting Turbine "lade0

5c6

Figure .' Method0 of ca0ting turbine blade08 5a6 directional 0olidificationD 5b6 ethod to

produce a 0ingle%cry0tal bladeD and 5c6 a 0ingle%cry0tal blade 7ith the con0triction portion 0till

attached. Source: 5a6 and 5b6 3fter ". . Kear, 5c6 4ourte0y of 3SM !nternational.


29/31


4ry0tal :ro7ing

(c)

Figure .( T7o ethod0 of cry0tal gro7ing8 5a6cry0tal pulling 54Bochral0ki proce006 and 5b6 the

floating%Bone ethod. 4ry0tal gro7ing i0 iportant

e0pecially in the 0eiconductor indu0try. 5c6 3 0ingle%

cry0tal ingot produced by the 4Bochral0ki proce00.

Source8 4ourte0y of !ntel 4orp.


30/31


Melt%Spinning

(b)

Figure . 5a6 Scheatic illu0tration of elt%0pinning to produce thin 0trip0 of

aorphou0 etal. 5b6 /hotograph of nickel%alloy production through elt%0pinning.

Source: Sieen0 3:


31/31

Manufacturing Engineering & Technology Fifth Edition by Serope

Type0 of Melting Furnace0

Figure .+ T7o type0 of elting furnace0 u0ed in foundrie08

5a6 crucible, and 5b6 cupola.

castingprocesses

Documents