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CASESTUDIES: ll.l |I.2 258 Lost-foamCastingof Engine Blocks 272 Investment Casting ofTotal Knee Replacements 275

Processes and

Equipment

1 Metal-Casting

° Building upon the fundamentals of solidification, fluidflow, and heat transfer discussed in Chapter10, this chapter presents theprinciples ofcastingprocesses.

° Castingprocessesare generally categorizedaspermanent-mold and

expendable-mold processes; expendable-mold processes are further categorized as

permanent-mold and expendable-patternprocesses.

° Thecharacteristics of each processare described, together withtypical applica-tions, advantages,and limitation.

° Special casting processes that produce single-crystal components as well as

amorphousalloys are then described.

° The chapterends witha discussionof inspectiontechniques for castings.

Typical products made by casting: engine blocks, crankshafts, hubcaps, power

toolhousings, turbine blades, plumbing parts, zipper teeth,dies and molds, gears,

railroadwheels,propellers, office equipment, and statues.

Alternativeprocesses: forging,powder metallurgy,machining, and fabrication.

I

|.l

Introduction

The first metal castings were made during the period from 4000 to 3000 B.C., using stoneand metal molds for castingcopper. Variouscasting processes have been devel-oped overtime, eachwith its own characteristics andapplications (see also Fig. I.6a), to meet specific design requirements (Table 11.1). A large variety ofparts and com-ponentsare made bycasting, such as engine blocks, crankshafts, automotive compo-nents and powertrains (Fig. 11.1), agricultural and railroad equipment, pipes and plumbing fixtures, power-tool housings,gun barrels, frying pans, jewelry, orthopedic implants, andvery large componentsfor hydraulic turbines.

Two trends have had a major impact on the casting industry. The first is the

mechanization and automation of the casting process, which has led to significant

changes in the use of equipment and labor. Advanced machinery and automated

process-control systems have replaced traditional methods of casting. The second

major trend has been the increasing demand for high-quality castings with close

dimensional tolerances.

This chapter is organized around the majorclassifications of casting practices

(2)

Section 11.1 Introduction 259

TABLE II.l

SummaryofCastingProcesses

Process Advantages Limitations

Sand Almost any metalcan becast; no limit to part size, Somefinishingrequired; relatively coarse shape,or Weight;lowtooling cost surface finish;Widetolerances

Shellmold Good dimensional accuracy and surface finish; Partsize limited; expensive patterns and

Evaporative pattern

Plaster mold

Ceramic mold

highproduction rate

Most metalscanbe cast, withno limit to size;

complexpart shapes

Intricate partshapes; good dimensionalaccuracy and surface finish;lowporosity

Intricate_Partsha_Pes'>close-tolerance Parts;

good surface finish

equipment

Patterns have low strength and can be

costly for low quantities

Limited tononferrous metals; limited

part sizeand volumeof production; mold-makingtime relatively long Limited partsize

Investment Intricate part shapes; excellent surface finish Partsizelimited; expensive patterns, molds, and accuracy; almostanymetalcan becast and labor

Permanent mold Goodsurface finish and dimensional accu- High mold cost; limited partshape and racy; lowporosity;highproduction rate complexity; not suitablefor

high-melting-pointmetals

Die Excellentdimensional accuracy and sur- High die cost;limitedpart size; generally

face finish; highproduction rate limited to nonferrousmetals; long lead time

Centrifugal Largecylindrical or tubular parts with Expensiveequipment; limitedpart shape good quality; high production rate

materials, pattern production, molding processes, and methods of feeding the mold

withmolten metal. The major categories are asfollows:

l. Expendable molds, which typically are made of sand, plaster, ceramics, and similarmaterials and generallyaremixed withvarious binders (bonding agents) for improved properties. A typical sand mold consists of 90% sand, 7% clay, and 3% Water. As describedin Chapter 8, these materials are refractories (that

is, they are capable of withstandingthe high temperatures of moltenmetals). After thecasting has solidified, the mold is broken up toremove the casting.

The mold is produced froma pattern; in some processes, such as sand and shell casting, themold is expendable, but thepattern is reused to produce several molds. Such processes are referred to as expendable-mold, permanent-pattern casting processes. On the other hand, investment casting consumes a pattern for each mold produced; itis an example of an mold, expendable-pattern process.

2. Permanent molds, which are made of metals that maintain their strength at high temperatures. As the name implies, they are usedrepeatedly and are de-signed insuch a Way thatthe casting can be removed easilyand the mold used for the next casting. Metal molds are better heat conductors than expendable nonmetallic molds (see Table 3.1); hence,the solidifyingcasting is subjected to a higherrate ofcooling, which inturn affects the microstructure and grain size

Withinthe casting.

3. Composite molds, which are madeoftwo or more differentmaterials (such as sand, graphite, and metal) combining the advantages of each material. These molds have a permanent and an expendable portion and are used in various casting processes toimprove mold strength, control the cooling rates, and op-timize theoverall economics of the casting process.

(3)

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FIGURE |l.I (a) Typicalgray-iron castings used in automobiles, including the transmission

valve body (left) and the hub rotor with disk-brake cylinder (front). Source: Courtesy of

Central Foundry Divisionof General Motors Corporation. (b) A cast transmission housing. (c) The Polaroid PDC-2000 digital camera with an AZ19lD die-cast, high-puritymagnesium

case.(d) Atwo-piece Polaroid camera case made bythehot-chamber die-casting process.

Source: (C) and (d) CourtesyofPolaroid Corporationand Chicago White Metal Casting, Inc.

The general characteristics ofsand casting and other casting processes are sum-marized in Table 11.2. Almost all commercial metals can be cast. The surfacefinish obtained is largely afunctionofthe moldmaterial and can be verygood, although, as

expected, sand castings generally have rough, grainy surfaces. Dimensional toler-ances generally arenot as good as those inmachining and othernet-shape processes. However, intricate shapes, such as cast-iron engine blocks and very large propellers for ocean liners,can be made bycasting.

Because oftheir unique characteristics and applications, particularly in

man-ufacturing microelectronic devices (Part V), basic crystal-growing techniques also

are described in this chapter, which concludes With a brief overview of modern foundries.

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ll.2

Expendable-mold,

Permanent-pattern

Castmg

Processes

The major categories of expendable-mold, permanent-pattern casting processes are

sand,shell mold, plaster mold, ceramic mold, and vacuum casting.

I

l.2.I

Sand

Casting

Thetraditional methodofcasting metalsis insand molds andhas beenused for

mil-lennia. Sand casting is still the most prevalent form of casting; inthe United States alone, about 15million tons of metal are cast by this method each year. Typical ap-plications of sand casting include machine bases, large turbine impellers, propellers, plumbing fixtures, and awidevariety ofother productsand components. The capa-bilities of sand casting are given in Table 11.2.

Basically, sand casting consists of (a) placing apattern (havingthe shapeof the desired casting) in sand to make an imprint, (b) incorporating a gating system, (c)

removingthe pattern and filling the mold cavitywithmolten metal, (d) allowing the metal to cool until it solidifies, (e) breaking away the sand mold, and (f) removing

the casting (Fig. 11.2).

