Docsity
Docsity
Prepare for your exams
Prepare for your exams

Study with the several resources on Docsity

Earn points to download
Earn points to download

Earn points by helping other students or get them with a premium plan

Guidelines and tips
Guidelines and tips
Sell on Docsity
Sell on Docsity
Docsity AI
Docsity AI
Log inSign up

Prepare for your exams

Study with the several resources on Docsity

Find documents

Prepare for your exams with the study notes shared by other students like you on Docsity

Search for your university

Find the specific documents for your university's exams

Docsity AINEW

Summarize your documents, ask them questions, convert them into quizzes and concept maps

Explore questions

Clear up your doubts by reading the answers to questions asked by your fellow students

Earn points to download

Earn points by helping other students or get them with a premium plan

Share documents
download point icon20 Points

For each uploaded document

Answer questions
download point icon5 Points

For each given answer (max 1 per day)

All the ways to get free points
Get points immediately

Choose a premium plan with all the points you need

Study Opportunities

Choose your next study program

Get in touch with the best universities in the world. Search through thousands of universities and official partners

Community

Ask the community

Ask the community for help and clear up your study doubts

Free resources

Our save-the-student-ebooks!

Download our free guides on studying techniques, anxiety management strategies, and thesis advice from Docsity tutors

Casting Processes: Types, Factors, and Techniques, Study notes of History of film

University of London (Lond)History of film

An in-depth exploration of casting processes, discussing six essential factors, seven major casting methods, and various techniques such as sand casting, permanent-mold casting, and die casting. It covers materials used, mold creation, melting and pouring, and finishing operations.

Typology: Study notes

2021/2022

Uploaded on 09/12/2022

ringostarr
ringostarr 🇬🇧

4.7

(12)

303 documents

1 / 12

Toggle sidebar

This page cannot be seen from the preview

Don't miss anything!

bg1
2.4_3 Casting Processes
• pouring a liquid material (molten metal) into a prepared
mold
• materials:
iron steel aluminum
brass bronze magnesium
certain zinc alloys
• iron is used most often
- fluidity, low shrinkage, strength, rigidity, and ease of
control
Chap 2, Casting – p. 1
pf3
pf4
pf5
pf8
pf9
pfa

Partial preview of the text

Download Casting Processes: Types, Factors, and Techniques and more Study notes History of film in PDF only on Docsity!

2.4_3 Casting Processes

  • pouring a liquid material (molten metal) into a prepared mold
  • materials:

iron steel aluminum

brass bronze magnesium certain zinc alloys

  • iron is used most often
    • fluidity, low shrinkage, strength, rigidity, and ease of control
  • Six factors of the casting process:
  1. A mold cavity must be produced.
  • must have desired shape
  • must allow for shrinkage of the solidifying metal
  • a new mold must be made for each casting, or a permanent mold must be made
  1. A suitable means must exist to melt the metal.
  • high temperatures
  • quality mix
  • low cost

  1. The molten metal must be introduced into the mold so that all air or gases in the mold will escape. The mold must be completely filled so that there are no air holes.

  2. The mold must be designed so that it does not impede the shrinkage of the metal upon cooling.

  3. It must be possible to remove the casting from the mold.

  4. Finishing operations must usually be performed on the part after it is removed from the mold.

Patterns

  • a pattern is a duplicate of the part being made
  • pattern material is dependent upon the number of parts being made - wood is most common for small quantities - aluminum is used for larger quantities
  • the pattern must be made slightly larger than the part
    • metal will shrink as it cools
    • cast iron 1/10 to 1/8 inch per foot steel 3/16 to 1/ aluminum 1/8 to 5/
  • the pattern maker uses a special shrink ruler
  • split patterns are most common

Cores

  • an advantage of casting is that holes can be cast into a part with relative ease
  • sand cores are inserted into the mold cavity

Permanent-Mold Casting Processes

  • a disadvantage of sand castings is that a new mold must be made for every part
  • permanent-mold casting only uses gravity to introduce the metal
  • molds are made of cast iron or steel
  • permanent molds are heated at the beginning of a pour
  • permanent-mold castings have better dimensional accuracy and smoother surfaces than can be obtained with sand casting

Melting and Pouring

The furnace used to melt the metal should:

  1. provide adequate temperature

  2. minimize contamination

  3. allow for holding the metal at high temperature without harmful effects for long period of time (while chemical composition is adjusted)

  4. be economical

  5. avoid atmospheric pollution

Pouring Practice

  • must transfer the metal from the melting furnace into the molds
  • a pouring device or a ladle are used
  • metal must be kept at proper temperature during the pour