Metal Casting Processes

Total Page：16

File Type：pdf, Size：1020Kb

Metal Casting Processes The metal components required for industrial use today are formed using many divergent technologies, such as casting, forging, and machining. Here at Stainless Foundry, we make steel, stainless steel and high alloy castings by pouring molten metal into pre-formed molds, using both the sand and investment casting processes. Here is an explanation of how we make castings at Stainless Foundry & Engineering. SAND CASTINGS Permanent Pattern Method Description: A sand and binder mixture is packed around halves of Process Applications: Produces low-cost parts, especially in smaller a pattern constructed from wood, metal or plastic. When the quantities. Short processing time. Better suited to parts weighing pattern is removed from the sand, an impression or mold of the over 5 pounds; best choice for large castings. More appropriate desired casting remains. Cores may be installed to form internal where tight dimensional repeatability is not required. passages, and then the two mold halves are assembled. Molten Process Applications: Well-suited to high-volume intricate metal is then poured into the mold cavity. After solidification, the no-bake molding. sand is shaken away from the casting. parts with 1) Mount pattern 2) Add risers 3) Position flasks 4) Add and halves (cope and and sprue to on the boards. compact sand. drag) on hoards. cope. 9) Completed 5) Remove patterns 6) Invert cope and 7) Pour molten 8) Remove casting casting ready to from molds place it on drag. metal into mold. from mold. Prepare for cut-off. ship. .

Copy Link

Recommended publications

Cast Stainless Steel Technology Developments
Cast Stainless Steel Technology Developments Raymond Monroe SFSA CN3MN CF8 CD4Cu CB 7 Cu CA 15 Calculation of Chromium Equivalent and Nickel Equivalent CrE = %Cr + 2 × %Si + 1.5 × %Mo + 5 × %V NiE = %Ni + 0.5 × %Mn + 30 × %C + 0.3 × %Cu Ferrite from Chemistry Schoefer Diagram 2.2 2.1 • Chemistry: C=0.07, 2 Mn=0.56, Si=1.30, 1.9 P=0.028, S=0.009, 1.8 o i t 1.7 Cr=19.5, Ni=10.7, a 1.6 on R i t i Mo=2.18 (Cb ~ 0.05 1.5 pos m o and N ~ 0.04) 1.4 C i N / r 1.3 C • ASTM A800 predicts 1.2 10.5 volume percent 1.1 1 ferrite with a range of Cr Cr (%) + 1.5Si (%) + 1.4 Mo (%) + Nb (%) − 4.99 0.9 e = 6.5 to 14.5 (chromium Ni e Ni (%) + 30 C (%) + 0.5Mn (%) + 26 ( N − 0.02 %) + 2.77 0.8 0 10203040506070 equivalent to nickel Volume Percent Ferrite equivalent = 1.19) Means of Calculating Ferrite • Severn Gage: 11 • Feritscope: 7 • Magne-Gage: 2 • Two different instruments: 5 • Manual point count • ASTM A800 • 1949 Schaeffler Diagram • WRC Diagram Unit of measure: • FN: 8 (all 4 of the non- foundry) • Volume percent: 7 • Use both methods: 2 Identification of Phases by Composition FERRITE AUSTENITE Stainless Steels - Strength Grade Yield (ksi) UTS (ksi) CF8 70 30 CF3MN 75 37 4A(2205) 90 60 6A(Zeron 100) 100 65 Stainless Steel - Corrosion Grade Critical pitting temperature oC CF8 5 (calculated) CF3MN 29 (calculated) 4A(2205) 35 - 40 6A(Zeron100) 45 – 55 Pseudo Phase Diagram for 68 % Fe – Cr Ni CCT Diagram - CD3MN 5oC/min 2oC/min 1oC/min 0.5oC/min 0.1oC/min 0.01oC/min 1100 1050 TTT curves 1000 (initial & final) 950 900 850 800 750 700 Temp.