Sands. Most sand-casting operations use silica sand (SiO2) as the mold material. Sand is inexpensive and is suitable as a mold material because of its high-tempera-ture characteristics and high melting point. There are two general types of sand:

naturallybonded (bank sand) and synthetic (lakesand). Because itscomposition can

be controlled more accurately, synthetic sand is preferred by most foundries. For

proper functioning, mold sand must be cleanand preferably new.

Several factors are important in the selection of sand for molds, and certain

tradeoffs with respect to properties are involved. Sand having fine, round grains can be packed closely and, thus, forms a smooth mold surface. Although fine-grained sand enhances mold strength, the fine grains also lower mold permeability (where fluids and gasespenetrate through pores). Good permeability of molds and

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Pattern y---Core making » --Grating system

Shakeout {f€§ VD¢Uf

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Furnaces Additional Detects,

heattreatment Pressure tightness, Dimensions

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Section11.2 Expendable-mold, Permanent-pattern Casting Processes 263 cores allows gases and steam evolved during the

casting to escape easily. The mold also should have good collapsibility to allow the casting to shrink while cooling and, thus, to avoid defects

in the casting, such as hot tearing and cracking

(see Fig.10.12).

Types ofSand Molds. Sand molds (Fig. 11.3)

are characterized bythe types of sandthat com-prise them and by the methods used to produce them. There arethree basic types ofsand molds: green-sand, cold-box, and no-bake molds. The most common mold material is green molding

sand, which is a mixture of sand, clay, and water. The term “green” refers to the fact that

the sand inthe mold is moist or damp while the metal is being poured into it. Green-sand mold-ing is the least expensive method of making

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features.

molds, and the sand is recycled easily for subsequent reuse. In the skin-dried method, the mold surfaces are dried, either bystoringthe mold inair or bydryingit

with torches. Because of their higher strength, these molds generally are used for large castings.

In the cold-box mold process, various organic and inorganic binders are

blended into the sand to bond the grains chemically for greater strength. These molds are more dimensionally accurate than green-sand molds, but are more ex-pensive. ln the no-bake mold process, a synthetic liquid resin is mixed with the

sand and the mixture hardens at room temperature. Because the bonding of the mold in this and in the cold-box process takes place without heat, they are called cold-setting processes.

Sandmolds can be oven dried (baked) priorto pouringthe moltenmetal; they are then stronger than green-sand molds and impartbetter dimensional accuracy and surface finishtothe casting.However, this method hasthe drawbacksthat (a) distor-tion ofthe moldis greater, (b) thecastings aremore susceptible to hot tearing because of thelower collapsibility ofthemold, and (c)the production rateis lower becauseof the considerable drying time required.

The major featuresofmolds in sand casting are as follows:

I. The flask, which supports the mold itself. Two-piece molds consist of a cope on top and a drag on the bottom; the seam between them is the parting line. When more than two pieces are used in a sand mold, the additional parts are called cbee/es.

2. A pouring basin or pouring cup, into which the _{molten metal} is poured.

3. A sprue, through which the molten metal flows downward.

4. The runner system, which has channels that carry the molten metal from the

sprue to the mold cavity. Gates are the inletsinto the mold cavity.

5. Risers, which supply additional molten metal to the casting as it shrinks dur-ing solidification. Two types of

risers-a

blind riser and an open

riser-are

shown in Fig. 11.3.

6. Cores, which are inserts made from sand. Theyare placed inthe moldto form hollow regions or otherwise define the interior surface of the casting. Cores also are used on theoutside of thecasting to formfeaturessuch as letteringon the surfaceor deep external pockets.

(7)

Cope side

Plate

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FIGURE

ll.4

A typical metal match-plate

patternused in sand casting.

7. Vents, which are placed in molds to carry off gases produced

whenthe molten metal comes into contact with the sand in the mold and the core. Vents also exhaustair from the mold cavity

as the molten metalflows intothe mold.

Patterns. Patternsare usedto mold the sand mixture intothe shape

ofthe casting and may be made of wood, plastic, or metal. The

selec-tion ofa pattern materialdepends on the size and shapeof thecasting,

the dimensional accuracy and the quantity of castings required, and the molding process. Because patterns are used repeatedly to make molds, the strength and durability of the material selected for a

patternmust reflectthe number ofcastingsthat the moldwill produce. Patterns may

be made of a combination of materials to reduce wear in critical regions, and they usually are coated witha parting agent to facilitate the removal of the casting from the molds.

Patterns can be designed with a variety of features tofit specific applications and economic requirements. One-piece patterns, also called loose or solidpatterns,

generally are used for simpler shapes and low~quantity production; they generally are made of wood and are inexpensive. Split patterns are two-piece patterns, made such that eachpart formsa portion ofthe cavityforthe casting;inthis way, castings with complicated shapes can beproduced. Match-plate patterns are acommon type of mounted pattern in which two-piece patterns are constructed by securing each half of one or more split patterns to the opposite sides of a single plate (Fig. 11.4). Insuch constructions, the gating system can be mounted on thedrag side ofthe pat-tern. This type of pattern is used most often in conjunction with molding machines and large productionruns to produce smaller castings.

An important development in molding and pattern making is the application

of rapid prototyping (Chapter 20). In sand casting, for example, a pattern can be

fabricated in a rapid-prototyping machine and fastened to a backing plate at a frac-tion ofthe timeandcost of machiningapattern. Thereare several rapid prototyping

techniques with which these tools can beproduced quickly.

Pattern design is a critical aspect of the total casting operation. The design should provide for metal shrinkage, permit proper metal flow in the mold cavity, and allowthe pattern tobe easily removed from the sand mold bymeans ofa taper or draft (Fig. 11.5) or some other geometric feature. (These topics are described in

greater detail in Chapter 12.)

Cores. For castings with internal cavities or passages, such as those found in an automotive engine block or a valve body, cores are utilized. Cores are placed in the mold cavity to form the interior surfaces of the casting and are removed from the finished partduring shakeoutand furtherprocessing. Like molds,coresmustpossess strength, permeability, the ability to withstand heat, and collapsibility; hence, cores

Draft angle are made ofsand aggregates. The core is anchoredby

Damage Pattern T((47 coreprints, which are recesses added to the patternto locate and support the core and to provide vents for the escape of gases (Fig. 11.6a). A common problem

»`,s, Flask with cores isthat (for somecasting requirements, as in

lf Sand mold the case wherea recess is required) they may lack

. ...,. "

'

...,.,, i ‘ ficient structural support in the cavity. To keep the

Poor Good core from shifting, metal supports (chaplets) may be

usedto anchorthe core inplace (Fig. 11.6b).

FIGURE I l.5 Taper onpatterns forease of removal from the Cores generally aremade in amannersimilar to

(8)

Section 11.2 Expandable-mold, Permanent-pattern Castlng Processes 2 \

Cavity Core Cavity Chaplet Core

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Examples of sand cores, showing core prints and chaplets to support the

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ll.7

Vertical flaskless molding. (a) Sand is squeezed between two halves of the

pattern.(b) Assembled molds pass along an assemblyline for pouring. (c) Aphotograph ofa vertical flasklessmolding line. Source: Courtesyof AmericanFoundry Society.

with shell (see Section 11.2.2), no-bake, or cold-box processes. Cores are shaped in

core boxes, which are used in much the same way that patterns are used to form sand molds.

