Chapter 12Expendable-Mold Casting Processes (Review)

EIN 3390 Manufacturing ProcessesSpring 2012

12.1 IntroductionThree Categories of Casting processesSingle-use molds with multiple-use patterns

Single-use molds with single-use patterns

Multiple-use molds ( to be introduced in Chapter 13)

12.1 IntroductionFactors to consider for selection of a casting process:Desired dimensional precisionSurface qualityNumber of castings and part production rateComplexity of processes and process toolingType of pattern and core box neededCost of required mold or dieRestrictions due to the selected material

12.1 IntroductionFrequently Cast MaterialsIronSteel, Stainless steelAluminum and alloysBrassBronze Magnesium alloysZinc alloysNickel alloys

12.2 Sand CastingSand casting is the most common and versatile form of casting90% of the casting produced in US

Granular material is mixed with clay and waterPacked around a patternRemoved before pouring

12.2 Sand CastingMolten metal is poured down a sprue hole, flows through runner, and enters mold cavityGravity flow is the most common method of introducing the liquid metal into the moldMetal is allowed to solidify and then the mold is broken and removed

Sand Casting SequenceFigure 12-1 Sequential steps in making a sand casting. a) A pattern board is placed between the bottom (drag) and top (cope) halves of a flask, with the bottom side up. b) Sand is then packed into the bottom or drag half of the mold. c) A bottom board is positioned on top of the packed sand, and the mold is turned over, showing the top (cope) half of pattern with sprue and riser pins in place. d) The upper or cope half of the mold is then packed with sand.

Sand CastingFigure 12-1 e) The mold is opened, the pattern board is drawn (removed), and the runner and gate are cut into the bottom parting surface of the sand. e) The parting surface of the upper or cope half of the mold is also shown with the pattern and pins removed. f) The mold is reassembled with the pattern board removed, and molten metal is poured through the sprue. g) The contents are shaken from the flask and the metal segment is separated from the sand, ready for further processing.

Patterns and Pattern MaterialsPattern Design and ConstructionA duplicate of the part to be made Modified in accordance with requirement of casting process, metal being cast, molding technique

Pattern Material Selection: determined by the number of castings, size and shape of castings, desired dimensional precision, and molding process

Patterns and Pattern MaterialsPattern materials

Wood patterns: easy to make, relatively cheap, but not dimensionally stable and tend to wear with repeat useMetal patterns expensive, but more stable and durableHard plastics, expanded polystyrene and wax

Types of PatternsThe type of pattern is selected based on the number of castings and the complexity of the partOne-piece or solid patterns are used when the shape is relatively simple and the number of castings is smallSplit patterns are used for moderate quantitiesPattern is divided into two segments

Types of PatternsFigure 12-3 (Below) Method of using a follow board to position a single-piece pattern and locate a parting surface. The final figure shows the flask of the previous operation (the drag segment) inverted in preparation for construction of the upper portion of the mold (cope segment).Figure 12-2 (Above) Single-piece pattern for a pinion gear.

Sands and Sand ConditioningFour requirements of sand used in castingRefractoriness-ability withstand high temperaturesCohesiveness-ability to retain shapePermeability-ability of gases to escape through the sandCollapsibility-ability to accommodate shrinkage and part removalSize of sand particles, amount of bonding agent, moisture content, and organic matter are selected to attain an acceptable compromise.

Processing of SandGreen-sand mixture is 88% silica, 9% clay, and 3% waterEach grain of sand needs to be coated uniformly with additive agentsMuller kneads, rolls, and stirs the sand to coat itFigure 12-8 Schematic diagram of a continuous (left) and batch-type (right) sand muller. Plow blades move and loosen the sand, and the muller wheels compress and mix the components. (Courtesy of ASM International. Metals Park, OH.)

Sand Properties and Sand-Related DefectsSilica sandCheap and lightweight but undergoes a phase transformation and volumetric expansion when it is heated to 585CCastings with large, flat surfaces are prone to sand expansion defects Trapped or dissolved gases can cause gas-related voids or blows

Sand Properties and Sand-Related DefectsPenetration occurs when the sand grains become embedded in the surface of the castingHot tears or crack occur in metals with large amounts of solidification shrinkageTensile stresses develop while the metal is still partially liquid and if these stresses do not go away, cracking can occur.

Sand Properties

The Making of Sand MoldsMolds begin with a pattern and a flaskMixed sand is packed in the flask Sand slinger uses rotation to fling sand against the patternJolting is a process in which sand is placed over the flask and pattern and they are all lifted and dropped to compact the sandSqueezing machines use air and a diaphragm

Methods of Compacting SandFigure 12-12 (Above) Jolting a mold section. (Note: The pattern is on the bottom, where the greatest packing is expected.)Figure 12-13 (Above) Squeezing a sand-filled mold section. While the pattern is on the bottom, the highest packing will be directly under the squeeze head. Figure 12-14 (Left) Schematic diagram showing relative sand densities obtained by flat-plate squeezing, where all areas get vertically compressed by the same amount of movement (left) and by flexible-diaphragm squeezing, where all areas flow to the same resisting pressure (right).