[Show full text]
Repoussé Work for Amateurs
rf Bi oN? ^ ^ iTION av op OCT i 3 f943 2 MAY 8 1933 DEC 3 1938 MAY 6 id i 28 dec j o m? Digitized by the Internet Archive in 2011 with funding from Boston Public Library http://www.archive.org/details/repoussworkforamOOhasl GROUP OF LEAVES. Repousse Work for Amateurs. : REPOUSSE WORK FOR AMATEURS: BEING THE ART OF ORNAMENTING THIN METAL WITH RAISED FIGURES. tfjLd*- 6 By L. L. HASLOPE. ILLUSTRATED. LONDON L. UPCOTT GILL, 170, STRAND, W.C, 1887. PRINTED BY A. BRADLEY, 170, STRAND, LONDON. 3W PREFACE. " JjJjtfN these days, when of making books there is no end," ^*^ and every description of work, whether professional or amateur, has a literature of its own, it is strange that scarcely anything should have been written on the fascinating arts of Chasing and Repousse Work. It is true that a few articles have appeared in various periodicals on the subject, but with scarcely an exception they treated only of Working on Wood, and the directions given were generally crude and imperfect. This is the more surprising when we consider how fashionable Repousse Work has become of late years, both here and in America; indeed, in the latter country, "Do you pound brass ? " is said to be a very common question. I have written the following pages in the hope that they might, in some measure, supply a want, and prove of service to my brother amateurs. It has been hinted to me that some of my chapters are rather "advanced;" in other words, that I have gone farther than amateurs are likely to follow me.
[Show full text]
Precision Investment Casting Solutions
PRECISION INVESTMENT CASTING SOLUTIONS One stop MEDICAL/DENTAL APPLICATIONS for your Precision SPOKANE INDUSTRIES has been supplying quality precision investment castings to the medical and dental industry for over 10 Investment years. We utilize a state-of-the-art investment casting process to casting needs produce high quality, precision parts tailored for the application. Typical • Castings from 3g to 45Kg alloys poured at Spokane Industries include all stainless and carbon steel grades, in addition to low alloy materials. • Full In-House • Engineering Our experienced engineering team will • Metallurgy work with you on new designs, to assess • Design/Development existing parts or production problems, • Non-Destructive Test or identify casting conversions from • Physical Test weldments, fabrications and assemblies. • Finishing We can help optimize the design to take full advantage of the • Industry Leading Quality benefits of investment casting • On-Time Delivery and recommend solutions that reduce production complexity and cost, and increase reliability and quality. Please contact us for more information and quotes: (800) 541-3601 X110 • www.SpokaneIndustries.com • [email protected] Copyright© 2011 • Spokane Industries, Inc. Spokane Precision Castings Services • Capabilities Production Capabilities From a few grams up to 45kg Thousands of units per week Commonly Poured Alloys Carbon Steels Cobalt Based Materials Industries Low Alloy Steels Supported Lead-free Copper Based Alloys Nickel Based Alloys Include: Tool Steels
[Show full text]
Application of Investment Casting: a Review Paper
Pramana Research Journal ISSN NO: 2249-2976 Application of Investment Casting: A Review paper 1Rahul Ojha, 2Gourav, 3Rohit Goyal 1,2 B.E, student, Mech. Engg. Department, Chandigarh University, Mohali, India 3Assistant Professor, Department of Mechanical Engineering Department [email protected] [email protected] [email protected] Abstract Investment casting process is a type casting process of producing clear net shape, high- dimensional accuracy and intricate design. Consistent research effort has been made by various researchers from all over the world with an objective to explore the world of investment casting. This article highlights the advancements made and proposed at each step of investment casting and its applications in practical world . Investment casting is being used from years to manufacture parts such as weapons, jewellery item, idols and statues of god and goddess; this article reviews the present and future applications of the investment casting. The aim of this review article is to present state of art review of applications of investment casting since 3200 BC. This article is organized as follows: in section ‘Introduction’, introduction to investment casting and process is given ; in section ‘Application in Aerospace Industries’, background is given on the application of investment casting in aerospace and related industries; section ‘Biomedical applications of investment casting’ presents the medicine or biomedical applications of investment casting; section ‘Conclusion’ closes the article by offering conclusions. Keywords: investment casting, biomedical application and aerospace industry application. Introduction Investment casting is a manufacturing process that can be traced back over 5,000 years to ancient Egypt and China. It is utilized to cast a wide variety of items, including high- quality, high-performance industrial parts.