Sand-molding Machines. The oldest known method of molding, which is still

used for simple castings, is to compact the sand by hand hammering (tamping) or ramming itaround the pattern. For most operations, however, the sand mixture is

compacted around the pattern by molding machines. These machines eliminate

arduous labor, offer high-quality casting byimproving the application and

distribu-tion of forces, manipulate the mold in a carefully controlled manner, and increase

production rate.

In vertical flaskless molding, the halves of the pattern form a verticalchamber

wall against which sand is blown and compacted (Fig. 11.7). Then the mold halves are packed horizontally, with the parting line oriented vertically, and moved along a

pouring conveyor. This operation is simple and eliminates the needtohandle flasks, allowing forveryhighproduction rates,particularly whenother aspectsof the oper-ation (such as coring and pouring) are automated.

(9)

Sandslingers fill the flask uniformly with sand under a high-pressure stream; they are used to filllarge flasks and are operated typically by machine. An impeller

in the machine throws sand from its blades (or cups) at such high speeds that the machine not only places the sand, but alsorams itappropriately.

Inimpactmolding, the sand is compacted by acontrolled explosion or

instan-taneous release of compressed gases. This method produces molds with uniform strength and good permeability.

Invacuum molding (alsoknownas the Vprocess), the patternis covered tightly

with a thin sheet of plastic.A flask is placed overthe coated patternand is filled with dry,binderless sand. Asecond sheet ofplasticthenis placedon topofthe sand, a

vac-uum action compacts the sand, and the pattern can then be withdrawn. Both halves

of the mold are made inthis manner and subsequently assembled. During pouring,

the mold remainsunder vacuum, but the castingcavity doesnot. When themetal has solidified, the vacuum is turned off and the sand falls away, releasing the casting. Vacuum molding produces castings with high-quality surface detail and dimensional accuracy;it is suited especially well for large, relatively flat (plane) castings.

The Sand-castingOperation. After the mold has beenshaped and the cores have

been placed in position, the two halves (cope and drag) are closed, clamped, and weighted down to prevent the separationofthe mold sectionsunder thepressure ex-erted whenthe molten metal is poured intothe mold cavity. Acomplete sequence of operations in sand castingis shown inFig. 11.8.

After solidification, the casting is shaken out of its mold, and the sand and oxide layersadhering to the casting are removed byvibration(using a shaker) or by

sand blasting. Castings also are cleaned by blasting with steel shot or grit (shot blasting; Section 26.8). The risers and gatesare cut off by oxyfuel-gas cutting, saw-ing, shearing, or abrasive wheels; or they are trimmed in dies. Gates and risers on

steel castings also may be removed with air carbon-arc cutting (Section 30.8) or torches. Castings may be cleaned further byelectrochemical means or by pickling

withchemicals to remove surface oxides.

The casting subsequently may be heat treatedto improve certain properties

re-quired forits intendeduse; heat-treatmentis particularly importantforsteel castings. Finishingoperations may involvemachining, straightening, or forging with dies

(siz-ing) to obtain final dimensions. Inspection is an important final step and is carried

outto ensure that thecasting meets all design andquality-control requirements.

Rammed-graphite Molding. Inthis process, rammed graphite (Section 8.6) is used

to make molds for casting reactive metals, such as titanium and zirconium. Sand

cannot be used because these metals react vigorously with silica. The molds are

packedlike sand molds, air dried, baked at 175°C, fired at870°C, and then stored under controlled humidity and temperature. The casting procedures are _similar to those for sand molds.

I

I.2.2

Shell

Molding

Shellmolding wasfirst developed inthe 19405 and has grown significantly because

itcanproduce many types ofcastings with close dimensional tolerances and agood surface finishat low cost. Shell-molding applications include small mechanicalparts

requiring high precision, such as gear housings, cylinder heads, andconnecting rods. The process also is used widely in producing high-precision molding cores. The capabilities ofshell-mold casting are given in Table 11.2.

In this process, a mounted pattern made of a ferrous metal or aluminum is (a) heated toa range of 175° to 37O°C, (b) coated witha parting agent (such as

(10)

Section 11.2 Expendable-mold, Permanent-pattern Casting Processes 26

Core prints

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Drag withcore Cope and dragassembled Casting as removed Casting ready set in place and ready forpouring frommold; heat treated forshipment

(i) (K) (l)

FIGURE

||.8

Schematic illustration of the sequence of operations for sand casting. (a) A

mechanical drawingof the part is used to generate a design forthe 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 toproduce thehollow area ofthe 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. (g) The flask isrammedwith

sand, and theplate and inserts areremoved.(h) The draghalfisproducedin a similarmanner 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 iswithdrawn, leaving the appropriate imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the cope ontop of the drag and securing the assemblywithpins. The flasks are then subjected to pressure tocounteract buoyant forcesin the liquid,which might liftthe cope. (l) After the metal solidifies, the casting is removed from the mold. (m) The sprue and risers are cut offand recycled, and the casting is cleaned, inspected, and heat treated (when necessary). Source: Courtesy ofSteelFounders’ Society ofAmerica.

with2.5 to 4% of a thermosetting resin binder (such as phenol-formaldehyde) that

coats the sand particles. Either the box is rotated upside down (Fig. 11.9), or the sand mixture is blown over the pattern, allowing it to form a coating.

The assembly is then placed in an oven for a short period of time to complete the curing of the resin. Inmost shell-molding machines, the oven consists of a metal

(11)

hard-Pattern Coated sand Shell \ Pattern ~ Coated sand

Coated Sand Investment

Dump box

1. Pattern rotated 2. Pattern and dump 3. Pattern and dumpbox

and clamped todump box box rotated in positionforthe investment

'/0

_g Shells

f

Excess Sandor

coated sand Adhesive C|ampS metal beads

4. Pattern and shell 5. Mold halvesjoined together 6. l\/loldplaced inflask

removed fromdump box and metal poured

FIGURE ll.9 Theshell-moldingprocess, also called the dump-box technique.

ens around the pattern and is removed from the pattern using built-in ejector pins.

Two half-shells are made in this manner and are bonded or clamped together to form a mold.

The thickness ofthe shell can be determined accuratelybycontrolling the time

that the patternis incontactWith the mold. In this way, the shell can be formedwith

the required strength and rigidity to hold the Weight of the molten liquid. Theshells are light and

thin-usually

5 to 10

mm-and

consequently, their thermal character-istics are different from those for thicker molds.

Shell sand has a much lovver permeability than the sand used for green-sand molding, because asand ofmuch smaller grain size is used for shellmolding. The de-compositionoftheshell-sand binderalsoproducesahighvolume of gas.Consequently, unless themoldsareventedproperly,trappedairandgascancause seriousproblemsin

the shellmoldingofferrous castings.The highqualityofthe finished casting can reduce cleaning, machining, and other finishing costs significantly. Complex shapes can be produced with less labor,andtheprocess canbeautomatedfairlyeasily.

