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Patterns are typically made of wood, metal, plastic, or plaster. Pattern-making is incredibly important for industrial part-making, where precise calculations are needed to make pieces fit and work together. 2. Core-making – If casting is hollow, an additional piece of sand or metal (called a core) shapes the internal form to make it hollow.
- Overview
- Casting
- Sand-casting
- Metal molds
- Investment casting
- Centrifugal casting
- Continuous casting
- Grain size
- Segregation
Casting consists of pouring molten metal into a mold, where it solidifies into the shape of the mold. The process was well established in the Bronze Age (beginning c. 3000 bc), when it was used to form most of the bronze pieces now found in museums. It is particularly valuable for the economical production of complex shapes, ranging from mass-produ...
Casting consists of pouring molten metal into a mold, where it solidifies into the shape of the mold. The process was well established in the Bronze Age (beginning c. 3000 bc), when it was used to form most of the bronze pieces now found in museums. It is particularly valuable for the economical production of complex shapes, ranging from mass-produ...
Sand-casting is widely used for making cast-iron and steel parts of medium to large size in which surface smoothness and dimensional precision are not of primary importance.
The first step in any casting operation is to form a mold that has the shape of the part to be made. In many processes, a pattern of the part is made of some material such as wood, metal, wax, or polystyrene, and refractory molding material is formed around this. For example, in greensand-casting, sand combined with a binder such as water and clay is packed around a pattern to form the mold. The pattern is removed, and on top of the cavity is placed a similar sand mold containing a passage (called a gate) through which the metal flows into the mold. The mold is designed so that solidification of the casting begins far from the gate and advances toward it, so that molten metal in the gate can flow in to compensate for the shrinkage that accompanies solidification. Sometimes additional spaces, called risers, are added to the casting to provide reservoirs to feed this shrinkage. After solidification is complete, the sand is removed from the casting, and the gate is cut off. If cavities are intended to be left in the casting—for example, to form a hollow part—sand shapes called cores are made and suspended in the casting cavity before the metal is poured.
Patterns are also formed for sand-casting out of polymers that are evaporated by the molten metal. Such patterns may be injection molded and can possess a very complex shape. The process is called full-mold or evaporative pattern casting.
A variant of sand-casting is the shell-molding process, in which a mixture of sand and a thermosetting resin binder is placed on a heated metal pattern. The resin sets, binding the sand particles together and forming half of a strong mold. Two halves and any desired cores are then assembled to form the mold, and this mold is backed up with moist sand for casting. Greater dimensional accuracy and a smoother surface are obtained in this process than in greensand-casting.
Other molds are made from metal. Here a die of the desired shape is machined from cast iron or steel. If the metal flows into the mold by gravity, the process is called permanent mold casting. If the molten metal is forced in under pressure, the process is called die casting. Die-casting dies are water-cooled; consequently, they can produce parts with thinner walls at a higher rate than permanent mold machines. The rapid cooling creates a stronger part than sand-casting, but ductility may be poorer owing to entrapped gas and porosity.
Since the initial cost of a die is substantial, metal molds are cost-effective only when many identical parts are to be made. Indeed, a die may be made to produce several parts at once.
In investment casting a mold is made by drying a refractory slurry on a pattern made of wax or plastic. A series of layers is applied and dried to make a ceramic shell, and the pattern is then melted or burned out to provide the mold. This process allows the mass production of parts with more complex shapes and finer surface detail than can be atta...
Centrifugal casting forces the metal into a mold by spinning it. It is used for the casting of small precious-metal objects, so that essentially all of the metal goes into the casting instead of the gates and risers. It is also used to produce long, hollow objects without resorting to cores—for example, to cast pipe. Here the long, cylindrical mold...
Actually not a means of casting parts, continuous casting is practiced in the primary production of metals to form strands for further processing. The metal is poured into a short, reciprocating, water-cooled mold and solidifies even as it is withdrawn from the other side of the mold. The process is widely used in the steel industry because it elim...
A fine-grained casting can be produced by rapidly cooling the liquid metal to well below its equilibrium freezing temperature—i.e., by pouring into a mold that cools the metal rapidly. For this reason, die castings have a finer grain size than the same alloy cast in a sand mold.
In cast iron, remarkable changes in microstructure result from various alloying additions and casting temperatures. For example, normal cast iron solidified in a sand mold forms what is known as gray iron, an iron matrix containing about 20 percent by volume graphite flakes. This type of iron has limited ductility. However, when a small amount of magnesium is added to the melt before casting, the result is a “spheroidal graphite” iron, in which graphite appears as spherical nodules and ductility is greatly increased. If the molten iron is chill cast (i.e., rapidly cooled), it will form a “white” iron containing about 60 percent cementite, or iron carbide. This material is hard and wear-resistant, but it has no ductility at all. These cast irons are usually given a heat treatment to improve their mechanical properties.
Different parts of a casting may have different compositions, stemming from the fact that the solid freezing out of a liquid has a different composition from the liquid with which it is in contact. (For example, when salt water is cooled until ice forms, the ice is essentially pure water while the salt concentration of the water rises.) Minor segre...
Jul 22, 2023 · Water molecules fit between the layers to form a thin film of water. When hydrated, clays can be easily molded, but during high-temperature heat treatment, called firing , a dense and strong ceramic is produced.
Nov 12, 2011 · This “guncotton” could be dissolved with organic solvents, and the resulting thick, syrupy liquid, called collodion, dried to a flexible film or a hard sheet, depending on the proportion of solvent.
Pulp is made from wood fibres mixed with water. These fibres usually come from softwood trees like spruce and pine. To make paper, trees are cut up and the bark is removed.
Metal molds are used in that type of founding known as die-casting. Often a hollow space is desired within the casting; in this case a core of fine sand is placed in one of the mold halves. Core boxes made of wood, metal, or resin are also used in this regard.
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Mar 16, 2023 · Shape-memory alloys sound brilliant, but they do have some drawbacks: they fatigue (break after repeated deformations) much more readily than ordinary stainless steel and they're notably more expensive to manufacture than traditional steel or aluminum alloys.