[Show full text]
Implementation of Metal Casting Best Practices
Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof.
[Show full text]
Piece Mold, Lost Wax & Composite Casting Techniques of The
Piece Mold, Lost Wax & Composite Casting Techniques of the Chinese Bronze Age Behzad Bavarian and Lisa Reiner Dept. of MSEM College of Engineering and Computer Science September 2006 Table of Contents Abstract Approximate timeline 1 Introduction 2 Bronze Transition from Clay 4 Elemental Analysis of Bronze Alloys 4 Melting Temperature 7 Casting Methods 8 Casting Molds 14 Casting Flaws 21 Lost Wax Method 25 Sanxingdui 28 Environmental Effects on Surface Appearance 32 Conclusion 35 References 36 China can claim a history rich in over 5,000 years of artistic, philosophical and political advancement. As well, it is birthplace to one of the world's oldest and most complex civilizations. By 1100 BC, a high level of artistic and technical skill in bronze casting had been achieved by the Chinese. Bronze artifacts initially were copies of clay objects, but soon evolved into shapes invoking bronze material characteristics. Essentially, the bronze alloys represented in the copper-tin-lead ternary diagram are not easily hot or cold worked and are difficult to shape by hammering, the most common techniques used by the ancient Europeans and Middle Easterners. This did not deter the Chinese, however, for they had demonstrated technical proficiency with hard, thin walled ceramics by the end of the Neolithic period and were able to use these skills to develop a most unusual casting method called the piece mold process. Advances in ceramic technology played an influential role in the progress of Chinese bronze casting where the piece mold process was more of a technological extension than a distinct innovation. Certainly, the long and specialized experience in handling clay was required to form the delicate inscriptions, to properly fit the molds together and to prevent them from cracking during the pour.
[Show full text]
Mahimkar, C., Richards, V., Lekakh, S., Metal-Ceramic Shell Interactions During Investment Casting, Transactions Of
Paper 11-077.pdf, Page 1 of 11 AFS Proceedings 2011 © American Foundry Society, Schaumburg, IL USA Metal-Ceramic Shell Interactions during Investment Casting C. Mahimkar, V. L. Richards, and S. N. Lekakh Missouri University of Science and Technology, Rolla, Missouri Copyright 2011 American Foundry Society When steel is poured into preheated ceramic shells, the ABSTRACT prime coat of the shells comes in contact with the melt and its oxides. Thus, there is the possibility of melting Interactions of liquid steel with preheated ceramic shell and/or chemical reactions at the mold-metal interface. molds can adversely affect the surface quality of Metal-mold interactions have been studied for decades in investment castings and increase casting cleaning and the casting industry but most of the work was dedicated to finishing expenses. This phenomenon was studied using a study the specific burn-in/burn-on surface defect special cube-shaped specimen with a deep pocket. The formation when using green sand and no-bake sand temperature field in the specimen and shell during the molds. Gilliland found the mold material at or near mold- casting process was simulated with MAGMAsoft. A metal surface often becomes a burnt sand layer, which has foam pattern was used to form investment casting shells experienced temperatures equal to or very close to solidus prepared in the Missouri S&T Laboratory with three point of metal being cast1. He conducted experiments by different prime coats: silica, zircon and alumina. For pouring gray iron, ductile iron and steel into sand molds comparison, shells prepared around the same specimen and observed interface reactions in hot and cold regions.