I

l.2.3

Plaster-mold Casting

This process, and the ceramic-mold and investment casting processes described in

Sections 11.2.4 and 11.3.2,are knownas precision casting, because of the high

di-mensional accuracy and good surface finish obtained. Typical parts made are lock components, gears, valves, fittings, tooling, and ornaments. The castings usually

Weigh lessthan 10 kgand are typically inthe range of 125 to 250g, although parts

as light as 1 g have been made. The capabilities ofplaster-mold casting are given in

(12)

Section11.2 Expendable-mold, Permanent-pattern Casting Processes 2

Inthe plaster-molding process, the mold is made ofplaster ofparis (gypsum or calcium sulfate) with the addition oftale and silica flour to improve strength and to control the time required for the plaster to set. These components are mixed with water, and the resulting slurry is poured over the pattern. After the plaster sets (usually within 15 minutes), it is removed, and the mold is dried at a temperature

range of 120°to 260°C. Higher dryingtemperatures may be used,depending on the type of plaster. The mold halves are assembled to form the mold cavityand are pre-heated toabout 120°C. Themolten metalis then poured into the mold.

Becauseplaster molds have verylow permeability, gasesevolved during solidi-ficationof the metalcannot escape.Consequently, the molten metalis pouredeither in avacuumor under pressure. Mold permeability can be increased substantially by

the Antioch process, inwhichthe molds are dehydrated in an autoclat/e (pressurized oven) for 6 to 12 hours and thenrehydrated in airfor 14 hours. Another methodof increasing the permeability of the mold is to use foamed plaster containing trapped

air bubbles.

Patterns for plaster molding generally are made ofmaterials such as aluminum alloys, thermosetting plastics,brass, or zinc alloys. Woodpatternsare notsuitable for making a large number of molds, because they are repeatedly in contact with thewater-basedplasterslurry andwarpor degrade quickly. Sincethereis alimittothe maximumtemperature thatthe plaster mold canwithstand (generallyabout1200°C), plaster-mold casting is used onlyfor aluminum, magnesium,zinc, and some copper-basedalloys. The castingshave agood surface finish with finedetails. Because plaster molds have lower thermal conductivity than other mold materials, the castings cool slowly, and thus a more uniform grain structure is obtained with less warpage. The wall thickness ofthe cast parts canbe 1 to2.5 mm.

I

l.2.4

Ceramic-mold Casting

The ceramic-mold casting process (also called cope-and-drag investment casting) is

similar to the plaster-mold process, except that it uses refractory mold materials suitable forhigh-temperature applications. Typical parts made are impellers, cutters for machining operations, dies formetalworking, and molds for making plastic and

rubber Components. Parts weighing as much as 700 kg have been cast by this

process.

The slurry is a mixture of fine-grained zircon (ZrSiO4), aluminum oxide, and fused silica, which are mixed with bonding agents and poured over the pattern

(Fig. 11.10), which has been placed in a flask.

Transfer bowl

I

Green

mold

Ceramic slurry

A

pattern My

Pattern P' t N

F'HSl< Flask Mold

Pouring slurry Stripping greenmold Burn-off

1. 2. 3.

FIGURE Il.l0 Sequence ofoperations inmakinga ceramic mold. Source: MetalsHandbook,

(13)

The pattern may be made ofwood or metal. After setting, the molds (ceramic facings) are removed, dried, ignitedto burnoff volatile matter, and baked. The molds areclampedfirmlyandusedas all-ceramic molds. In the Shawprocess,theceramic fac-ings are backed by fireclay (which resists high temperatures) to give strength to the mold. The facings then areassembledintoacomplete mold,ready tobe poured.

Thehigh-temperature resistanceoftherefractory molding materials allows these moldstobeused forcasting ferrousand other high-temperaturealloys,stainlesssteels, and toolsteels.Althoughtheprocess issomewhat expensive,thecastings havegood

di-mensional accuracy and surface finishoverawide rangeof sizes and intricate shapes.

ll.3

Expendable-mold,

Expendable-pattern

Casting

Processes

Evaporative-pattern and investment castingare sometimesreferred toas

expendable-pattern casting processes or expendable mold-expendable pattern processes. They

are unique in that a mold and a patternmust beproduced foreach casting, whereas

the patterns in the processes described inthe preceding section are reusable. Typical

applications are cylinder heads,engine blocks,crankshafts, brake components, man-ifolds, and machine bases.

I

I.3.l

Evaporative-pattern Casting (Lost-foam Process)

The evaporative-pattern casting process uses a polystyrene pattern, which

evapo-rates upon contact withmolten metal to form acavityfor thecasting; this process is

alsoknownas lost-foam casting and falls under the trade namefull-mold process. It

has become one of themore important casting processes for ferrous and nonferrous metals, particularly forthe automotive industry.

In this process,polystyrene beads containing5 to 8% pentane (a volatile hy-drocarbon) are placed in a preheated die that is usually made of aluminum. The polystyrene expandsand takesthe shapeof the die cavity. Additional heat is applied

to fuse and bond the beads together. The die is then cooled and opened, and the

polystyrene pattern is removed. Complex patterns also may be made by bonding various individual pattern sections usinghot-melt adhesive (Section 32.4.1).

The patternis coated with awater-basedrefractory slurry, dried, and placed in

aflask. Theflask is then filled with loose, fine sand, which surrounds and supports

the pattern (Fig 11.11) andmay bedried ormixed with bondingagentsto give it

ad-ditional strength. The sand is compacted periodically, withoutremoving the

poly-styrene pattern; then the molten metal is poured into the mold. The molten metal

vaporizes the pattern andfills the mold cavity, completely replacingthe space previ-ously occupied by the polystyrene. Any degradation products from the polystyrene arevented intothe surrounding sand.

Theflow velocity of the molten metalinthemold depends on therateof

degra-dationofthepolymer. Studies haveshown thatthe flow of themetalis basically

lam-inar, with Reynoldsnumbers inthe rangeof400 to 3000. The velocityofthe molten metal at the metal-polymer pattern front (interface) is in the rangeof 0.1 to 1.0 mfs and can be controlled by producing patterns with cavities or hollow sections. Thus, the velocity will increase as the molten metal crosses these hollow regions, similar to pouring the metal into an emptycavity.

Because the polymer requires considerable energy to degrade, large thermal gradients are present at the metal-polymer interface. In other words, the molten metal cools faster than it would if it were poured directly into an empty cavity. Consequently, fluidity is lessthan insand casting. This has important effects on the

(14)

1.Pattern molding Section ,»‘é

' '

A

I

2. Clusterassembly 11.3 .... ., . ...

4.Compacted insand 5.Casting

Expendable-mold, Expendable-pattern Casting Processes

3.Coating

6.Shakeout

FIGURE I l.| I Schematicillustrationof theexpendable-pattern castingprocess, also known

aslost-foam or evaporative-pattern casting.

microstructure throughout the casting and also leads to directional solidificationof

the metal. Polymethylmethacrylate (PMMA) and polyalkylene carbonate also may be used as pattern materials for ferrous castings.

The evaporative-pattern process has a number of advantages over other

cast-ing methods:

° The process is relatively simple because there are no parting lines, cores, or riser systems. Hence, ithas design flexibility.

'

Inexpensive flasks are satisfactoryforthe process.

° Polystyrene is inexpensiveand canbe processedeasily intopatterns having com-plex shapes,various sizes, andfine surfacedetail.

° The casting requires minimal finishing and cleaning operations.

° Theprocesscan be automated andis economical for longproduction runs.

How-ever, major factors are the costto produce the die used for expanding the

poly-styrene beadsto make thepattern and the need for two sets oftooling.

