METAL-
CASTING
PROCESS
AND
EQUIPMENT
Zulfikar saifudin Habi Burrohman/
0211174000010
METAL-CASTING PROCESS AND
EQUIPMENT
• Permanent-mold Casting Processes
• Inspection of Castings
• Casting Techniques for Single-crystal Components
• Inspection of Castings
• Melting Practice and Furnaces
Permanent
-mold
Casting
Processes
Permanent-mold
Casting
• Permanent-mold casting produces castings
with a good surface finish, close
dimensional tolerances, uniform and good
mechanical properties, and at high
production rates.
• The process is not economical for small
production runs and is not suitable for
intricate shapes
Vacuum Casting
• good surface finish, close dimensional
tolerances
• The vacuum reduces the air pressure inside
the mold
• Need more cost for vacuum machine
Slush Casting
• This process is suitable for small production
• Doesn’t need machine
• Easy process
• Need repeated step
• Need more than one layer
• The thickness can different at different
point
Pressure Casting/ low
pressure casting
• molten metal is forced upward by gas
pressure into mold
• The molten metal also may be forced
upward by a vacuum
• high-quality castings,
• Need chamber and gass fill
Die Casting
• Molten metal inject to the mold with piston
or injector
• Need piston or injection
• Need more pressure
• Good detail, high strength, fine surface
• Shaft, pin, thread
Centrifugal Casting
• process utilizes inertial forces (caused by
rotation) to distribute the molten metal into
the mold
• True Centrifugal Casting, Semicentrifugal
Casting, Centrifuging.
• Just rotational shapes
Squeeze Casting and
Semisolid-metal Forming
• Proses uses casting and forging
• For semisolid metal
• Fast machining rate
CONVENTIONAL D I R E C T I O N A L LY S I N G L E - C R Y S TA L
CASTING OF TURBINE SOLIDIFIED BLADES. BLADES.
BLADES.
Ceramics mold ceramic mold is preheated by mold has a constriction in the
radiant heating and the mold is shape of a corkscrew or helix so
supported by a water-cooled chill allows only one crystal to fit
plate. through
crystal begins to solidify at the Crystals begin to grow at the chill- crystal-pulling method: crystal
ceramic walls plate surface and on upward and pull out slowly from seed
solidified directionally crystal when it rotated
floating-zone method: crystal
grow because moving coil
grain structure developed is Columnar grains -
polycrystalline
Structure susceptible to creep and stronger in the direction of the lack of grain boundaries
cracking along the boundaries centrifugal forces makes them resistant to creep
and thermal shock
Casting
Techniques for
Single-crystal
Components
Rapid
Solidification
• amorphous alloys
(metallic glasses)
• cooling the molten metal
at rates as high as 106
K/s, so that it does not
have sufficient time to
crystallize
• Rapid solidification results
in a significant extension
of solid solubility, grain
refinement, and
reduced
microsegregation
• From mold preparation to the removal of
castings from molds or die
• To maintaining good quality
• Castings can be inspected visually, or optically,
for surface defects.
• Subsurface and internal defects are
investigated using various nondestructive
Inspection of techniques
Castings • Destructive testing, specimens are removed
from various sections of a casting and tested for
strength, ductility, and other mechanical
properties
• Pressure tightness of cast components (valves,
pumps, and pipes) usually is determined by
sealing the openings in the casting and
pressurizing it with water, oil, or air.
• Melting practice for direct bearing on
the quality of castings
• Melting furnaces are charged with
melting stock, consisting of metal,
alloying elements, and various other
materials (such as flux and slag-forming
Melting Practice Constituents) to refine the molten
and Furnaces metal(dissolved gases and various
impurities)
a. Electric-arc furnaces
b. Induction furnaces
c. Crucible furnaces
d. Cupolas
Electric-arc furnaces
• Using electrode
• Advantages as a high rate
of melting (and thus high-
production rate), much less
pollution than other types of
furnaces, and the ability to
hold the molten metal
(keep it at a constant
temperature for a period of
time) for alloying purposes.
Induction furnaces
• Using coil
• smaller foundries and produce
smaller Composition-controlled
melts
• Clean, less pollutant, controllable
process
• coreless induction uses high-
frequency current and has coil
that surrounds all of unit.
• channel furnace uses a low-
frequency Current (as low as 60
Hz) and has a coil that surrounds
only a small portion of the unit.
Crucible furnaces
• are heated with various
fuels, such as commercial
gases, fuel oil, and fossil
fuel, as well as electricity.
• Crucible furnaces may be
stationary, tilting, or
movable.
Cupolas
• The most popular melting
furnace in the ferrous
foundries
• metal, coke, and flux
• operate continuously,
have high melting rates,
and produce large
amounts of molten metal
