Mike Bloomfield Kahra Fishburn Chanse Starmer ENGR45, Fall 2013, SRJC 3200 B.C. A copper frog, 1455 Dillenburg Castle in the oldest known casting in Germany is the first to use existence, is cast in cast iron pipe to transport Mesopotamia. water 2000 B.C. Iron is 1709 Englishman Abraham discovered. Darby creates the first true 645 B.C. Earliest known foundry flask for sand and sand casting (Chinese) loam casting. 1809 Centrifugal casting is developed by A. G. Eckhardt of Soho, England.
1825 Aluminum, the most 1960s Compactibility and common metal in the methylene blue clay tests earth's crust, is isolated. are developed for green 1897 Investment casting is sand control. Also rediscovered by B.F. developed at this time are Philbrook of Iowa. He uses high-pressure molding it to cast dental inlays processes and fast-setting no bake binders for sand.
Casting has been used by every major civilization throughout history Most casting was used for weapons making and art Some of the most famous castings are the Greek and Roman era bronze statues (most of the famous ones you know are marble copies of their bronze originals) Most of these statues have been lost. Very few remain today because they were melted down for their metal during the major wars of history
• A bronze Cast statue of a She-Wolf suckling Romulus and Remus (the mythical founders of Rome) Definition: an object made by shaping molten metal or similar material in a mold.
Major Types of Casting Lost Wax Sand Casting Investment Casting Lost Foam Centrifugal Permanent Mold
Metal casting can be used to form almost any shape All major metals can be cast Useful for high volume parts Used in the auto industry, pipes, toys, kitchen appliances, farming/construction equipment, planes, turbines, etc. 90% of all manufactured goods contain some form of metal casting Fun fact: in America, you are rarely more than 10 feet from a metal casting
In sand casting, usually a two piece mold is used for more complex parts First, a part is used to form a mold by compacting green sand around the part, half of the part being molded in the drag, and half of the part being molded in the cope Vent holes, risers and runners would be made on one half of the mold to allow the metal to flow into the mold The part would then be removed, leaving a hollow cavity The two halves are then joined together and a casting can be made!
A rough cast before it has been cleaned up. The runner, riser and seam of the part is visible. A special type of sand called Green Sand is used for most sand casting
Contrary to popular belief, the sand is not actually green in color. The name refers to its water content, much like a green tree limb contains a high amount of water.
Unlike the name suggests, "green sand" is not a type of sand on its own, but is rather a wet mixture of:
Silica sand (SiO2), 75 to 85% Bentonite (clay), 5 to 11% water, 2 to 4% Inert sludge 3 to 5% anthracite (0 to 1%)
The goal of our project was to make a repeatable casting process for the Engineering Club We hope to cast a small plaque every year to commemorate the club, as a replacement to the marble stone pavers that have been used previously We decided on sand casting because of its repeatability and consistency We had originally planned on lost wax casting, but because we wanted a consistent look through the years, we chose sand casting instead We had hoped to make multiple casts from different materials, but due to some unforeseen challenges we were only able to complete one. Some of the challenges we ran into: The zinc we had planned to use was not pure zinc, and we could not get it to consistently melt We had a limited supply of bismuth One of our crucibles broke while in the oven, and we lost that material We tried to combine zinc with gold leaf for an interesting effect, and it just failed…
Oops!!!
Compacting the sand around the piece to get a good mold Bismuth melts at 271 °C (520 °F)
Bismuth Crystals through a microscope
http://www.metal-technologies.com/HistoryofMetalCasting.aspx http://www.tanyfoundry.com/case-study-of-lost-wax-casting- technique-for-bronze-sculpture/ http://faculty.evansville.edu/rl29/art105/f01/art105-2.html http://www.oxforddictionaries.com/us/definition/american_english/c ast http://aluminumfoundry.wordpress.com/2009/12/09/sand-casting/ http://www.hnsa.org/doc/foundry/part2.htm http://en.wikipedia.org/wiki/Green_sand_%28casting%29#Green_san d http://periodictable.com/Elements/083/ http://www.amazingrust.com/Experiments/how_to/Bismuth_Crystals. html