In a modificationof the evaporative-patternprocess, called the Replicc1st® C-S

process, a polystyrene pattern is surrounded by a ceramic shell;then the pattern is

burned out priorto pouring the molten metal into the mold. Its principal advantage over investment casting (using Wax patterns, Section

II.3.2)

is that carbon pickup

into the metal is avoidedentirely. Further developments in evaporative-pattern cast-ing include the production of metal-matrix composites (Sections 9.5 and 19.14). Duringthe moldingof thepolymerpattern, fibers orparticlesare embedded through-out, which then become an integralpart ofthe casting.Additional techniques include the modification and grain refinementofthe castingby using grain refinersand mod-ifiermaster alloys withinthe pattern while itis beingmolded.

Cluster Parts

(15)

CASE

STUDY

I

I.l

Lost-foam

Casting

of Engine

Blocks

One of the most important components in an

internal combustion engine is the engine block; it

provides the basic structure that encloses the pistons and cylinders and thus encounters significant pressure during operation. Recent industry trends

have focused upon high-quality, low-cost lightweight designs;additional economic benefits can beattained

through casting more complex geometries and by

incorporating multiple components into one part.

Recognizing that evaporative-pattern (lost-foam) casting can simultaneously satisfy all of these requirements, Mercury Castings built a lost-foam casting line to produce aluminum engine blocks and cylinder heads.

One example of a part produced through

lost-foam casting is a 45 kW, three-cylinder engine block used for marine applications and illustrated

in Fig. 11.12a. Previously manufactured as eight

separate die castings, the block was converted to a

single 10 kgcasting, with a weight and costsavings of 1 kg and $25 on each block, respectively.

Lost-foam casting also allowed consolidation of the engine’s cylinder head and exhaust and cooling systems into the block, thus eliminating the associated machining operations and fasteners required in sand-cast ordie-cast designs. Inaddition,

since the pattern contained holes, and these could be

cast without the use of cores, numerous drilling

operations were eliminated.

Mercury Marine also was in the midst of developinganewV6engineutilizinganew corrosion-resistant aluminum alloy with increased wear resistance. Thisengine design also required acylinder block and head integration, featuring hollow sections

forwaterjacketcoolingthatcould notbecored outin

die casting or semipermanent mold processes (used

for its other V6 blocks). Based on the success the

foundry had with the three-cylinder lost-foam block, engineers applied this process for casting the V6 die

block (Fig. 11.12b). The new engine block involves only one casting that is lighter and cheaper than the

previousdesigns. Produced withan integrated cylinder headandexhaust and coolingsystem, thiscomponent

is cast hollow to create more efficient water jacket

coolingofthe engine during itsoperation.

The companyalso has developed a pressurized

lost-foam process. First a foam pattern is made,

placed in a flask, and surrounded by sand. Then the flask is inserted into a pressure vessel where a

robot pours molten aluminum onto the polystyrene

pattern. A lid on the pressure vessel is closed, and

a pressure of 1 MPa is applied to the casting until

it solidifies (in about 15 minutes). The result is a

casting with better dimensional accuracy, lower porosity, and improved strength as compared to

conventionallost-foam casting.

Source: Courtesyof MercuryMarine.

(H) (D)

FIGURE

ll.|2

(a) Metal is poured into a mold for lost-foam casting of a

60-hp, three-cylinder marineengine; (b) finishedengine block. Source:Mercury Marine.

(16)

Section11.3 Expendable-mold, Expendable-pattern Casting Processes 2

I

l.3.2 Investment

Casting

The investment-casting process, also calledthe lost-wax process, wasfirst used dur-ing the period from 4000 to 3000 B.C. Typical parts made are components foroffice

equipment, as well as mechanical components such as gears, cams, valves, and ratchets. Parts upto 1.5 m indiameter and weighing as muchas 1140 kg have been cast successfully bythis process. The capabilities of investment casting are given in

Table 11.2.

The sequence involved in investment casting is shown in Fig. 11.13. The

pattern is made of wax, or of a plastic such as polystyrene, by molding or

rapid-prototyping techniques. Thepattern is then dippedinto aslurry of refractory

mate-rial such as very fine silica and binders, including water, ethyl silicate, and acids. After this initial coating has dried, the pattern is coated repeatedly to increase its thickness for better strength. Notethatthe initial coating can usesmaller particles to develop a better surface finish in the casting; subsequent layersuse larger particles and are intended to buildcoating thickness quickly.

The term investment derives fromthe fact that the pattern is invested (sur-rounded) with the refractory material. Wax patterns require careful handling be-cause they are not strong enough to withstand the forcesencountered during mold making; however, unlike plastic patterns,wax can berecovered and reused.

The one-piece mold is driedinair and heated toa temperatureof90° to 175°C.

Itis heldin an invertedposition fora fewhours to melt out thewax. The mold is then

fired to 650° to 1050°C forabout four hours (depending on the metal to be cast) to drive off the waterofcrystallization(chemicallycombined water) and to burn offany residual wax. After the metal has beenpoured andhas solidified, themold is broken

fitf

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FIGURE I l.l3 Schematic illustration of the investment-casting (lost-wax) process. Castings

producedby thismethodcan bemade withvery finedetail andfromavarietyofmetals. Source:

(17)

FIGURE I l.l4 Investment castingof an integrally cast rotor for a

gasturbine. (a) Waxpattern assembly. (b) Ceramic shellaround wax pattern.(c)Waxismelted outand themoldisfilled, under avacuum, with molten superalloy. (d) The cast rotor, produced to net or near-netshape. Source: Courtesyof HowmetCorporation.

up and the casting is removed. A number of pat-terns can bejoinedto makeone mold, calledatree

(Fig. 11.13), significantly increasing the produc-tion rate. For small parts, the tree can be inserted into apermeableflask andfilled witha liquid slur-ryinvestment. The investmentthenis placed intoa

chamber and evacuated (to remove the air bubbles

in it) until the mold solidifies. The flask usually is

placed in a vacuum-casting machine, so that

molten metal is drawn into the permeable mold

and onto the part, producing finedetail.

Although the mold materials and labor

in-volvedmake the lost-wax process costly,itis suit-able for casting high-melting-point alloys with good surface finish and close dimensional toler-ances; few or no finishing operations, which oth-erwisewould add significantly tothe totalcost of the casting, are required. The process is capable of producing intricate shapes, with

parts weighing from 1 g to 35 kg, from a wide variety of ferrous and nonferrous

metals and alloys. Recent advances include the casting of titanium aircraft-engine and structural airframe components with wall thicknesseson the order of 1.5 mm, thuscompeting with previouslyused sheet-metal structures.

Ceramic-shellInvestmentCasting. Avariationofthe investment-casting process is

ceramic-shell casting. Ituses the same type ofwax or plasticpattern, which is dipped

first in ethyl silicate gel and subsequently into a fluidized bed (see Section 4.12) of fine-grained fused silica or zircon flour. The pattern is then dipped into coarser

grained silica to build up additional coatings and develop a proper thickness so that

thepatterncanwithstandthethermal shockdue topouring. Therest of theprocedure

is similarto investment casting. The process is economical andis used extensively for theprecision casting of steels and high-temperaturealloys.

