2.casting and Powder Metallurgy

CASTING AND POWDER
METALLURGY
15/08/22
Casting Processes
• Casting is basically a process of pouring molten metal into a mold
that contains the desired shape in the form of a cavity.
• The principal types of casting used in manufacturing today are

sand casting, investment casting, centrifugal casting, and die
casting.
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Sand Casting
• Sand casting is the most common type of casting method. The
major components of the molds used to make sand castings
include the flask, pattern, and green sand. Riser Vent holes Sprue
The flask is a two‑part box, or

frame, used to contain the
sand.
The top half of the flask is
called the cope and the bottom
half is called the drag
occasionally.
• The mold is prepared by ramming the green sand around a model of a part, called
the pattern.
• The model is then removed to form the cavity for the molten metal.
• The plane of division between the cope and drag is called the parting line.
• In many castings, the parting line occurs at the approximate middle of the part. The
parting line can be seen on most casting by a ragged line which is usually ground off.
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Sand Casting (cont..)
• The molten metal enters the mold through the sprue hole Vent holes Sprue
Riser
and is directed to the cavity by one or more gates.
• The sprue hole is formed by installing a sprue peg in the

cope. This peg is then removed after the final ramming of
the cope.
• The riser is used to vent the mold and to allow gases to

escape. The riser also acts as a small reservoir to keep the
cavity full as the metal begins to shrink during the cooling
process.
• In some cases a hollow part, to reduce the amount of

material needed to fill the cavity and to reduce the time
necessary to machine the part a sand core may be installed
in the cavity.
• When sand cores are intended to be installed in a cavity,

core prints must also be provided to locate and anchor the
sand cores during the casting process. Core prints are
normally a simple extension of the pattern.
4
Making Patterns
When patterns are made for casting two important factors must
always be considered.
1. The first is the draft.
- Draft is the slope or taper of the sides of a pattern which
permits it to be removed from the cope and drag without
disturbing the cavity.
- The draft also permits the cast part to be removed easily from
some molds. The amount of draft necessary will normally
depend on the part being cast, but will normally be about one
degree.
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2. The second consideration is shrinkage.
- When metals are cast a certain amount of shrinkage occurs as the
metal cools.
- The specific amount of shrinkage depends on the metal being cast.
Steel, for example, shrinks at a rate of approximately
three‑sixteenths of an inch per foot, while cast iron shrinks about
sixteenth of an inch per foot. The pattern maker will normally use a
shrink rule to compensate for the shrinkage. A shrink rule, is a
standard steel rule which has the graduations marked for a specific
amount of shrinkage is often used.
- To allow for this shrinkage and to make sure the final part is the
correct size, the pattern must be made slightly larger than the final
size of the desired part. The pattern maker will then make all the
necessary calculations needed to make the oversized pattern
6
Investment Casting
• Investment casting produces parts with great detail and accuracy
while at the same time allowing very thin cross sections to be cast.
• In this process, the pattern is made by casting wax in the desired

form. The pattern is then placed in a sand mold and the mold is
fired to melt out the wax pattern.
• This process is also referred to as lost wax casting. The molten

metal is then fed into the mold to produce the cast part.
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Centrifugal Casting
• Centrifugal casting is a process of pouring a measured amount of
molten metal into a rotating mold.
• This process can be used for a single mold or
multiple molds.
• The centrifugal force created by the rotation,

forces the molten metal to fill the cavity. It also
controls the wall thickness of the cast part and
results in a less porous cast surface than is
possible with sand casting.
• The molds used for this purpose are usually

permanent molds made from metal rather than
sand.
• These molds are used repeatedly and produce

highly accurate parts requiring very little
machining. However, due to their cost, permanent
molds are normally used only for high‑volume
Centrifugal casting production.
8
Die Casting
• Die casting is a process where molten metal is forced into metal
dies under pressure.
• This process is very well suited for alloys

materials as zinc alloys, aluminum alloys,
copper alloys, and magnesium alloys.
• Parts produced by die casting are superior in

appearance and accuracy and require little or
no machining to final size.
Die casting 9
Powder Metallurgy
• In the powder metallurgy process, metal
particles, or powder, are blended and mixed
to achieve the desired composition.
• The powder is then forced into a die of the

desired form under pressure from 15,000 to
100,000 pounds per square inch. The
resulting heat fuses the powder into a solid
piece which can be machined.
Figure-5 Producing parts with powder metallurgy
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Q&A
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CASTING AND POWDER

• The principal types of casting used in manufacturing today are

The flask is a two‑part box, or

• The sprue hole is formed by installing a sprue peg in the

• The riser is used to vent the mold and to allow gases to

• In some cases a hollow part, to reduce the amount of

• When sand cores are intended to be installed in a cavity,

• In this process, the pattern is made by casting wax in the desired

• This process is also referred to as lost wax casting. The molten

• The centrifugal force created by the rotation,

• The molds used for this purpose are usually

• These molds are used repeatedly and produce

• This process is very well suited for alloys

• Parts produced by die casting are superior in

• The powder is then forced into a die of the

Figure-5 Producing parts with powder metallurgy

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