Green-SandGreen-sand castingProcess for both ferrous and nonferrous metalsSand is blended with clay, water, and additivesMolds are filled by a gravity feedLow tooling costsLeast expensiveDesign limitationsRough surface finishPoor dimensional accuracyLow strength

Green-Sand Casting

Shell MoldingBasic steps1) Individual grains of fine silica sand are precoated with a thin layer of thermosetting resinHeat from the metal pattern partially cures a layer of material2) Pattern and sand mixture are inverted and only the layer of partially cured material remains3) The pattern with the shell is placed in an oven and the curing process is completed

Shell MoldingBasic steps (- continue)4) Hardened shell is stripped from the pattern5) Shells are clamped or glued together with a thermoset adhesive6) Shell molds are placed in a pouring jacket and surrounded with sand, gravel, etc. for extra support

Casting Materials:Casting irons, alloys of aluminum, and copper

Shell MoldingAdvantages:Excellent dimensional accuracy with tolerance of 0.08 0.13 mmVery smooth surfacesExcellent Collapsibility and permeabilityLess cost of cleaning, and machiningLess amount of required mold materialHigh productivity, low labor costs.

Shell MoldingDisadvantages:Cost of a metal pattern is often highDesign must include the gate and the runnerExpensive binderLimited Part size

Shell-Mold Casting

12.3 Cores and Core MakingComplex internal cavities can be produced with coresCores can be used to improve casting designMost fragile part of mold assemblyMethods for making coresGreen sand coresDry-sand coresAdditional Core Methods

Green Cores and Core MakingGreen cores may have relatively low strengthIf long cores are used, machining may need to be done afterwardsGreen sand cores are not an option for more complex shapes

Dry-Sand CoresProduced separate from the remainder of the mold Inserted into core prints that hold the cores in positionDump-core box Sand is packed into the mold cavityScrap level with top surface (like paring line)Invert box and leave molded sand on a plateSand is baked or hardenedSingle-piece cores in a split-core boxTwo-halves of a core box are clamped together

Casting Core CharacteristicsSufficient strength before hardeningSufficient hardness and strength after hardeningSmooth surfaceMinimum generation of gasesAdequate permeabilityAdequate refractoriness Good collapsibility

Techniques to Enhance Core PropertiesAddition of internal wires or rodsVent holes formed by small wire into coreCores can be connected to the outer surfaces of the mold cavityCore printsChaplets- small metal supports that are placed between the cores and the mold cavity surfaces and become integral to the final casting

ChapletsFigure 12-24 (Left) Typical chaplets. (Right) Method of supporting a core by use of chaplets (relative size of the chaplets is exaggerated).

Mold ModificationsCheeks are second parting lines that allow parts to be cast in a mold with withdrawable patternsInset cores can be used to improve productivity

Figure 12-25 (Left) Method of making a reentrant angle or inset section by using a three-piece flask. Figure 12-26 (Right) Molding an inset section using a dry-sand core.

12.5 Expendable-Mold Processes Using Single-Use PatternsInvestment castingOne of the oldest casting methodsProducts such as rocket components, and jet engine turbine bladesComplex shapes Most materials can be castedFigure 12-30 Typical parts produced by investment casting. (Courtesy of Haynes International, Kokomo, IN.)

Investment CastingSequential steps for investment casting

1) Produce a master pattern2) Produce a master die3) Produce wax patterns4) Assemble the wax patterns onto a common wax sprue5) Coat the tree with a thin layer of investment material6) Form additional investment around the coated cluster

Investment CastingSequential steps for investment casting (- continue)

7) Allow the investment to harden8) Remove the wax pattern from the mold by melting or dissolving9) Heat the mold10) Pour the molten metal11) Remove the solidified casting from the mold

Advantages and Disadvantages of Investment CastingAdvantageComplex shapes can be castThin sections, down to 0.4 mm can be madeExcellent dimensional precisionVery smooth surfaceMachining can be eliminated or reducedEasy for process steps automationDisadvantageComplex processCostly for dieQuantity of investment casting 100 10,000/year

Investment CastingFigure 12-28 Investment-casting steps for the flask-cast method. (Courtesy of Investment Casting Institute, Dallas, TX.)

Investment CastingFigure 12-28 Investment-casting steps for the flask-cast method. (Courtesy of Investment Casting Institute, Dallas, TX.)

Investment CastingFigure 12-29 Investment-casting steps for the shell-casting procedure. (Courtesy of Investment Casting Institute, Dallas, TX.)

Investment CastingFigure 12-29 Investment-casting steps for the shell-casting procedure. (Courtesy of Investment Casting Institute, Dallas, TX.)

Investment Casting

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