The sequence of operations involved in making a turbine diskby this method

is shown in Fig. 11.14. Ifceramic cores are used in the casting,they are removed by leaching with caustic solutions under high pressure and temperature. The molten metal may be poured in a vacuum to extract evolved gases and reduce oxidation,

thus improving the casting quality. To further reduce microporosity, the castings made by this (as well as other processes) are subjected to hot isostatic pressing. Aluminum castings, for example, are subjected toa gaspressure up to 100 MPa at 500°C.

EXAMPLE I |.l Investment-cast SuperalloyComponents for GasTurbines

Sincethe 1960s,investment-cast superalloys have been replacing wrought counterparts in high-performance gas turbines. The microstructure of an integrally investment-cast gas-turbinerotoris shownintheupper half of Fig. 11.15. Note the fine, uniform equiaxed grainsthroughouttherotorcross section. Casting pro-cedures include the use of a nucleant additionto the molten metal, aswell as close controlof itssuperheat,

pouring techniques, andthe coolingrateofthe casting

(see Section 1O.2). Incontrast, notethecoarse-grained structure in the lower half of Fig. 11.15 showing the same type ofrotor cast conventionally. Thisrotor has inferior properties compared with the fine-grained rotor. Dueto developments inthese processes,the

pro-portion ofcast partsto otherparts in aircraft engines

(18)

Section11.3 Expendable-mold, Expendable-pattern Casting Processes 275

FIGURE

|l.l5

Cross section and microstructure

of two rotors: (top) investment cast; (bottom) conventionally cast. Source: Courtesy of ASM

International.

CASE

STUDY

I

l.2

Investment Casting

of Total Knee

Replacements

With great advances in medical care in the past few decades, life expectancies have increased considerably, but sohaveexpectations thatthe qualityof life in later years will remain high. One of the reasons for improvementsin the qualityoflife in thepast40 years has been the great success of orthopedic implants. Hip, knee, shoulder, spine, and other implants have resulted in increased activity and reduced pain for millionsof peopleworldwide.

An example of an orthopedic implant that has greatly improved patient qualityoflifeis the total knee replacement(TKR), as shown in Fig. 11.16a. TKRS are verypopular andreliable for the relief ofosteoarthritis,

a chronic and painful degenerative condition of the knee joint thattypically setsin after middleage. TKRs consist ofmultiple parts, including femoral, tibial, and patellar components. Typical materials used include cobalt alloys, titaniumalloys, and ultrahigh-molecular-weight polyethylene (UI-IMWPE; Section 7.6). Each materialischosenfor specificpropertiesthatare

impor-tantin theapplication ofthe device.

This casestudy describes the investment casting of femoralcomponents ofTKRS, whichare produced

from cobalt-chrome alloy (Section 6.6). The

manufacturing process begins _with the injection

molding of patterns, which are then hand assembled

onto trees, as shown in Fig. 11.16b. Thepatterns are spaced properly on a central wax sprue and then are weldedinplace bydipping them into molten wax and

pressing them against the sprue until the patterns are held in place. The final assembled tree is shown in Fig. 11.17a, which contains 12 knee implants arranged into four rows.

The completed trees areplaced in arack, where they form a queue and are then taken in order byan industrial robot (Section 37.6). The robotfollows a

set sequence inbuilding up the mold; itfirst dips the

pattern into adilute slurry andthen rotatesitunder a

sifting of fine particles. Next, the robot moves the tree beneath a blower to quickly dry the ceramic coating, and then it repeats the cycle. After a few cycles of such exposure to dilute slurry and fine particles,the details ofthepatterns are wellproduced

and good surface finish is ensured. The robot then

dips the pattern into a thicker slurry that quickly

builds up the mold thickness (Fig. 11.16c). The trees are then dried and placed into a furnace to melt out and burn the wax. The trees are then placed into

another furnace topreheat them in preparation for

the casting process.

A mold ready for investment casting is placed into a casting machine. The mold is placed upside down on the machine, directly over a measured volume of molten cobalt chrome. The machine then rotatessothatthe metal flows intothemold, as _shown

in Fig. 11.16d. The tree is then allowed to cool and the mold is removed. The cast parts are machined from the tree and then are further machined and (continued)

(19)

polished to the required dimensional tolerance and subjected to finishing operations to obtain the final surfacefinish. Figure 11.17 shows the progression of product.

investment casting, from tree, to investment, to

casting.The parts arethen removed from thetree and Source: Courtesyof M. Hawkins, Zimmer, Inc.

¢.¢f».»1¢¢.. W

(H) (D)

(C) (Ci)

FIGURE I l.l6 Manufactureoftotalkneereplacements.(a) TheZimmerNeXGen mobile-bearing

knee (MBK); the femoralportionof the totalknee replacement is the subject of the case study.

(b) Assembly ofpatterns ontoa centraltree. (C) Dippingof thetree into slurry to develop a mold from investment. (d) Pouringofmetal intoa mold. Source: CourtesyofM. Hawkins, Zimmer, Inc.

(8) (b) (C)

FIGURE II.l1 Progression of the tree. (a) After assembly of blanks ontothe tree; (b) after

coatingwith investment; (c) after removalfrom the mold. Source: Courtesy of M. Hawkins,

(20)

Section11.4 Permanent-mold Casting Processes 277

ll.4

Permanent-mold Casting

Processes

Permanent-mold casting processes have certain advantages over other casting

processes.

I

l.4.l

Permanent-mold Casting

In permanent-mold casting (also called hard-mold casting), twohalves ofa mold are made from materials with highresistance to erosion and thermalfatigue, suchas cast iron, steel, bronze, graphite, or refractory metal alloys. Typicalparts made are auto-mobile pistons, cylinder heads, connecting rods, gear blanks for appliances, and kitchenware. Partsthat canbe made economicallygenerally weighless than 25 kg, al-though special castings weighing a fewhundredkilograms have been made using this process. The capabilities ofpermanent-mold castingare given inTable 11.2.

The moldcavity andgating system aremachined intothe moldand thusbecome an integral partof it. To producecastings with internal cavities, cores made of metal or sand aggregate are placed in the mold prior to casting. Typical core materials are oil-bonded or resin-bonded sand, plaster, graphite, gray iron, low-carbon steel, and

hot-work die steel. Gray iron is used mostcommonly, particularly for largemolds for

aluminum and magnesium casting. Inserts also are used for variousparts of themold. In orderto increasethe life ofpermanent molds, the surfaces of themold cavity usually are coated with a refractory slurry (such as sodium silicate and clay) or sprayed with graphite every few castings. Thesecoatings also serve as partingagents andas thermal barriers, thus controllingthe rate of cooling of thecasting.Mechanical ejectors (such as pins locatedin various parts ofthe mold)may berequired forthe

re-moval ofcomplex castings; ejectors usually leave smallroundimpressions.

The molds are clamped together by mechanical means and heated to about

150° to 200°C to facilitate metal flow and reduce thermal damage tothe dies due to high-temperature gradients. Moltenmetal is thenpoured throughthe gatingsystem. Aftersolidification,the moldsare opened andthe castingis removed. The mold often

incorporates special cooling features, such as a means of pumping cooling water

throughthe channels located inthe mold and the use of cooling fins. Although the

permanent-mold casting operation canbeperformed manually, it is often automated

forlargeproductionruns. The processis usedmostly foraluminum, magnesium, and

copperalloys, as well as forgray iron, because oftheir generally lower melting points,

although steels also can be cast using graphite or heat-resistant metal molds. Permanent-mold casting produces castings with a good surface finish, close dimen-sional tolerances, uniform and good mechanical properties, and at high production

rates.

Although equipment costs can be high because of high die costs, labor costs

are kept low through automation. The process is not economical for small

produc-tion runs and is not suitable for intricate shapes, because ofthe difficulty in remov-ing the casting from the mold. However, easily collapsable sand cores can be used, which are then removed from castings, leaving intricate internal cavities. This process then is called semipermanent-mold casting.

I

l.4.2

Vacuum Casting

A schematic illustration of the vacuum-casting process, or countergraz/ity low-pressure(CL)process (nottobeconfused with thevacuum-moldingprocess described

in Section 11.2.1) is shown in Fig. 11.18. Vacuum casting is an alternative to invest-ment, shell~mold, and green-sand casting and is suitable particularly for thin-walled (0.75 mm) complex shapes with uniform properties. Typical parts madeare superal-loy gas-turbinecomponents with wallsas thin as 0.5 rnm.

(21)

2 8 Chapter 11 Metal-CastingProcesses andEquipment V?i Vacuum Mold ,,__, sssuu Gate .. __ Castmg O O O ,,.= O O O O Molten metal O O O O O O O O Inductionfurnace (8) (b)

FIGURE ll.l8 Schematicillustrationofthevacuum-castingprocess. Notethatthe mold has

a bottomgate. (a) Before and (b) after immersion ofthemold into themolten metal. Source: After R. Blackburn.

In the vacuum-casting process, a mixture of fine sand and urethane is molded

overmetal dies and curedwithamine vapor. The mold is thenheld with arobotarm

and immersed partially into molten metal held in an induction furnace. The metal may be melted in air(CLA process) or in avacuum (CLVprocess). Thevacuum

re-duces the air pressure insidethe mold to about two-thirds of atmosphericpressure,

thus drawingthemolten metal intothe mold cavitiesthroughagateinthe bottom of

the mold. The metalinthe furnace is usuallyatatemperatureof 55°C above the liq-uidus temperature ofthe alloy. Consequently, it beginsto solidifywithina very short time. After the mold is filled, itis withdrawn from the molten metal.

The process can be automated, and production costs aresimilar to those for green-sand casting. Carbon, low- and high-alloy steel, and stainless steel parts

weighing as much as 70 kg have been vacuum cast bythis method. CLA parts are made easily at highvolume and relatively low cost. CLV parts usually involve reac-tive metals, such as aluminum, titanium, zirconium, and hafnium.

I

l.4.3

Slush

Casting

It was noted in Fig. 10.11 that a solidified skin develops in a casting and becomes thicker withtime. Hollowcastings withthin walls can be made bypermanent-mold

casting usingthis principle: aprocess called slush casting. This process is suitable for

small production runs and generally is used for making ornamental and decorative

objects (such as lamp bases and stems) and toys from low-melting-point metals such as zinc, tin, and lead alloys.

The molten metal is poured intothe metal mold. After the desiredthickness of

solidified skinis obtained, the mold is inverted (orslung) and the remaining liquid metal is poured out. The mold halves then are opened and the casting is removed.

Note that this operation is similar to making hollow chocolate shapes, eggs, and

other confectionaries.

I

I.4.4 Pressure Casting

In the two permanent-mold processes described previously, the molten metal flows

into the mold cavity by gravity. In pressure casting (also called pressurepouring or lou/-pressure casting), the molten metal is forced upward by gas pressure into a

(22)

Section 11.4 Permanent-mold Castrng Processes 2

graphite or metal mold. The pressure is maintained until the metal has solidified

completelyin the mold. Themolten metal also may be forced upward by a vacuum, which also removes dissolved gases and produces a casting with lower porosity. Pressure casting generallyis used for high-quality castings, such as steelrailroad-car

wheels, although these wheels also may be cast in sand molds or semipermanent molds made ofgraphite and sand.

I

I.4.5

Die

Casting

The die-casting process, developed in the early 1900s, is a further example of

permanent-mold casting. TheEuropean term forthis process is pressure die casting

and should not be confused with pressure casting described in Section 11.4.4. Typical parts made by die casting are housings, business-machine and appliance components, hand-tool components, and toys. The weight of most castings ranges

from less than 90 g to about 25 kg.Equipment costs, particularly the cost of dies,

are somewhathigh, butlaborcosts are generallylow, because theprocess is semi- or

fully automated. Die casting is economical for large production runs. The capabili-ties of die casting are given inTable 11.2.

In the die-casting process, molten metal is forced into the die cavity at pres-sures ranging from 0.7 to 700 MPa. There are two basic types of die-casting ma-chines: hot-chamber and cold-chamber machines.

The hot-chamberprocess (Fig. 11.19) involves the use of_a piston, which _forces

a certain volume of metal into the die cavity through a gooseneck and nozzle. Pressures range upto 35MPa, with an average of about 15 MPa. The metalis held under pressure untilitsolidifiesinthe die.To _improvedie lifeand toaid inrapidmetal cooling (thereby reducingcycletime) diesusually arecooledbycirculating water or oil through various passageways inthedie block. Low-melting-point alloys (suchas zinc, magnesium, tin, and lead) commonly arecast using thisprocess. Cycle times usually range from200 to 300 shots (individual injections) per hour forzinc, although very smallcomponents, such as zipper teeth, canbe castatrates of 18,000 shots per hour. In the cold-chamber process (Fig. 1120), molten metal is poured _into the injection cylinder (shot chamber). The chamber is not

heated-hence

the term cold chamber. The metal is forced intothe die cavityat pressures usually ranging from 20 to 70MPa, although they may be as highas 150 MPa.

Hydraulic shot Nozzle cylinder

1-

Plunger rod

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Gooseneck Ejectordie Plunger

D'eCav” Molten metal

Pot

Coverdie

Furnace

(23)

Ejectorbox

Cavity Stationary platen

Electignpcgiri Hydraulic Ladle C_Y'|'nder Ejector iri _® die half 1 I or

m_

.ll

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_

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Stationary Shot Plunger

diehalf sleeve rod

,_ , Pouring hole rr rr_tt .,rtra i. plunger M"““'““ T P'U'"'QefVOC* t.: fu. Av.

x

_,,_, .

,

Closing Clamp Ejector Cover Metal Shot

cylinder mechanism box disc sleeve cylinder

FIGURE I I.20 Schematicillustration ofthecold-chamber die-casting process. These machines

arelargecompared to the size ofthe casting, because high forcesarerequired to keep thetwo

halves ofthediesclosedunder pressure.

The machines may be horizontal (asin the

figure)-or

vertical, inwhich case the shot chamber is vertical. High-melting-point alloys of aluminum, magnesium,

and copper normally are cast using this method, although other metals (including

ferrous metals) also can be cast. Molten-metal temperatures start at about 600°C for aluminum and some magnesium alloys, and increase considerably for copper-based and iron-based alloys.

Process Capabilities and Machine Selection. Diecastinghasthe capabilityfor rapid production of strong, high-quality parts with complex shapes, especially with alu-minum, brass, magnesium, and zinc (Table 11.3). It alsoproduces good dimensional accuracyand surface details,so thatparts requirelittle orno subsequent machiningor finishing operations (net-shape forming). Because of the high pressures involved, walls

as thinas 0.38mmareproduced, whicharethinner than thoseobtained byother cast-ingmethods. However, ejector marks remain,as may smallamounts offlash (thin ma-terial squeezed out betweenthe dies) at the die partingline.

Atypical partmade by die castingis shownin Fig. 11.1d; note the intricate shape

and fine surfacedetail. In the fabrication of certain parts, die casting can compete favorably with other manufacturing methods (such as sheet-metalstamping and forg-ing)or other castingprocesses. In addition, because themoltenmetal chills rapidly at the die walls, the casting has a fine-grained, hard skin with high strength. Consequently, the strength-to-weight ratio of die-cast parts increases with decreasing

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Section11.4 Permanent-mold Casting Processes 28l

TABLE l l.3

Properties andTypical ApplicationsofSame (Zommon Die-castingAlloys Ultimate

tensile Yield Elongation strength strength in 50 mm

Alloy (MPa) (MPa) (%) Applications

Aluminum 380 (3.5 Cu-8.5 Si) 320 2.5 Appliances,automotive components,

electricalmotor frames and housings

13 (12Si) 300 2.5 Complex shapeswith thinwalls, parts

requiring strength at elevated

temperatures

Brass 858 (60 Cu) 380 15 Plumbingfixtures, lockhardware,

bushings,ornamental castings

MagnesiumAZ91 B (9 Al-0.7 Zn) 230 3 Powertools, automotive parts,

sportinggoods

ZincNo. 3 (4 Al) 280 10 Automotive parts,office equipment,

household utensils, building

hardware, toys

No. 5 (4 Al-1 Cu) 320 7 Appliances, automotive parts,

buildinghardware, business

equipment

Source: American DieCasting Institute.

wall thickness. With a good surface finish and dimensional accuracy, die casting can produce smooth surfaces forbearings that otherwise normally wouldbe machined.

Components such as pins, shafts, and threaded fasteners can be die cast inte-grally. Called insert molding, this processis similar to placing woodensticksin pop-sicles prior to freezing (see also Section 19.3). For good interfacial strength, insert surfaces may be knurled (see Fig. 23.11 on page 616), grooved, or splined. Steel, brass, and bronze inserts are used commonlyindie-casting alloys. In selectinginsert materials, the possibility of galvanic corrosion should be taken into account. To

avoid this potential problem, the insert can be insulated, plated, or surface treated. Because of thehigh pressures involved, dies for die casting have a tendency to

part unless clamped togethertightly. Die-casting machines are thusrated according to the clamping force that can be exerted to keep the dies closed. The capacities of commercially available machines range fromabout 23 to 2700 metric tons. Other factors involved in the selection of die-casting machines are die size, piston stroke, shotpressure, and cost.

Die-casting dies(Fig. 11.21) may be single cat/ity, multiplecat/ity (with several identical cavities), combination cavity (with several different cavities), or unit dies

,, ,,_,

Q’ @

$1

ii

5

iii

Single-cavity die Multiple-cavity die Combination die Unitdie

(H) (D) (C) (d)

FIGURE ll.2I Various types ofcavities in a die-casting die. Source: Courtesy ofAmerican

(25)

(simple, small dies that can be combined in two or more units in a master holding die). Typically, the ratio of die weight to partweight is 1000 to 1; thus, the die fora

casting weighing 2 kg would weigh about 2000 kg. The dies usually are made of

hot-work die steels or mold steels (seeSection 5.7). Die wear increaseswith the

tem-perature of the molten metal. Heat checking ofdies (surface cracking from repeated

heating and cooling ofthe die, discussedin Section 3.6) can bea problem. When die

materials are selected and maintained properly, dies may last more than a half mil-lion shots before any significant die wear takes place.

I

l.4.6

Centrifugal Casting

As itsname implies, the centrifugal-casting process utilizes inertial forces (caused by

rotation) to distribute the molten metal intothe mold

cavities-a

method that was

first suggested in the early 1800s. There are three types of centrifugal casting: true centrifugal casting, semicentrifugal casting, and centrifuging.

True Centrifugal Casting. In true centrifugal casting, hollow cylindrical parts (such

as pipes, gun barrels, bushings, engine-cylinderliners, bearing rings with or without

flanges, and street lampposts) are produced bythe technique shown in Fig. 11.22. In this process,molten metalis poured intoarotating mold. Theaxis ofrotationis

usu-ally horizontal, but can be vertical for short workpieces. Molds are made of steel,

iron, orgraphite andmay becoated witha refractorylining to increase mold life. The mold surfaces can be shaped so that pipeswith various external designs can be cast. The inner surface ofthe casting remains cylindrical, becausethe molten metal is dis-tributed uniformly bythecentrifugal forces. However, becauseof densitydifferences, lighter elements (such asdross, impurities, and pieces ofthe refractorylining) tend to collect on the inner surface ofthecasting. Consequently, theproperties ofthe casting can varythroughout itsthickness.

Cylindrical parts ranging from 13mm to 3 m in diameter and 16 m long can be cast centrifugally with wall thicknesses ranging from 6 to 125 mm. The pres-suregenerated by the centrifugal force is high (as much as 150 g); such high pres-sure is necessary for casting thick-walled parts. Castings with good quality,

dimensional accuracy, and external surface detail are produced by this process.

The capabilities of centrifugal casting are given in Table 11.2.

Semicentrifugal Casting. An example of semicentrifugal casting is shown in

Fig. 11.23a. This method is used to cast parts with rotational symmetry, suchas a

wheel with spokes.

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a g

»-ee

SW

Driveshaft Rollers

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gi

(3) (b)

FIGURE II.22 (a) Schematic illustration of the centrifugal-casting process. Pipes, cylinder

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Section 11.4 Permanent-mold Casting Processes 28

Pouring basin

-1

Casting

and_Qate °

Cope Molten metal

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FIGURE I |.23 (a)Schematic illustrationofthe semicentrifugalcastingprocess. Wheelswith

spokes can becast by this process. (b) Schematic illustrationof 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.

Centrifuging. In centrifuging (also called centrifuge casting), mold cavities of any

shape are placed at a certain distance fromthe axis ofrotation. The molten metal is

poured fromthe _centerandis forcedintothe moldby centrifugalforces (Fig. 11.23b).

The properties of the castings can vary by distance from the axis of rotation, as in

true centrifugal casting.

I

I.4.7 Squeeze Casting

and

Semisolid-metal

Forming

Two casting processes that incorporate features of both casting and forging (Chapter 14) aresqueeze casting andsemisolid-metal forming.

Squeeze Casting. The squeeze-casting (or liquid-metal forging) process was

de-veloped in the _{1960s and involves} the solidification of molten metal under high pressure (Fig. 11.24). Typical products made are automotive components and

mortar bodies (a short-barrelled cannon). The machinery includes a die, punch,

A

' mfg,/" Finished

f;r.::; y ;..;;¢;:;., casting

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Ejector

1. Melt metal 2. Pour molten 3. Close dieand 4. Eject squeezecasting,

metal intodie applypressure charge meltstock, repeat cycle

FIGURE I I.24 Sequence ofoperationsin thesqueeze-casting process. Thisprocesscombines