Scribd
Upload
197 views

Sand Casting Semester Presentation

The document discusses the history of metal casting and provides details about the sand casting process. It describes how the student project aimed to create a repeatable casting process to cast commemorative plaques for their Engineering Club using sand casting. They faced challenges with impure metals not melting as expected and lost materials when a crucible broke. Their single successful cast was made of bismuth.

Uploaded by

Mindrila Bogdan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
197 views

Sand Casting Semester Presentation

The document discusses the history of metal casting and provides details about the sand casting process. It describes how the student project aimed to create a repeatable casting process to cast commemorative plaques for their Engineering Club using sand casting. They faced challenges with impure metals not melting as expected and lost materials when a crucible broke. Their single successful cast was made of bismuth.

Uploaded by

Mindrila Bogdan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 32

Mike Bloomfield

Kahra Fishburn
Chanse Starmer
ENGR45, Fall 2013, SRJC
 3200 B.C. A copper frog,  1455 Dillenburg Castle in
the oldest known casting in Germany is the first to use
existence, is cast in cast iron pipe to transport
Mesopotamia. water
 2000 B.C. Iron is  1709 Englishman Abraham
discovered. Darby creates the first true
 645 B.C. Earliest known foundry flask for sand and
sand casting (Chinese) loam casting.
 1809 Centrifugal casting is
developed by A. G.
Eckhardt of Soho, England.
 1825 Aluminum, the most  1960s Compactibility and
common metal in the methylene blue clay tests
earth's crust, is isolated. are developed for green
 1897 Investment casting is sand control. Also
rediscovered by B.F. developed at this time are
Philbrook of Iowa. He uses high-pressure molding
it to cast dental inlays processes and fast-setting
no bake binders for sand.
 Casting has been used by every major civilization
throughout history
 Most casting was used for weapons making and art
 Some of the most famous castings are the Greek and
Roman era bronze statues (most of the famous ones
you know are marble copies of their bronze originals)
 Most of these statues have been lost. Very few remain
today because they were melted down for their metal
during the major wars of history
• A bronze Cast statue of a She-Wolf suckling Romulus
and Remus (the mythical founders of Rome)
 Definition: an object made by shaping molten
metal or similar material in a mold.

 Major Types of Casting


Lost Wax
Sand Casting
Investment Casting
Lost Foam
Centrifugal
Permanent Mold
 Metal casting can be used to form almost any shape
 All major metals can be cast
 Useful for high volume parts
 Used in the auto industry, pipes, toys, kitchen
appliances, farming/construction equipment, planes,
turbines, etc.
 90% of all manufactured goods contain some form of
metal casting
 Fun fact: in America, you are rarely more than 10 feet
from a metal casting
 In sand casting, usually a two piece mold is used for
more complex parts
 First, a part is used to form a mold by compacting
green sand around the part, half of the part being
molded in the drag, and half of the part being molded
in the cope
 Vent holes, risers and runners would be made on one
half of the mold to allow the metal to flow into the
mold
 The part would then be removed, leaving a hollow
cavity
 The two halves are then joined together and a casting
can be made!
A rough cast before it has been cleaned up. The runner,
riser and seam of the part is visible.
 A special type of sand called Green Sand is used for most sand
casting

 Contrary to popular belief, the sand is not actually green in color.


The name refers to its water content, much like a green tree limb
contains a high amount of water.

 Unlike the name suggests, "green sand" is not a type of sand on


its own, but is rather a wet mixture of:
Silica sand (SiO2), 75 to 85%
Bentonite (clay), 5 to 11%
water, 2 to 4%
Inert sludge 3 to 5%
anthracite (0 to 1%)
 The goal of our project was to make a repeatable
casting process for the Engineering Club
 We hope to cast a small plaque every year to
commemorate the club, as a replacement to the marble
stone pavers that have been used previously
 We decided on sand casting because of its
repeatability and consistency
 We had originally planned on lost wax casting, but
because we wanted a consistent look through the
years, we chose sand casting instead
 We had hoped to make multiple casts from different
materials, but due to some unforeseen challenges we
were only able to complete one.
 Some of the challenges we ran into:
 The zinc we had planned to use was not pure zinc, and
we could not get it to consistently melt
 We had a limited supply of bismuth
 One of our crucibles broke while in the oven, and we lost
that material
 We tried to combine zinc with gold leaf for an
interesting effect, and it just failed…
Oops!!!
Compacting the
sand around the
piece to get a
good mold
Bismuth melts at
271 °C (520 °F)
Bismuth Crystals through a
microscope
 http://www.metal-technologies.com/HistoryofMetalCasting.aspx
 http://www.tanyfoundry.com/case-study-of-lost-wax-casting-
technique-for-bronze-sculpture/
 http://faculty.evansville.edu/rl29/art105/f01/art105-2.html
 http://www.oxforddictionaries.com/us/definition/american_english/c
ast
 http://aluminumfoundry.wordpress.com/2009/12/09/sand-casting/
 http://www.hnsa.org/doc/foundry/part2.htm
 http://en.wikipedia.org/wiki/Green_sand_%28casting%29#Green_san
d
 http://periodictable.com/Elements/083/
 http://www.amazingrust.com/Experiments/how_to/Bismuth_Crystals.
html

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy