Casting Complete

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Sandcasting
Sand casting uses ordinary sand as the primary mould material. The sand grains are mixed with small amounts of other materials, such as clay and water, to improve strength, mouldability and cohesive strength and are then packed around a pattern that has the shape of the desired casting. The pattern must be removed before pouring, the mold is usually made in two or more pieces. An opening called a sprue hole is cut from the top of the mold through the sand and connected to a Compiledby:SKMondalMadeEasy system of channels called runners. Contd.
MetalCasting M t lC ti
BySKMondal
Compiledby:SKMondalMadeEasy
The molten metal is poured into the sprue hole, flows through the runners, and enters the mold cavity through an opening called a gate. Gravity flow is the most common means of introducing the metal into the mold. After solidification, the mold is broken and the finished casting is removed. The casting is then fettled by cutting off the ingate and the feeder head. Because the mold is destroyed, a new mold must be made for each casting.
Contd
Sequentialstepsinmakingasandcasting
Apatternboardisplacedbetweenthebottom(drag) andtop(cope)halvesofaflask,withthebottomsideup. Sandisthenpackedintothedraghalfofthemold. Abottomboardispositionedontopofthepackedsand, andthemoldisturnedover,showingthetop(cope)half ofpatternwithsprue andriserpinsinplace. Thecopehalfofthemoldisthenpackedwithsand.
The mold is opened, the pattern board is drawn (removed), and the runner and gate are cut into the surface of the sand. The mold is reassembled with the pattern board removed, and molten metal is poured through the d d l l d h h h sprue. The contents are shaken from the flask and the metal segment is separated from the sand, ready for further processing.
Contd
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CastingTerms
Flask: A moulding flask is one which holds the sand mould intact. It is made up of wood for temporary applications or metal for longterm use. pp g Drag: Lower moulding flask. Cope: Upper moulding flask. Cheek: Intermediate moulding flask used in three piece moulding.
Pattern: Pattern is a replica of the final object to be made with some modifications. Parting line: This is the dividing line between the two moulding fl k that makes up the sand mould. ld flasks h k h d ld Bottom board: This is a board normally made of wood, which is used at the start of the mould making.
Contd
Contd
Moulding sand: The freshly prepared refractory material used for making the mould cavity. It is a mixture of silica, clay and moisture in appropriate proportions. Backing sand: This is made up of used and burnt sand. Core: Used for making hollow cavities in castings.
Pouring basin: A small funnelshaped cavity at the top of the mould into which the molten metal is poured. Sprue: The passage through which the molten metal from the pouring basin reaches the mould cavity cavity. Runner: The passage ways in the parting plane through which molten metal flow is regulated before they reach the mould cavity. Gate: The actual entry point through which molten
metal enters the mould cavity in a controlled rate. Contd Compiledby:SKMondalMadeEasy
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Padding
Chaplet: Chaplets are used to support cores inside the mould cavity. Chill: Chills are metallic objects, which are placed in the mould to increase the cooling rate of castings. h ld i h li f i Riser: It is a reservoir of molten metal provided in the casting so that hot metal can flow back into the mould cavity when there is a reduction in volume of metal due to solidification
Tapering of thinner section towards thicker section is known as 'padding'. This will require extra material. p g p g If padding is not provided, centre line shrinkage or porosity will result in the thinner section.
Contd
IES2001
The main purpose of chaplets is (a) To ensure directional solidification (b) To provide efficient venting (c) For aligning the mold boxes (d) To support the cores Ans. (d)
IES1996
Which of the following methods are used for obtaining directional solidification for riser design 1. 2. 3. Suitable placement of chills Suitable placement of chaplets Employing padding
Select the correct answer. (a) 1 and 2 (b) 1 and 3 Ans. (b)
(c) 2 and 3
(d) 1, 2 and 3
IES2007
Which one of the following is the correct statement? Gate is provided in moulds to (a) Feed the casting at a constant rate (b) Give passage to gases (c) Compensate for shrinkage (d) Avoid cavities Ans. (a)
GATE2009
MatchtheitemsinColumnIandColumnII. ColumnIColumnII P.MetallicChills1.Supportforthecore Q.MetallicChaplets2.Reservoirofthemoltenmetal R.Riser3.Controlcoolingofcritical sections S.ExothermicPadding4.Progressivesolidification (a) P1,Q3,R2,S4 (b) P1,Q4,R2,S3 (c) P3,Q4,R2,S1 (d) P4,Q1,R2,S3 Ans.(d)
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GATE1992
Inagreensandmouldingprocess,uniform rammingleadsto (a) Lesschanceofgasporosity (b) Uniformflowofmoltenmetalintothemould cavity (c) Greaterdimensionalstabilityofthecasting (d) Lesssandexpansiontypeofcastingdefect Ans.(c)
GATE2011
Green sand mould indicates that (a) polymeric mould has been cured (b) mould has been totally dried ( ) g (c) mould is green in colour (d) mould contains moisture Ans. (d)
Pattern
A pattern is a replica of the object to be made by the casting process, with some modifications. The main modifications are The addition of pattern allowances, allowances The provision of core prints, and Elimination of fine details, which cannot be obtained by casting and hence are to be obtained by further processing
PatternAllowances
1. Shrinkageorcontractionallowance 2. Draftortaperallowance 3. M hi i fi i h ll Machiningorfinishallowance 4. Distortionorcamberallowance 5. Rappingallowance
Shrinkageallowance
All metals shrink when cooling except perhaps bismuth. This is because of the interatomic vibrations which are amplified by an increase in temperature. The shrinkage allowance is always to be added to the linear dimensions. Even in case of internal dimensions.
Liquidshrinkageandsolidshrinkage
Liquid shrinkage refers to the reduction in volume when the metal changes from liquid to solid state at the solidus temperature. To account for this, risers are provided in the moulds. Solid shrinkage is the reduction in volume caused, when a metal loses temperature in the solid state. The shrinkage allowance is provided to take care of this reduction.
Contd
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Pattern Allowances Cast Iron Brass, Copper, Aluminium Steel Zinc, Lead
IES1995
10 mm/m 15 mm/m 20 mm/m 25 mm/m Which one of the following materials will require the largest size of riser for the same size of casting? ( ) (a) Aluminium (b) Cast iron (c) Steel (d) Copper Ans. (c)
In grey cast iron and spheroidal graphite iron, the amount of graphitization controls the actual shrinkage. When graphitization is more, the shrinkage would be less and vice versa.
GATE1999
Which of the following materials requires the largest shrinkage allowance, while making a pattern for casting? (a) Aluminium ( ) l (b) Brass (c) Cast Iron (d) Plain Carbon Steel Ans. (d)
IES1999
In solidification of metal during casting, compensation for solid contraction is (a) Provided by the oversize pattern (b) Achieved by properly placed risers (c) Obtained solidification (d) Made by providing chills Ans. (a)
by
promoting
directional
GATE2001
Shrinkage allowance on pattern is provided to compensate for shrinkage when (a) The temperature of liquid metal drops from pouring to freezing temperature (b) The metal changes from liquid to solid state at freezing temperature (c) The temperature of solid phase drops from freezing to room temperature (d) The temperature of metal drops from pouring to room temperature Compiledby:SKMondalMadeEasy Ans. (c)
GATE2004
Gray cast iron blocks 200 x 100 x 10 mm are to be cast in sand moulds. Shrinkage allowance for pattern making is 1%. The ratio of the volume of pattern t th t of th casting will b tt to that f the ti ill be (a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03 Ans. (d)
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GATE2008
While cooling, a cubical casting of side 40 mm undergoes 3%, 4% and 5% volume shrinkage during the liquid state, phase transition and solid state, respectively. The volume of metal t t ti l Th l f t l compensated from the riser is (a) 2% (b) 7% (c) 8% (d) 9% Ans. (b)
GATE2011
A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and volumetric solid contraction of 4% and 6% respectively. No riser is used. Assume uniform cooling in all directions. The side of the cube after solidification and contraction is (a) 48.32 mm (b) 49.90 mm (c) 49.94 mm (d) 49.96 mm Ans. (a)
IAS1995
Assertion (A): A pattern is made exactly similar to the part to be cast. Reason (R): Pattern is used to make the mould cavity for pouring in molten for casting. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)
IAS2003
Match List I (Material to be cast) with List II (Shrinkage Allowance in mm/m) and select the correct answer using the codes given below the lists: ListI ListII (MaterialtoCast)(ShrinkageAllowanceinmm/m) (A) Greycastiron 1. 7 10 (B) Brass 2. 15 (C) Steel 3. 20 (D) Zinc 4. 24[Ans.(c)] Codes:A B C D A B C D (a) 1 2 3 4 (b) 3 4 1 2 (c) 1 4 Compiledby:SKMondalMadeEasy3 3 2 (d) 2 1 4
Draft
To reduce the chances of the damage of the mould cavity at the time of pattern removal, the vertical faces of the pattern are always tapered from the parting line. This provision is called draft allowance. Inner surfaces of the pattern require higher draft than outer surfaces. Draft is always provided as an extra metal.
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DRAFTALLOWANCE
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ShakeAllowance
At the time of pattern removal, the pattern is rapped all around the vertical faces to enlarge the mould cavity slightly to facilitates its removal. removal It is a negative allowance and is to be applied only to those dimensions, which are parallel to the parting plane.
DistortionAllowance
A metal when it has just solidified is very weak and therefore is likely to be distortion prone. This is particularly so for weaker sections such as long flat portions, V, U sections or in a complicated casting which may have thin and long sections which are connected to thick sections. The foundry practice should be to make extra material provision for reducing the distortion.
PatternMaterials
Wood patterns are relatively easy to make. Wood is not very dimensionally stable. Commonly used teak, white pine and mahogany wood. Metal patterns are more expensive but are more dimensionally stable and more durable. Commonly used durable CI, Brass, aluminium and white metal. Hard plastics, such as urethanes, and are often preferred with processes that use strong, organically bonded sands that tend to stick to other pattern materials. In the fullmold process, expanded polystyrene (EPS) is used. Investment casting uses wax patterns. Compiledby:SKMondalMadeEasy
Thepatternmaterialshouldbe
Easilyworked,shapedandjoined Lightinweight Strong,hardanddurable Resistanttowearandabrasion Resistanttocorrosion,andtochemicalreactions Dimensionallystableandunaffectedbyvariationsin temperatureandhumidity. Availableatlowcost.
IES1994
Which of the following materials can be used for making patterns? 1. Aluminium 2. Wax 3 Mercury 4 Lead 3. y 4.
GATE2000
Disposablepatternsaremadeof (a) (b) (c) (d) Wood Rubber Metal Polystyrene
Select the correct answer using the codes given below: Codes: (a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3 Ans. (d)
Ans.(d)
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TypesofPattern
Single Piece Pattern These are inexpensive and the simplest type of patterns. As the name indicates, they are made of a single piece. Gated Pattern
TypesofPattern
Split Pattern or Two Piece Pattern This is the most widely used type of pattern for intricate castings. When the contour of the casting makes its withdrawal from the mould difficult, or when the depth high, of the casting is too high then the pattern is split into two parts so that one part is in the drag and the other in the cope.
Gating and runner system are integral with the pattern. This would eliminate the hand cutting of the runners and gates and help in improving the productivity of a moulding.
TypesofPattern
Cope and Drag Pattern These are similar to split patterns. In addition to splitting the pattern, the cope and drag halves of the p pattern along with the g g gating and riser systems g y are attached separately to the metal or wooden plates along with the alignment pins. They are called the cope and drag patterns.
TypesofPattern
Match Plate Pattern The cope and drag patterns along with the gating and the risering are mounted on a single matching metal or wooden plate on either side.
TypesofPattern
Loose Piece Pattern This type of pattern is also used when the contour of the part is such that withdrawing the pattern from the mould is not possible. possible
TypesofPattern
Follow Board Pattern This type of pattern is adopted for those castings where there are some portions, which are structurally weak and if not supported properly are likely to break under the force of ramming.
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IES2008
The pattern adopted for those castings where there are some portions which are structurally weak and are likely to break by the force of ramming are called: ll d (a) Loose piece pattern (b) Follow board pattern (c) Skelton pattern (d) Single piece pattern Ans. (b)
TypesofPattern
Sweep Pattern
It is used to sweep the complete casting by means of a plane sweep. These are used for generating large shapes, which are axisymmetrical or prismatic i nature such as b ll h bellshaped or i ti in t h d cylindrical.
TypesofPattern
Skeleton Pattern A skeleton of the pattern made of strips of wood is used for building the final pattern by packing sand around the skeleton. After packing the sand, the desired form is obtained with the help sand of a strickle. This type of pattern is useful generally for very large castings, required in small quantities where large expense on complete wooden pattern is not justified.
CoolingCurve
Fluidity The ability of a metal to flow and fill a mold is known as fluidity.
Pouring Temperature The most important controlling factor of fluidity is the p pouring temperature or the amount of superheat. g p p Higher the pouring temperature, the higher the fluidity. Excessive temperatures should be avoided, however. At high pouring temperatures, metalmold reactions are accelerated and the fluidity may be so great as to permit penetration. Penetration is a defect where the metal not only fills the mold cavity but also fills the small voids between the sand particles in a sand mold.
Core
Used for making cavities and hollow projections. All sides of core are surrounded by the molten metal and are therefore subjected to much more severe thermal and mechanical conditions and as a result the core sand should be of higher strength than the moulding sand.
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Desiredcharacteristicsofacore
Green Strength: A core made of green sand should be strong enough to retain the shape till it goes for baking. Dry Strength: It should have adequate dry strength h h ld h d d h so that when the core is placed in the mould, it should be able to resist the metal pressure acting on it. Refractoriness: Since in most cases, the core is surrounded all around it is desirable that the core material should have higher refractoriness.
Permeability: Gases evolving from the molten metal and generated from the mould may have to go through the core to escape out of the mould. Hence cores are required to have higher permeability.
Permeability Number: The rate of flow of air passing through a standard specimen under a standard pressure i is th h t d d i d t d d termed as permeability number.
Contd
The standard permeability test is to measure time taken by a 2000 cu cm of air at a pressure typically of 980 Pa (10 g/cm2), to pass through a standard sand specimen confined in a specimen tube. The standard specimen size is 50.8 mm in diameter and a length of 50.8 mm. Compiledby:SKMondalMadeEasy
Then, the permeability number, R is obtained by VH R= pAT WhereV=volumeofair=2000cm3 H=heightofthesandspecimen=5.08cm p p=airpressure,g/cm2 p , g/ A=crosssectionalareaofsandspecimen=20.268cm2 T=timeinminutesforthecompleteairtopassthrough Insertingtheabovestandardvaluesintothe expression,weget 501.28 R= p.T
Calculatethepermeabilitynumberofsandifittakes1min 25stopass2000cm3 ofairatapressureof5g/cm2 through thestandardsample.
p = 5.0 g / cm 2 T = 1 min 25 s = 1 417 min 1.417 501.28 R= = 70.75 5 1.417
Collapsibility: At the time of cooling, casting shrinks, and unless the core has good collapsibility (ability to decrease in size) it is likely to provide resistance against shrinkage and thus can cause hot tears. Friability: The ability to crumble should be a very important consideration at the time of removal. Smoothness: Surface of the core should be smooth for good finish to the casting. Low Gas Emission
CoreSands
Used clay free silica sand. Binders used are linseed oil, core oil, resins, dextrin, molasses, etc. Core oils are mixtures of linseed, soy, fish and petroleum oils and coal tar. The general composition of a core sand mixture could be core oil (1%) and water (2.5 to 6%).
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CarbonDioxideMoulding
Sodium silicate (water glass, SiO2:Na2O) is used as a binder. This is essentially a quick process of core or mould preparation. The mould is prepared with a mixture of sodium silicate and sand and then treated with carbon dioxide for two to three minutes such that a dry compressive strength of over 1.4 MPa is arrived. The carbon dioxide is expected to form a weak acid, which hydrolyses the sodium silicate resulting in amorphous silica, which forms the bond. The introduction of CO2 gas starts the reaction by forming hydrated sodium carbonate (Na2CO3 + H2O).
The compressive strength of the bond increases with standing time due to dehydration. Because of the high strength of the bond, the core need not p y be provided with any other reinforcements. It does not involve any distortions due to baking and also better dimensional accuracies are achieved. The sand mixture does not have good shelf life and therefore should be used immediately after preparation.
Contd
IES2002
Assertion (A): In CO2 casting process, the mould or core attains maximum strength. Reason (R): The optimum gassing time of CO2 through the mould or core forms Silica Gel which imparts sufficient strength to the mould or core. core (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
MouldingSandComposition
Sand: Ordinary silica Sand (SiO2), zircon, or olivine sands. Clay: Acts ss binding agents mixed to the moulding sands Kaolinite or fire clay (Al2O3 2SiO2 2H2O), and Bentonite (Al2O3 4SiO2 H2O nH2O). Water: Clay is activated by water.
Ans. (a)
OtherAdditives
Cereal binder up to 2% increases the strength. Pitch if used up to 3% would improve the hot strength. g Saw dust up to 2% may improve the collapsibility by slowly burning, and increase the permeability. Other materials: sea coal, asphalt, fuel oil, graphite, molasses, iron oxide, etc.
MouldingSandProperties
Porosity or Permeability: Permeability or porosity of the moulding sand is the measure of its ability to permit air to flow through it. Strength: It is defined as the property of holding together f t th of sand grains. A moulding sand should h d i ldi d h ld have ample strength so that the mould does not collapse or get partially destroyed during conveying, turning over or closing. Refractoriness: It is the ability of the moulding sand mixture to withstand the heat of melt without showing any signs of softening or fusion.
Contd
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Plasticity: Itisthemeasureofthemouldingsandtoflow aroundandoverapatternduringrammingandtouniformly filltheflask. Collapsibility:Thisistheabilityofthemouldingsandto decreaseinvolumetosomeextentunderthecompressive p y g g g forcesdevelopedbytheshrinkageofmetalduringfreezing andsubsequentcooling. Adhesiveness:Thisisthepropertyofsandmixtureto adheretoanotherbody(here,themouldingflasks).The mouldingsandshouldclingtothesidesofthemoulding boxessothatitdoesnotfalloutwhentheflasksarelifted andturnedover.Thispropertydependsonthetypeand amountofbinderusedinthesandmix.
OtherSands
Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a better surface finish to the castings. Backing sand: It is what constitutes most of the mould. refractory material found in the mould This is made up of used and burnt sand. Green Sand: The molding sand that contains moisture is termed as green sand. The green sand should have enough strength so that the constructed mould retains its shape. Dry sand: When the moisture in the moulding sand is completely expelled, it is called dry sand. Compiledby:SKMondalMadeEasy
IES2008
Small amount of carbonaceous material sprinkled on the inner surface of mould cavity is called (a) Backing sand (b) Facing sand (c) Green sand (d) Dry sand Ans. (b)
Grainsizenumber
ASTM (American Society for Testing and Materials) grain size number, defined as n-1 N 2 Where N is the number of grains per square inch visible in a prepared specimen at 100X and n is the ASTM grainsize number. Low ASTM numbers mean a few massive grains; high numbers refer to many small grains.
IES2002
Inthegrainsizedeterminationusingstandard charts,therelationbetweenthegivensize numbernandtheaveragenumberofgrains'N' persquareinchatamagnificationof100Xis (a) N=2n (b) N=2nl (c) N=2n+1 (d) N=2n+1
CastingYield
The casting yield is the proportion of the actual casting mass, w, to the mass of metal poured into the mould, W, expressed as a percentage.
Casting yield =
w 100 W
Ans.(b)
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GatingSystem
GatingSystem
Pouring basin: A small funnel shaped cavity at the top of the mould into which the molten metal is poured. Sprue: Th passage th The through which th molten metal, S h hi h the lt t l from the pouring basin, reaches the mould cavity. In many cases it controls the flow of metal into the mould. Runner: The channel through which the molten metal is carried from the sprue to the gate.
Contd
Contd
Ingate: Achannelthroughwhichthemoltenmetal entersthemouldcavity. Vent: Smallopeninginthemouldtofacilitateescape ofairandgases.
TypesofGateorIngate
Top gate: Causes turbulence in the mould cavity, it is prone to form dross, favourable temperature gradient towards the gate, only for ferrous alloys. Bottom gate: No mould erosion, used for very deep moulds, higher pouring time, Causes unfavourable temperature gradients. Parting Gate: most widely used gate, easiest and most economical in preparation. Step Gate: Used for heavy and large castings, size of ingates Compiledby:SKMondalMadeEasy are normally increased from top to bottom.
In light metal casting, runner should be so designed that: 1. It avoids aspiration 2. It avoids turbulence 3. The path of runner is reduced in area so that unequal volume of flow through each gate takes place (a) 1 and 2 only (b) 1 and 3 only (c) 2 and 3 only (d) 1, 2 and 3 Ans. (a)
IES2011
IES2011
Match List I with List II and select the correct answer using the code given below the lists : ListI A.Topgate B.Bottomgate g C.Partinggate D.Stepgate Codes A (a) 3 (c) 3 B 4 2 ListII 1.Heavyandlargecastings 2.Mostwidelyusedandeconomical y 3.Turbulence 4.Unfavourable temperaturegradient C D A 2 1 (b) 1 4 1 (d) 1 Compiledby:SKMondalMadeEasy B 4 2 [Ans. (a)] C D 2 3 4 3
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IES1998
A sand casting mould assembly is shown in the above figure. The elements marked A and B are respectively (a) Sprue and riser (b) Ingate and riser (c) Drag and runner (d) Riser and runner Ans. (a)
GATE2002
The primary purpose of a sprue in a casting mould is to (a)Feed the casting at a rate consistent with the rate of solidification (b)Act as a reservoir for molten metal (c)Feed molten metal from the pouring basin to the gate (d)Help feed the casting until all solidification takes place Ans. (c)
Thegoalsforthegatingsystem
To minimize turbulence to avoid trapping gasses into the mold To get enough metal into the mold cavity before the metal starts to solidify To avoid shrinkage Establish the best possible temperature gradient in the solidifying casting so that the shrinkage if occurs must be in the gating system not in the required cast part. Incorporates a system for trapping the nonmetallic inclusions.
IES1998
Whichofthefollowingaretherequirementsofanideal gatingsystem? 1. Themoltenmetalshouldenterthemouldcavitywithas highavelocityaspossible. 2. Itshouldfacilitatecompletefillingofthemouldcavity. 2 Itshouldfacilitatecompletefillingofthemouldcavity 3. Itshouldbeabletopreventtheabsorptionofairorgases fromthesurroundingsonthemoltenmetalwhile flowingthroughit. Selectthecorrectanswerusingthecodesgivenbelow: (a)1,2and3 (b)1and2 (c)2and3 (d)1and3
Ans.(c)
IES2009
Considerthefollowingstatements: 1.Theactualentrypointthroughwhichthemolten metalentersthemouldcavityiscalledingate. g 2.Bottomgateincaseofamouldcreatesunfavourable temperaturegradient. 3.Sprueincaseofamouldismadetaperedtoavoidair inclusion. Whichoftheabovestatementsis/arecorrect? (a)1only (b)1and2 (c)2and3 (d)1and3 Ans.(d)
TypesofGatingSystems
Thegatingsystemsareoftwotypes: Pressurizedgatingsystem Unpressurizedgatingsystem
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PressurizedGatingSystem
The total cross sectional area decreases towards the mold cavity Back pressure is maintained by the restrictions in the metal flow Flow of liquid (volume) is almost equal from all gates Back pressure helps in reducing the aspiration as the sprue always runs full Because of the restrictions the metal flows at high velocity leading to more turbulence and chances of mold erosion.
UnPressurizedGatingSystem
The total cross sectional area increases towards the mold cavity y p Restriction only at the bottom of sprue Flow of liquid (volume) is different from all gates Aspiration in the gating system as the system never runs full Less turbulence.
Sprue Design
Sprue: Sprue is the channel through which the molten metal is brought into the parting plane where it enters the runners and gates to ultimately reach the mould cavity. The molten metal when moving from the top of the cope to the p parting p g plane g gains in velocity and some lowpressure y p area would be created around the metal in the sprue. Since the sand mould is permeable, atmospheric air would be breathed into this lowpressure area which would then be carried to the mould cavity. To eliminate this problem of air aspiration, the sprue is tapered to gradually reduce the cross section as it moves away from the top of the cope as shown in Figure below (b).
Theexacttaperingcanbeobtainedbytheequationof continuity.DenotingthetopandchokesectionsofThesprue by thesubscriptstand'c'respectively,weget
A t Vt = A c Vc
At = Ac
Vc Vt
Contd
Contd
Sincethevelocitiesareproportionaltothesquareof thepotentialheads,ascanbederivedfrom Bernoulli'sequation,

At = Ac hc ht
GATE2001
The height of the downsprue is 175 mm and its crosssectional area at the base is 200 mm2. The crosssectional area of the horizontal runner is also 200 mm2. A l Assuming no l i losses, i di t th indicate the correct choice for the time (in seconds) required to fill a mould cavity of volume 106 mm3. (Use g = 10 m/s2). (a)2.67 Ans. (a) (b)8.45 (c)26.72 (d)84.50
WhereH=actual sprue height andht=h+H

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GATE2007
A 200 mm long down sprue has an area of cross section of 650 mm2 where the pouring basin meets the down sprue (i.e. at the beginning of the down sprue). A constant head of molten metal is maintained by the p g 5 pouring basin. The Molten metal flow rate is 6.5 105 mm3/s. Considering the end of down sprue to be open to atmosphere and an acceleration due to gravity of 104mm/s2, the area of the down sprue in mm2 at its end (avoiding aspiration effect) should be (a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
Ans.(c)
Gatingratio
Gatingratioisdefinedas:Sprue area:Runnerarea: Ingate area. Forhighqualitysteelcastings,agatingratioof1:2:2or 1:2:1.5willproducecastingsnearlyfreefromerosion, willminimizeoxidation,andwillproduceuniform flow. Agatingratioof1:4:4mightfavour theformationof oxidationdefects.
IES2003
A gating ratio of 1: 2: 4 is used to design the gating system for magnesium alloy casting. This gating ratio refers to the cross section areas of the various gating elements as given below: 1. Down sprue 2. Runner bar 3. Ingates The correct sequence of the above elements in the ratio 1: 2: 4 is (a) 1, 2 and 3 (b) 1,3 and 2 (c) 2, 3 and 1 (d) 3, 1 an 2
Ans. (a)
IES2005
The gating ratio 2: 8: 1 for copper in gating system design refers to the ratio of areas of: (a) Sprue: Runner: Ingate (b) Runner: Ingate: Sprue (c) Runner: Sprue: Ingate (d) Ingate: Runner: Sprue Ans. (a)
GATE2010
Inagatingsystem,theratio1:2:4represents (a) Sprue basearea:runnerarea:ingate area (b) Pouringbasinarea:ingate area:runnerarea (c) Sprue basearea:ingate area:castingarea (d) Runnerarea:ingate area:castingarea Ans.(a)
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IAS1999
Assertion (A): The rate of flow of metal through sprue is NOT a function of the crosssectional areas of sprue, runner and gate. Reason (R): If respective crosssectional areas of sprue, runner and gate are in the ratio of 1: 2: 2, the system is known as unpressurised gating system. system (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)
RisersandRiserDesign
Risers are added reservoirs designed to feed liquid metal to the solidifying casting as a means of compensating for solidification shrinkage. To perform this function, the risers must solidify after casting. the casting According to Chvorinov's rule, a good shape for a riser would be one that has a long freezing time (i.e., a small surface area per unit volume). Live risers (also known as hot risers) receive the last hot metal that enters the mold and generally do so at a time when the metal in the mold cavity has already Compiledby:SKMondalMadeEasy begun to cool and solidify.
IES1994
Assertion (A): In a mould, a riser is designed and placed so that the riser will solidify after the casting has solidified. Reason (R): A riser is a reservoir of molten metal which will supply molten metal where a shrinkage cavity would have occurred. (a) Both A and R are individually true and R is the correct ( ) B h d i di id ll d i h explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
Chvorinovs rule
Totalsolidificationtime(ts)=B(V/A) n wheren=1.5to2.0 [Where,B=mouldconstantandisafunctionof(mould material,castingmaterial,andconditionofcasting] n=2 andtriser =1.25tcasting
or
Forcylinder ofdiameterD andheightH
V V = 1.25 A riser A casting
Ans. (a)
V = D2H / 4
2 A = DH + 2 D
The relationship between total freezing time t, volume of the casting V and its surface area A, according to Chvorinovs rule is :
V (a ) t = k A A (b ) t = k V A (c ) t = k V
2
IES2011
IES1998
A spherical drop of molten metal of radius 2 mm was found to solidify in 10 seconds. A similar drop of radius 4 mm would solidify in (a) 14.14 seconds (b) 20 seconds (c) 28.30 seconds
Where K is a constant
V (d ) t = k A
[Ans. (d)]
(d) 40 seconds
[Ans. (d)]
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GATE2003
With a solidification factor of 0.97 x 106 s/m2, the solidification time (in seconds) for a spherical casting of 200 mm diameter is (a) 539 (b) 1078 (c) 4311 (d) 3233 [Ans. (b)] According to
IES2006
Chvorinov's equation, the solidification time of a casting is proportional to: (a) v2 (b) v (c) 1/v (d) 1/v2 Where, v = volume of casting [Ans. (a)]
GATE2007
Volume of a cube of side 'l' and volume of a sphere of radius r are equal. Both the cube and the sphere are solid and of same material. They are being cast. The ratio of the solidification time of the cube to the same ti f th lidifi ti ti f th b t th of the sphere is:
(a )
4 r 6 l
3 6
( b)
4 r 6 l
(c)
4 r 6 l
(d )
4 r 6 l
Ans.(d)
ConventionalQuestionESE2003:
Comparethesolidificationtimeoftwo optimumside risersofthesamevolume withonehascylindricalshapeandotheris i h h li d i l h d h i parallopiped. [30Marks]
ModulusMethod
It has been empirically established that if the modulus of the riser exceeds the modulus of the casting by a factor of 1.2, the feeding during solidification would be satisfactory. MR = 1.2 Mc Modulus = volume/Surface area In steel castings, it is generally preferable to choose a riser with a heighttodiameter ratio of 1.
Contd
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ConventionalQuestionIES2008
Calculate the size of a cylindrical riser (height and diameter
D
4
+ D2
equal) necessary to feed a steel slab casting of dimensions riser, 30 x 30 x 6 cm with a side riser casting poured horizontally into the mould. [Use Modulus Method] [10 Marks]
Caines Method
Freezingratio=ratio ofcoolingcharacteristicsofcastingto theriser. (A )
x=
Table:ConstantsinCaines Method
(A V)
a
casting
riser
Therisershouldsolidifylastsox>1 Th i h ld lidif l AccordingtoCaine

V Vcasting
X= Y b + c
riser Y=anda,b,careconstant.
Conventional QuestionIES2007
Calculate the size of a cylindrical riser (height and diameter equal) necessary to feed a steel slab casting of dimensions 25 x 25 x 5 cm with a side riser, casting poured horizontally into the mould. [Use Caines Method]
Chills
External chills are masses of highheatcapacity, highthermal conductivity material that are placed in the mould (adjacent to the casting) to accelerate the cooling of various regions. Chills can effectively promote directional solidification or increase the effective feeding distance of a riser. They can often be b used to reduce the number of risers required f a casting. d d h b f i i d for i Internal chills are pieces of metal that are placed within the mould cavity to absorb heat and promote more rapid solidification. Since some of this metal will melt during the operation, it will absorb not only the heatcapacity energy, but also some heat of fusion. Since they ultimately become part of the final casting, internal chills must be made from the same alloy as that being cast.
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IES1995
Directional solidification in castings can be improved by using (a) Chills and chaplets ( ) Chill d h l t (b) Chills and padding (c) Chaplets and padding (d) Chills, chaplets and padding [Ans. (b)]
GATE1998,2007
Chills are used in moulds to (a) Achieve directional solidification (b) Reduce the possibility of blowholes (c) Reduce freezing time (d) Smoothen metal flow for reducing splatter [Ans. (a)]
IAS1994
Chillsareusedincastingmouldsto (a) Achievedirectionalsolidification (b) Reducepossibilityofblowholes (c) Reducethefreezingtime (d) Increasethesmoothnessofcastsurface Ans.(a)
Cupola
Steelcanbemeltedinhotblastcupola. Inhotblastcupola,thefluegasesareusedtopreheat theairblasttothecupolasothatthetemperaturein p p thefurnaceisconsiderablyhigherthanthatina conventionalcupola. Cupolahasbeenthemostwidelyusedfurnacefor meltingcastiron.
IES1997
Assertion (A): Steel can be melted in hot blast cupola. Reason (R): In hot blast cupola, the flue gases are used to preheat the air blast to the cupola so that the temperature in the furnace is considerably higher than that in a conventional cupola. i l l (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
ElectricArcFurnace
For heavy steel castings, the openhearth type of furnaces with electric arc or oil fired would be generally suitable in view of the large heat required for melting. Electric arc furnaces are more suitable for ferrous materials and are larger in capacity.
[Ans. (a)]
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Crucible Furnace Smaller foundries generally prefer the crucible furnace. The crucible is generally heated by electric resistance or gas flame. Induction Furnace The induction furnaces are used for all types of materials, the chief advantage being that the heat source is isolated from the charge and the slag and flux get the necessary heat directly from the charge instead of the heat source.
Ladles
Twotypesofladlesusedinthepouringofcastings.
CastingCleaning(fettling)
Impuritiesinthemoltenmetalarepreventedfrom reachingthemouldcavitybyprovidinga (i) Strainer (ii) Buttonwell (iii) Skimbob
GATE1996
Light impurities in the molten metal are prevented from reaching the mould cavity by providing a (a) Strainer (b) Button well (c) Skim bob (d) All of the above Ans. (c)
Pouringtime
Timetakentofillthemouldwithtopgate Where A=Areaofmould A.H tA = H=Heightofmould A g 2gh m Ag =AreaofGate Hm =Gateheight Timetakentofillthemouldwithbottomgate
GATE2005
A mould has a downsprue whose length is 20 cm and the cross sectional area at the base of the downsprue is 1cm2. The downsprue feeds a horizontal runner l di i t th mould cavity of h i t l leading into the ld it f volume 1000 cm3. The time required to fill the mould cavity will be (a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s Ans. (b)
tB =
2A A g 2g
hm hm H
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In a sand casting operation, the total liquid head is maintained constant such that it is equal to the mould height. The time taken to fill the mould with a top gate is tA. If the same mould is filled with a bottom gate, then the time taken is tB. Ignore the time required to fill the runner and frictional effects. Assume h d fi i l ff A atmospheric pressure at the top molten metal surfaces. The relation between tA and tB is
(A) tB = 2 t A tB = 2 t A tB = tA 2
GATE2006
Expressionforchokearea
CA = m mm2 ct 2gH
(B) (C) (D)
Ans.(b)
Wherem=massofthecasting,kg =Densityofmetal,kg/m3 t=pouringtime c=Efficiencyfactorandisthefunctionofgate systemused H=Effectiveheadofliquidmetal =hfortopgate

tB = 2 2 t A
Contd
CastingDefects
h H=h m 2
forbottomgate forpartinglinegate
Thefollowingarethemajordefects,whicharelikelyto occurinsandcastings: Gasdefects Shrinkagecavities Moldingmaterialdefects

hC
=h
hc2 2h m
hm
hm
hm
Pouringmetaldefects Moldshift.
li
topgatepartinglinegatebottomgate
GasDefects
A condition existing in a casting caused by the trapping of gas in the molten metal or by mold gases evolved during the pouring of the casting. The defects in this category can be classified into g y blowholes and pinhole porosity. Blowholes are spherical or elongated cavities present in the casting on the surface or inside the casting. Pinhole porosity occurs due to the dissolution of hydrogen gas, which gets entrapped during heating of molten metal.
ShrinkageCavities
These are caused by liquid shrinkage occurring during the solidification of the casting. To compensate for this, proper feeding of liquid metal is required. For this reason risers are placed at the appropriate places in the mold. Sprues may be too thin, too long or not attached in the proper location, causing shrinkage cavities. It is recommended to use thick sprues to avoid shrinkage cavities.
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MoldingMaterialDefects
Cutsandwashes, Scab Metalpenetration, Fusion,and Swell
Cutandwashes
These appear as rough spots and areas of excess metal, and are caused by erosion of molding sand by the flowing metal. This is caused by the molding sand not having enough velocity. strength and the molten metal flowing at high velocity The former can be taken care of by the proper choice of molding sand and the latter can be overcome by the proper design of the gating system.
Scab
This defect occurs when a portion of the face of a mould lifts or breaks down and the recess thus made is filled by metal. When the metal is poured into the cavity, gas may be disengaged with such violence as to break up the sand, which is then washed away and the resulting cavity filled hi h i h h d d h li i fill d with metal. The reasons can be: too fine sand, low permeability of sand, high moisture content of sand and uneven mould ramming.
Metalpenetration
When molten metal enters into the gaps between sand grains, the result is a rough casting surface. This occurs because the sand is coarse or no mold wash was applied on the surface of the mold. The coarser the sand g grains more the metal penetration. p
Fusion
This is caused by the fusion of the sand grains with the molten metal, giving a brittle, glassy appearance on the casting surface. g The main reason for this is that the clay or the sand particles are of lower refractoriness or that the pouring temperature is too high.
Swell
Under the influence of metallostatic forces, the mold wall may move back causing a swell in the dimension of the casting. A proper ramming of the mold will correct this defect.
Inclusions
Particles of slag, refractory materials sand or deoxidation products are trapped in the casting during pouring solidification. The provision of choke in the gating system and the pouring basin at the top of the mold can prevent this defect
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PouringMetalDefects
The likely defects in this category are Misruns and Cold shuts A misrun is caused when the metal is unable to fill the mold cavity completely and thus leaves unfilled cavities. A cold shut is caused when two streams while meeting in the mold cavity, do not fuse together properly thus forming a discontinuity in the casting.
The misrun and cold shut defects are caused either by a lower fluidity of the mold or when the section thickness of the casting is very small. Fluidity can be improved by changing the composition of the metal and by increasing the pouring temperature of the metal. metal
Contd
GATE2004
Misrun is a casting defect which occurs due to (a) Very high pouring temperature of the metal (b) Insufficient fluidity of the molten metal (c) Absorption of gases by the liquid metal (d) Improper alignment of the mould flasks Ans. (b)
GATE2009
Two streams of liquid metal which are not hot enough to fuse properly result into a casting defect known as (a) Cold shut (b) Swell (c) Sand wash (d) Scab
[Ans. (a)]
MoldShift
The mold shift defect occurs when cope and drag or molding boxes have not been properly aligned. Scabisa
IES2001
(a) Sandcastingdefect (b) Machiningdefect (c) Weldingdefect (d) Forgingdefect Ans.(a)

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IAS2004
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect answerusingthecodesgivenbelowthelists: ListI ListII (CastingDefects) (Explanation) A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities includingblowholesandpinholes B.Cavities 2.Formedduringmelting,solidificationandmoulding. C.Inclusions 3.Includessinglefolds,laps,scarsadheringsandlayersand oxidescale D.Discontinuities 4.Includecracks,coldorhottearingandcoldshuts 5.Consistoffins,flashormassiveprojectionsandrough surfaces Codes:A B C D A B C D (a) 1 5 3 2 (b) 1 5 2 4 (c) 5 1 2 4 (d) 5 1 3 2 Ans.(d)
GATE2003
Hardnessofgreensandmouldincreaseswith (a) Increaseinmoisturecontentbeyond6percent (b) Increaseinpermeability (c) Decreaseinpermeability (d) Increaseinbothmoisturecontentand permeability Ans.(c)
IES1998
Assertion(A):Stiffeningmembers,suchaswebs andribs,usedonacastingshouldbeliberally provided. Reason(R):Theywillprovideadditionalstrength toacastmember. toacastmember (a) BothAandRareindividuallytrueandRisthe correctexplanationofA (b) BothAandRareindividuallytruebutRisnot the correctexplanationofA (c) AistruebutRisfalse (d) AisfalsebutRistrue [Ans.(a)]
IES2005
In gating system design, which one of the following is the correct sequence in which choke area, pouring time, pouring basin and sprue sizes are calculated? (a) Choke area Pouring time Pouring basin Sprue (b) Pouring basin Sprue Choke area Pouring time (c) Choke area Sprue Pouring basin Pouring time (d) Pouring basin Pouring time Choke area Sprue Ans. (a)
IES1997
Ifthemeltingratioofacupolais10:1,thenthe cokerequirementforonetonmeltwillbe (a) 0.1ton (b) 10tons (c) 1ton (d) 11tons Ans.(a)
IES2009
Inwhichoneofthefollowingfurnacesmostofthe nonferrousalloysaremelted? (a) Reverberatory furnace (b) Inductionfurnace (c) Cruciblefurnace (d) Potfurnace Ans.(d)
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IAS2001
Whichofthefollowingpatternmaterialsareused inPrecisionCasting? 1. PlasterofParis 2. Plastics 3. AnodizedAluminium Alloy 4. FrozenMercury Selectthecorrectanswerusingthecodesgivenbelow: (a)1and2(b) 2and4(c)3and4(d)1and3 Ans.(b)
IAS2004
Which one of the following gating systems is best suited to obtain directional solidification? (a) Top grating (b) Partline grating Part line (c) Bottom grating (d) Stepped grating Ans. (d)
CastAluminiumCode
Fourdigitidentificationsystem Firstdigitindicatesalloygroup 1 Aluminium,99%ormore 2 copper 3 Silicon,withcopperand/ormagnesium 3 Silicon withcopperand/ormagnesium 4 silicon 5 magnesium 6 notused 7 zinc 8 tin 9 otherelements Compiledby:SKMondalMadeEasy
CastAluminiumCodeContd..
Second two digits identify the aluminium alloy or indicate the aluminium purity. The last digit is separating from the other three by a decimal point and indicates the product form; that is, castings or ingots A modification of the original alloy is indicated by a serial letter before the numerical designation. Alloy A514.0 indicates an aluminium alloy casting with magnesium as the principal alloy. One modification to the original alloy has made, as indicated by the letter A.
IES2011
In the designation of Aluminium casting A514.0 indicates : (a) Aluminium purity (b) Aluminium content (c) Percentage of alloy element (d) Magnesium Content Ans. (d)
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ShellMoulding
SpecialCasting
BySKMondal
The sand is mixed with a thermosetting resin is allowed to come in contact with a heated metal pattern (2000C). A skin ( h ll) of about 3.5 mm of sand and plastic ki (shell) f b f d d l i mixture adhere to the pattern. Then the shell is removed from the pattern. The cope and drag shells are kept in a flask with necessary backup material and the molten metal is poured into the mold.
Can produce complex parts. A good surface finish and good size tolerance reduce the need for machining. g Materials can be cast: CI, Al and Cu alloys.
Shellmouldingprocess
MoldingSandinShellMolding
The molding sand is a mixture of fine grained quartz sand and powdered bakelite. Cold coating and Hot coating methods are used for coating the sand grains with bakelite. Cold coating: quartz sand is poured into the mixer and then the solution of powdered bakelite in acetone and ethyl aldehyde are added. (mixture is 92% quartz sand, 5% bakelite, 3% ethylaldehyde )
Contd
Hot coating: the mixture is heated to 150oC 180oC prior to loading the sand. In the course of sand mixing, the soluble phenol formaldehyde resin is added. The mixer is allowed to cool up to 80 90o C. Hot coting gives better properties to the mixtures than cold method.
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Advantages
Dimensional accuracy. Smoother surface finish. (Due to finer size grain used) y Very thin sections can be cast. Very small amount of sand is needed.
Limitations
Expensive pattern Small size casting only. Highly complicated shapes cannot be obtained. More sophisticated equipment is needed for handling the shell moldings.
Applications
Cylinders and cylinder heads for air cooled IC engines Automobile transmission parts. Piston rings
IES2010
Considerthefollowingadvantagesofshell mouldcasting: 1.Closedimensionaltolerance. 2.Goodsurfacefinish. 3.Lowcost. 4.Easier. Whichofthesearecorrect? (a)1,2and3only (b)2,3and4only (c)1,2and4only (d)1,2,3and4
IES1996
Consider the following ingredients used in moulding: 1. Dry silica sand 2.Clay 3.Phenol formaldehyde 4.Sodium silicate Those used for shell mould casting include (a) 1, 2 and 4 (b) 2, 3 and 4 (c) 1and 3 (d) 1, 2, 3 and 4
IES2005
Inshellmoulding,howcantheshellthickness beaccuratelymaintained? (a)Bycontrollingthetimeduringwhichthepattern isincontactwithmould (b)Bycontrollingthetimeduringwhichthepattern isheated (c)Bymaintainingthetemperatureofthepatternin therangeof175oC 380oC (d)Bythetypeofbinderused
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IES2006
Shellmouldingcanbeusedfor: (a) Producingmillingcutters (b) Makinggoldornaments (c) Producingheavyandthickwalledcasting (d) Producingthincasting
IES2007
Which of the following are employed in shell moulding? 1. Resin binder 2. Metal pattern 3. Heating coils Select the correct answer using the code given below: (a) 1 and 2 only (b) 1 and 3 only (c) 2 and 3 only (d) 1, 2 and 3
IAS2007
The mould in shell moulding process is made up of which of the following? (a) Gypsum + setting agents (b) Green sand + clay (c) Sodium silicate + dried sand (d) Dried silica + phenolic resin
IAS1999
Match List I (Moulding Process) with List II (Binding Agent) and select the correct answer using the codes given below the lists: List I List II A. Green sand 1. Silicate B. Core sand 2. Organic C. Shell moulding 3. Clay D. CO2 process 4. Plaster of Paris 5. Plastic Codes:A B C D A B C D (a) 3 2 5 1 (b) 3 2 4 1 (c) 2 3 5 4 (d) 2 3 4 5
InvestmentCasting
Investment casting process or lost wax process Basic steps: 1. Produce expendable wax, plastic, or polystyrene patterns. 2. Assemble these patterns onto a gating system 3. Investing or covering the pattern assembly with refractory 3 slurry 4. Melting the pattern assembly to remove the pattern material 5. Firing the mould to remove the last traces of the pattern material 6. Pouring molten metal 7. Knockout, cutoff and finishing. Fig.Investmentflaskcastingprocedure
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CeramicShellInvestmentCasting
In ceramic shell investment casting a ceramic shell is built around a tree assembly by repeatedly dipping a pattern into a slurry (refractory material such as zircon with binder). After each dipping and stuccoing is completed, the assembly is allowed to thoroughly dry before the next coating is applied.
IES2009
2marks
Advantages
Tight dimensional tolerances Excellent surface finish (1.2 to 3.0 m ) Machining g eliminated High melting point alloy can be cast, almost any metal can be cast Almost unlimited intricacy can be reduced or completely p y
Limitations
Costly patterns and moulds Labour costs can be high Limited size
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Applications
Aerospace and rocket components. Vanes and blades for gas turbines. Surgical instruments
IES2011
The proper sequence of investment casting steps is : (a) Slurry coating pattern melt outShakeout Stucco coating (b) Stucco coating Slurry coating Shakeout Pattern melt out (c) Slurry coating Stucco coating Pattern melt out Shakeout (d) Stucco coating Shakeout Slurry coating Pattern melt out
GATE2006
An expendable pattern is used in (a) Slush casting (b) Squeeze casting (c) Centrifugal casting (d) Investment casting
IES1992
Themostpreferredprocessforcastinggasturbine bladesis: (a) Diemoulding (b) Shellmoulding (c) Investmentmoulding (d) Sandcasting
JWM2010
Considerthefollowingmaterials: 1.Wax 2.Wood 3.Plastic Whichofthesematerialscanbeusedaspatternin investmentcastingprocess? (a)1,2and3 (b)1and2only (c)2and3only (d)1and3only
IES2010
Assertion (A): These investment casting is used for precision parts such as turbine plates, sewing machines etc. Reason (R): The investment castings have a good surface finish and are exact reproductions of the master pattern. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is NOT the correct explanation of A (c) A is true but R is false (d) A is false but R is true
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IES2007
Consider the following statements in respect of investment castings: 1. The pattern or patterns is/are not joined to a stalk or sprue also of wax to form a tree of patterns. 2.The prepared moulds are placed in an oven and heated gently to dry off the invest and melt out the bulk of wax. 3.The moulds are usually poured by placing the moulds in a vacuum chamber. Which of the statements given above are correct? (a) 1 and 2 only (b) 1 and 3 only (c)2 and 3 only (d) 1, 2 and 3
IES2006
Which of the following materials are used for making patterns in investment casting method? 1. Wax 2. Rubber 3. Wood 4. Plastic Select the correct answer using the codes given below: (a) Only 1 and 3 (b) Only 2 and 3 (c) Only 1, 2 and 4 (d) Only 2, 3 and 4
IAS1996
Light and intricate parts with close dimensional tolerances of the order of 0.005 mm are produced by (a) Investment casting g (b) Die casting (c) Centrifugal casting (d) Shell mould casting
PermanentMouldCasting
The process in which we use a die to make the castings is called permanent mold casting or gravity die casting, since the metal enters the mold under gravity. gravity Some time in diecasting we inject the molten metal with a high pressure. When we apply pressure in injecting the metal it is called pressure die casting process. Grey cast iron is used for mould material.
Advantages
Good surface finish and dimensional accuracy Metal mold gives rapid cooling and finegrain structure Multipleuse molds.
Disadvantages
High initial mold cost Shape, size, and complexity are limited Mold life is very limited with highmeltingpoint metals such an steel steel. Low melting point metals can be cast Aluminum Zinc Magnesium alloys Brass Cast iron
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Applications
Pistons/cylinders/rods Gears Kitchenware
DieCasting
Molten metal is injected into closed metal dies under pressures ranging from 100 to 150 MPa. Pressure is maintained during solidification After which the dies separate and the casting is ejected along with its attached sprues and runners. Cores must be simple and retractable and take the form of moving metal segments
Diecastingmachinescanbe
Video
Hotchamber Coldchamber
Hotchambermachinesare
Good for low temperature (approx. 400C) Faster than cold chamber machines Cycle times must be short to minimize metal contamination Metal starts in a heated cylinder A piston forces metal into the die The piston retracts, and draws metal in Metal: Lead, Tin, Zinc
HotChamber
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Coldchambermachines
Castshighmeltingpointmetals(>600C) Highpressuresused Metalisheatedinaseparatecrucible l h d bl Metalisladledintoacoldchamber Themetalisrapidlyforcedintothemoldbeforeit cools Copper,BrassandAluminiumcancast.
Advantages
Extremelysmoothsurfaces(1m) Excellentdimensionalaccuracy Rapidproductionrate Bettermechanicalpropertiescomparedtosand casting Intricatepartspossible Minimumfinishingoperations Thinsectionspossible
Limitations
Highinitialdiecost Limitedtohighfluiditynonferrousmetals Partsizeislimited Porositymaybeaproblem Somescrapinsprues,runners,andflash,butthiscan bedirectlyrecycled
Applications Carburettors Automotive parts Bathroom fixtures Toys Common metals Alloys of aluminum, zinc, magnesium, and lead Also possible with alloys of copper and tin
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Consider the following advantages of die casting over sand casting : 1. Rapidity of the process 2. Smooth surface 3. Strong dense metal structure 3 Which of these advantages are correct ? (a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
IES2011
IES2009
Which of the following are the most suitable materials for die casting? (a) Zinc and its alloys (b) Copper and its alloys (c) Aluminium and its alloys (d) Lead and its alloys
JWM2010
Assertion (A) : In die casting method, small thickness can be filled with liquid metal. Reason (R) : The air in die cavity trapped inside the casting causes problems. (a) BothAandRareindividuallytrueandRisthe correctexplanationofA (b) BothAandRareindividuallytruebutRisnot the correctexplanationofA (c) AistruebutRisfalse (d) AisfalsebutRistrue
IES2005
Which one of the following processes produces a casting when pressure forces the molten metal into the mould cavity? (a) Shell moulding g (b) Investment casting g (c) Die casting (d) Continuous casting
IES2006
In which of the following are metal moulds used? (a) Greensand mould (b) Dry sand mould (c) Die casting process (d) Loam moulding
IES1995
Assertion (A): An aluminium alloy with 11 % silicon is used for making engine pistons by die casting technique. Reason (R): Aluminium has low density and addition of silicon improves its fluidity and therefore its p y castability. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
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IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp ofcodesgivenbelowthelists: ListI ListII (Products) (Processofmanufacture) A. Automobilepistoninaluminium alloy 1.Pressurediecasting B. Enginecrankshaftinspheroidal graphiteiron hi i 2.Gravitydiecasting G i di i C. Carburettor housinginaluminium alloy 3.Sandcasting D. Casttitaniumblades 4.Precisioninvestment casting 5.Shellmoulding Code: A B C D A B C D (a) 2 3 1 5 (b) 3 2 1 5 (c) 2 1 3 4 (d) 4 1 2 3
IAS2007
Considerthefollowingstatements: 1. Zincdiecastingshavelowstrength. 2. Inthediecastingprocess,verythinsectionsor complexshapescanbeobtainedeasily. Whichofthestatementsgivenaboveis/arecorrect? (a) 1only (b) 2only (c) Both1and2 (d) Neither1nor2
IAS1996
Assertion (A): Die casting yields a product of good accuracy and finish. Reason (R): Low melting alloys used in die casting. (a) Both A and R are individually true and R is the ( ) B h d i di id ll d i h correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
IES2011
Consider the following statements : 1. Hot chamber machine is used for casting zinc, tin and other low melting alloys. 2. Cold chamber machine is used for die casting of ferrous alloys 3. Rapid cooling rate in die casting produces high strength and quality in many alloys. Which of these statements are correct? (a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
GATE2007
Which of the following engineering materials is the most suitable candidate for hot chamber die casting? (a) Low carbon steel ( ) b l (b) Titanium (c) Copper (d) Tin
IES1995
Assertion (A): Aluminium alloys are cast in hot chamber die casting machine. Reason (R): Aluminium alloys require high melting when compared to zinc alloys. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
10
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CentrifugalCasting
Process: Molten metal is introduced into a rotating sand, metal, or graphite mould, and held against the mould wall by centrifugal force until it is solidified A mold is set up and rotated along a vertical (rpm is reasonable), or horizontal (2001000 rpm is reasonable) axis. The mold is coated with a refractory coating. During cooling lower density impurities will tend to rise towards the center of rotation.
Fig.Truecentrifugalcasting
Properties
The mechanical properties of centrifugally cast jobs are better compared to other processes, because the inclusions such as slag and oxides get segregated towards the centre and can be easily removed by machining. Also, the p pressure acting on the metal throughout the solidification g g causes the porosity to be eliminated giving rise to dense metal. No cores are required for making concentric holes in the case of true centrifugal casting.
Advantages
Fine grained structure at the outer surface of the casting free of gas and shrinkage cavities and porosity Formation of hollow interiors in cylinders without cores Can produce a wide range of cylindrical parts, including ones of large size. Good dimensional accuracy, soundness, and cleanliness There is no need for gates and runners, which increases the casting yield, reaching almost 100 %.
Limitations
More segregation of alloy component during pouring under the forces of rotation Contamination of internal surface of castings with non metallic i l i lli inclusions Inaccurate internal diameter Shape is limited. Spinning equipment can be expensive Poor machinability
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Commonmetals
Iron steel stainlesssteel alloysofaluminium,copper,andnickel
GATE2002
In centrifugal casting, the impurities are (a) Uniformly distributed (b) Forced towards the outer surface (c) Trapped near the mean radius of the casting (d) Collected at the centre of the casting
GATE1993
Centrifugally cast products have (a) Large grain structure with high porosity (b) Fine grain structure with high density (c) Fine grain structure with low density (d) Segregation of slug towards the outer skin of the casting
IES2008
Which of the following casting processes does not /do not require central core for producing pipe? 1. Sand casting process 2. Die casting process 3. 3 Centrifugal casting process Select the correct answer using the code given below: (a) 1 and 2 (b) 2 only (c) 2 and 3 (d) 3 only
IES2009
Which one of the following casting processes is best suited to make bigger size hollow
IES2007
Which one of the following is the correct statement? In a centrifugal casting method (a) No core is used (b) Core may be made of any metal (c) Core is made of sand (d) Core is made of ferrous metal
symmetrical p p y pipes? (a) Die casting (b) Investment casting (c) Shell moulding (d) Centrifugal casting
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IES1998
Poormachinability ofcentrifugallycastironpipe isdueto (a) Chilling (b) Segregation (c) Densestructure (d) Highmouldrotationspeed
IES2009
Which of the following are the most likely characteristics in centrifugal casting? (a) Fine grain size and high porosity (b) Coarse grain size and high porosity (c) Fine grain size and high density (d) Coarse grain size and high density
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven belowtheLists: ListI ListII (CastingProcess) (Principle) A. Diecasting 1.Themetalsolidifiesinarotatingmould B. Investmentcasting 2.Thepatternclusterisrepeatedlydipped intoaceramicslurryanddustedwith refractory f C. Shellmoulding 3.Moltenmetalisforcedbypressureinto ametallicmould D. Centrifugalcasting 4.Aftercooling,theinvestisremoved fromthe Castingbypressurejettingor vibratorycleaning Code: A B C D A B C D (a) 2 1 3 4 (b) 3 4 2 1 (c) 2 4 3 1 (c) 3 1 2 4
IES2000
MatchListI(Process)withListII(Products/materials) andselectthecorrectanswerusingthecodesgiven belowtheLists: ListI ListII A. Diecasting 1.Phenolformaldehyde B. Shellmolding 2.C.I.pipes C. CO2 molding 3.Nonferrousalloys D. Centrifugalcasting 4.Sodiumsilicate Codes:A B C D A B C D (a) 1 3 4 2 (b) 3 1 4 2 (c) 3 1 2 4 (d) 1 3 2 4
IAS2004
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect answerusingthecodesgivenbelowthelists: ListI ListII (NameoftheProcess) (Advantage) A. SandCasting 1.Largecylindricalpartswithgoodquality B. B Ceramicmoldcasting C i ld i 2.Excellentdimensionalaccuracyandsurface E ll di i l d f finish C. Diecasting 3.Intricateshapesandclosetoleranceparts D. Centrifugalcasting 4.Almostanymetaliscastandthereifnolimitto size,shapeandweight 5.Gooddimensionalaccuracy,finishandlow porosity Codes:A B C D A B C (a) 2 3 5 1 (b) 4 1 2 (c) 2 1 5 3 (d) 4 3 2
SemicentrifugalCasting
Centrifugal force assists the flow of metal from a central reservoir to the extremities of a rotating symmetrical mold, which may be either expendable or y , y p multipleuse Rotational speeds are lower than for true centrifugal
D 3 1
casting Cores can be used to increase the complexity of the product.
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IAS2003
Assertion (A): Semicentrifugal casting process is similar to true centrifugal casting except that the central core is used in it to form inner surface. Reason (R): In semicentrifugal casting process the axis of spin is always vertical p y (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true
Fig. Semicentrifugalcasting
Centrifuging
Uses centrifuging action to force the metal from a central pouring reservoir into separate mold cavities that are offset from the axis of rotation. Low speed May used to assist in the pouring of investment casting trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples) andselectthecorrectanswerusingthecodesgivenbelowthe Lists: ListI ListII A. Diecasting 1.Moltenmetalisforcedintothedie underpressure B. Centrifugalcasting 2.Axisofrotationdoesnotcoincidewith axisofmould C. Centrifuging 3.Metalsolidifieswhenmouldisrotating D. Continuouscasting 4.Continuouslypouringmoltenmetal intomould Codes: A B C D A B C D (a) 1 3 2 4 (b) 4 3 2 1 (c) 1 2 3 4 (d) 4 2 3 1
DrySandMolding
To reduce gas forming materials air dried mould used. Types: 1.Skin 1 Skin drying and 2.Complete mold drying
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SlushCasting
Slush casting is a variation of the permanent mold process in which the metal is permitted to remain in the mold only until a shell of the desired thickness has formed. The mold is then inverted and the remaining liquid is poured out. When the mold halves are separated, the resulting casting is a hollow shape with good surface detail but variable wall thickness. Frequently used to cast lowmeltingtemperature metals into ornamental objects such as candlesticks, lamp bases, and statuary.
IAS2004
Which of the following are produced by slush casting? (a) Hollow castings with thick walls (b) Hollow castings with thin walls (c) Thin castings (d) Thick castings
IES2011
The method of casting for producing ornamental pieces are: (a) Slush and gravity casting (b) Pressed and slush casting (c) Gravity and semi permanent mould casting (d) Semi permanent mould and pressed casting
SqueezeCasting
Process: 1. Molten metal is poured into an open face die. 2. A punch is advanced into the die, and to the metal. 3.Pressure 3 Pressure (less than forging) is applied to the punch and die while the part solidifies. 4.The punch is retracted, and the part is knocked out with an ejector pin. Overcomes problems with feeding the die, and produces near net, highly detailed parts.
IAS2002
MatchListI(CastingProcess)withListII (Applications)andselectthecorrectanswerusingthe codesgivenbelowtheLists: ListI ListII (CastingProcess) (Applications) A. Centrifugalcasting 1. Carburetor B. Squeezecasting 2. Pipes C. DieCasting 3. Wheelsfor automobiles 4. Gearhousings Codes:A B C A B C (a) 2 3 1 (b) 4 1 3 (c) 2 1 3 (d) 4 3 1
SingleCrystalCasting
Theprocessiseffectively: 1. Prepareamoldsothatoneendisaheatedoven,and theotherendchilled.Thepartshouldbeorientedso thatthecoolinghappensoverthelongestdistance. 2. C t t li t th ld Castmetalintothemold 3. Solidificationwillbeginatthechillplate.These dendriteswillgrowtowardstheheatedendofthe partaslongdendritic crystals.Thepartisslowly pulledoutoftheoven,pastthechillplate. 4. Removethesolidifiedpart.
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IES2009
Creepandthermalshockresistanceproperties.
2marks
PlasterCasting
Process: A slurry of plaster, water, and various additives is additives is pouted over a pattern and allowed to set. The pattern is removed and the mould is baked to remove excess water. After pouring and solidification, the mould is broken and the casting is removed. g Advantage: High dimensional accuracy and smooth surface finish, thin sections and intricate detail can produce. Limitations: Lowertemperature nonferrous metals only: Common metals: Primarily aluminium and copper
PitMoulding
This method is used for very large castings and is done on the foundry floor.
IES1996
Whichofthefollowingpairsarecorrectlymatched? 1. Pitmoulding ..................Forlargejobs. 2. Investmentmoulding ...Lostwaxprocess. 3. Plastermoulding Mouldpreparedin 3 Mouldpreparedin gypsum. (a) 1,2and3 (b) 1and2 (c) 1and3 (d) 2and3
LoamMoulding
Moulding loam is generally artificially composed of common brickclay, and sharp sand. Loam means mud. Loam Moulding is restricted to forms which cannot be cast conveniently in any other process. It is costly.
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IES1997
Which one of the following pairs is not correctly matched? (a) Aluminium alloy piston Pressure die casting (b) Jewellery.. Lost wax process (c) Large pipes ..Centrifugal casting (d) Large bells Loam moulding
GATE1998
ListI (A) Sandcasting circularshapesonly (B) Plastermouldcasting skinsandsoftinterior (C) Shellmouldcasting castingprocessing (D) Investmentcasting ListII (1) Symmetricaland (2) (3) (4) (5) (6) Partshavehardened Minimumpost Partshaveatendency towarp Partshavesoftskin andhardinterior Suitableonlyfornon ferrousmetals
GATE1992
Matchthefollowingmoulding/castingprocesseswith theproduct: Moulding/Castingprocesses Product (A) Slushcasting (P)Turbineblade (B) Shellmoulding (Q)Machinetoolbed (C) Drysandmoulding (R)Cylinderblock (D) Centrifugalcasting (S)Hollowcastings likelampshades (T)Rainwaterpipe (U)Castironshoe brake
GATE1996
ListI ListII (A) Rivetsforaircraftbody 1. Forging (B) Carburettor body 2. Coldheading (C) Crankshafts 3. 3 Aluminiumbased alloy (D) Nails 4. Pressurediecasting 5. Investmentcasting
IES2003
MatchListI(Products)withListII(CastingProcess)andselect thecorrectanswerusingthecodesgivenbelowtheLists: ListI ListII (Products) (CastingProcess) A. Hollowstatues 1. CentrifugalCasting B. Dentures B 2. 2 InvestmentCasting C. Aluminium alloypistons 3. SlushCasting D. Rockerarms 4. ShellMoulding 5. GravityDieCasting Codes: A B C D A B C D (a) 3 2 4 5 (b) 1 3 4 5 (c) 1 2 3 4 (d) 3 2 5 4
IES1993
MatchtheitemsofListI(Equipment)withtheitems ofListII(Process)andselectthecorrectanswerusing thegivencodes. ListI(Equipment) ListII(Process) P HotChamberMachine 1 1. Cleaning Q Muller 2. Coremaking R DielectricBaker 3. Diecasting S SandBlaster 4. Annealing 5. Sandmixing (a) P2,Q1,R4,S5 (b) P4,Q2,R3,S5 (c) P4,Q5,R1,S2 (d) P3,Q5,R2,S1
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IAS2004
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect thecorrectanswerusingthecodesgivenbelowthelists: ListI ListII (NameoftheCastingProcess) (ProcessDefinition) A. Diecasting 1.Thisprocessinvolvesuseofamouldmadeof Driedsilicasandandphenolic resinmixture B. B Electroslag casting El l i 2.Inthisprocess,moltenmetalisforcedby I hi l li f db Pressureintoametalmould C. Centrifugalcasting 3.Thisprocessemploysaconsumableelectrode D. Precisioncasting 4.Thisprocessinvolvesrotatingamouldwhilethe metalsolidifies 5.Thisprocessproducesverysmooth,highly Accuratecastingsfrombothferrousandnon ferrousalloys Codes:A B C D A B C D (a) 5 4 1 2 (b) 2 3 4 5 (c) 5 3 4 2 (d) 2 4 1 5
ConventionalCastingProcessCh21
Q.No 1 2 3 4 5 6 7 8 9 10 11 12 Option A A C A D A D C B D A B Q.No 13 14 15 16 17 18 19 20 21 Option C D D B B B D A A
SpecialCastingProcessCh22
Q.No 1 2 3 4 5 6 7 8 9 10 Option D C C B C A D C B D Q.No 11 12 13 14 15 16 17 Option A A D A A B A
18