[Show full text]
SAVED by the BELL ! the RESURRECTION of the WHITECHAPEL BELL FOUNDRY a Proposal by Factum Foundation & the United Kingdom Historic Building Preservation Trust
SAVED BY THE BELL ! THE RESURRECTION OF THE WHITECHAPEL BELL FOUNDRY a proposal by Factum Foundation & The United Kingdom Historic Building Preservation Trust Prepared by Skene Catling de la Peña June 2018 Robeson House, 10a Newton Road, London W2 5LS Plaques on the wall above the old blacksmith’s shop, honouring the lives of foundry workers over the centuries. Their bells still ring out through London. A final board now reads, “Whitechapel Bell Foundry, 1570-2017”. Memorial plaques in the Bell Foundry workshop honouring former workers. Cover: Whitechapel Bell Foundry Courtyard, 2016. Photograph by John Claridge. Back Cover: Chains in the Whitechapel Bell Foundry, 2016. Photograph by John Claridge. CONTENTS Overview – Executive Summary 5 Introduction 7 1 A Brief History of the Bell Foundry in Whitechapel 9 2 The Whitechapel Bell Foundry – Summary of the Situation 11 3 The Partners: UKHBPT and Factum Foundation 12 3 . 1 The United Kingdom Historic Building Preservation Trust (UKHBPT) 12 3 . 2 Factum Foundation 13 4 A 21st Century Bell Foundry 15 4 .1 Scanning and Input Methods 19 4 . 2 Output Methods 19 4 . 3 Statements by Participating Foundrymen 21 4 . 3 . 1 Nigel Taylor of WBF – The Future of the Whitechapel Bell Foundry 21 4 . 3 . 2 . Andrew Lacey – Centre for the Study of Historical Casting Techniques 23 4 . 4 Digital Restoration 25 4 . 5 Archive for Campanology 25 4 . 6 Projects for the Whitechapel Bell Foundry 27 5 Architectural Approach 28 5 .1 Architectural Approach to the Resurrection of the Bell Foundry in Whitechapel – Introduction 28 5 . 2 Architects – Practice Profiles: 29 Skene Catling de la Peña 29 Purcell Architects 30 5 .
[Show full text]
Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting
applied sciences Article Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting Wei-Hao Lee, Yi-Fong Wu, Yung-Chin Ding and Ta-Wui Cheng * Institute of Mineral Resources Engineering, National Taipei University of Technology, Taipei 10608, Taiwan; [email protected] (W.-H.L.); [email protected] (Y.-F.W.); [email protected] (Y.-C.D.) * Correspondence: [email protected] Received: 1 June 2020; Accepted: 29 June 2020; Published: 1 July 2020 Abstract: Lost-wax casting, also called precision casting, is the process of casting a duplicate metal sculpture cast an original sculpture. The ceramic shell mould used in lost-wax casting usually consists of several layers formed with fine zircon and granular mullite particles using silica gel as a binder. However, it is a complicated and time-consuming process. Large amounts of waste moulds that need to be disposed and recycled become an environmental concern. In this study, waste shell sand from the recycled mould and calcium carbonate/metakaolin were used as raw materials to prepare geopolymer slurry and coating. The influence of mixing ratio and the SiO2/K2O modulus of the alkali solution on the setting time and green/fired strength were evaluated. Ceramic shells with one to four layers of geopolymer slurry and waste sand sprinkling were fabricated and tested for their permeability and green/fired strength. It was found that geopolymer shells had higher green/fired strength and better permeability than the original zircon/mullite shell. For foundry practice, metal casts were fabricated using recycled ceramic shell moulds with one to four layers of geopolymer coating.
[Show full text]
Study of Ceramic Slurries for Investment Casting with Ice Patterns
Study of Ceramic Slurries for Investment Casting with Ice Patterns Qingbin Liu, Ming C. Leu Department of Mechanical and Aerospace Engineering University of Missouri – Rolla, Rolla, MO 65409 Harish Jose, Von L. Richards Department of Materials Science and Engineering University of Missouri – Rolla, Rolla, MO 65409 ABSTRACT Ice patterns generated by rapid freeze prototyping or a molding process can be used to make ceramic investment molds for metal castings. Due to the use of ice, the ceramic slurries must be poured around the pattern and cured at sub-freezing temperatures. Success of this process depends greatly on the mold strength after the gelation of the slurries. This paper describes the experimental results of the mold strength after the gelation of the slurries under different compositions. The parameters considered include mixing time, alumino-silicate vs. fused silica ratio, volume of binder, and volume of catalyst. The strength of the gelled slurries is examined by breaking test bars on a four-point bending apparatus. Weibull modulus for each trial is calculated based on the breaking strength from four-point bend tests. Analysis of variance for breaking strength and Weibull analysis is performed to evaluate the significance of the effect of each parameter. The casting of a bolt is used to demonstrate that metal castings of complex geometry can be fabricated using investment casting with ice patterns. 1. Introduction Every foundry has shell cracking problems in investment casting as a result of mechanical stress. To avoid the shell cracking problems, the investment casting process and the materials used must be strictly controlled. New approaches to improve the performance of investment casting process are constantly being sought.
[Show full text]
The Lost-Wax Casting Process—Down to Basics by Eddie Bell, Founder, Santa Fe Symposium
The Lost-Wax Casting Process—Down To Basics By Eddie Bell, Founder, Santa Fe Symposium. Lost-wax casting is a ancient technique that is used today in essentially the same manner as it was first used more than 5,000 years ago. As they say, there's no messing with success. Today, of course, technology has vastly expanded the technique and produced powerful equipment that makes the process faster, easier and more productive than ever, but the basic steps remain the same. The steps below represent a simple overview and are intended to provide a beginning understanding of the casting process. Concept This is obviously where the design is initally conceived, discussed,evolved, and captured on paper—or on computer; CAD (computer aided design) software is increasingly popular among designers. You create the design you envision using the computer tool and the software creates a file that can be uploaded into a CNC mill or 3D printer. Model Build a model, either by hand-carving, guided by the paper rendering, or by uploading the CAD file into a computer controlled milling machine or a 3D printing machine. Models are made using carving wax, resin or similar material. This process can also be done in metal by a goldsmith or silversmith. Note: If a 3D printer or other rapid prototyping equipment is used, it is possible to skip the molding and wax-injection steps by using one of the resins that are specially made to go directly to the treeing process. Molding Create a mold from your master model, placing it in one of a variety of rubber or silicone materials, curing the material, then removing the model from the finished mold.
[Show full text]
Extrusion Blow Molding ___Fiberg
Woman Owned Small Busines • ITAR Certified 710 South Patrick Drive • Satellite Beach, Florida 32937 321.536.2611 • [email protected] • www.rapidps.com ABS • POLYCARBONATE • POLYPHENYLSULFONE • ULTEM ADVANCED APPLICATIONS _____________________________ RTV MOLDS __________________________ Parts produced can be used in lots of different manufacturing applications. Parts built using RPS provide the fast, accurate and af- Parts can be painted, electroplated and drilled. They can also be used in ad- fordable patterns that drive RTV molding. By replacing vanced applications such as investment castings, RTV molding and sand cast- machined patterns, the entire process can be com- ing. Each application includes the benefits to using an RPS part with detailed pleted in 2-3 days. And unlike machining, complex instructions. and intricate shapes have no effect on the time or cost for the RPS pattern. ELECTROPLATING ____________________ Electroplating deposits a thin layer of metal on the RTV MOLDING SOLUBLE CORE _________ surface of a part built. This improves the part’s me- Complex geometries normally requiring core removal chanical properties and gives the appearance of pro- such as curved hoses, water tanks, bottles, and arterial duction metal or plated parts and provides a hard, structures are good examples where it may be helpful wear-resistant surface with reflective properties. to use this alternative method. Instead of building the core in thermoplastic material (traditional RPS build EXTRUSION BLOW MOLDING __________ process) the mold is built in the Water Soluble sup- Polycarbonate RPS molds are used in the blow port material making it easy to dissolve away the mate- molding process, reducing lead time and expense.
[Show full text]