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8/28/2011

metal enters the mould cavity in a controlled rate. Contd Compiledby:SKMondalMadeEasy

Calculatethepermeabilitynumberofsandifittakes1min 25stopass2000cm3 ofairatapressureof5g/cm2 through thestandardsample.

p = 5.0 g / cm 2 T = 1 min 25 s = 1 417 min 1.417 501.28 R= = 70.75 5 1.417

Ingate: Achannelthroughwhichthemoltenmetal entersthemouldcavity. Vent: Smallopeninginthemouldtofacilitateescape ofairandgases.

Theexacttaperingcanbeobtainedbytheequationof continuity.DenotingthetopandchokesectionsofThesprue by thesubscriptstand'c'respectively,weget

Sincethevelocitiesareproportionaltothesquareof thepotentialheads,ascanbederivedfrom Bernoulli'sequation,

WhereH=actual sprue height andht=h+H

V V = 1.25 A riser A casting

Therisershouldsolidifylastsox>1 Th i h ld lidif l AccordingtoCaine

(B) (C) (D)

Wherem=massofthecasting,kg =Densityofmetal,kg/m3 t=pouringtime c=Efficiencyfactorandisthefunctionofgate systemused H=Effectiveheadofliquidmetal =hfortopgate

Thefollowingarethemajordefects,whicharelikelyto occurinsandcastings: Gasdefects Shrinkagecavities Moldingmaterialdefects

(a) Sandcastingdefect (b) Machiningdefect (c) Weldingdefect (d) Forgingdefect Ans.(a)

casting Cores can be used to increase the complexity of the product.

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