1. NATIONAL INSTITUTE OF
FOUNDRY FORGE TECHNOLOGY
TOPIC-COSWORTH PROCESS
SUBMITTED TO- DR.NANDITA GUPTA SUBMITTED BY- ANIRUDH KUMAR
2. HISTORY
• It was developed by Dr. Campbell, at the instance
of Mr. Cosworth a performance engine-
manufacturer, who wanted a suitable process of
high-integrity aluminium casting. The name
Cosworth is now synonymous with racing car
engines.
• Since its development in 1987,it has been
adopted by many foundries.
• American Foundrymen’s Association has
identified this process as the best emerging
process that can be commercialized.
3. PROCESS
• Designed for high volume production of high quality
automotives casting.
• An electromagnetic pump is used to remove the
molten which is taken from mid-depth in the furnace
to minimize the risk of transferring oxides.
• The large reservoir of liquid metal in the holding
furnaces allows time for impurities to sink or float, and
the electromagnetic pump(no moving parts) displaces
the best quality metal from the mid-depth of the
holding furnace up and into the mould, displacing the
air ahead of its as it goes.
4. PROCESS
• This approach ensures that the metal rises
through the system in a non turbulent
manner, thereby minimizing the formation of
excessive oxide films and their incorporation
into the casting.
• Firstly, the mould has to remain attached to
the pump until the casting solidifies, which
results in a slow production rate.
• It uses precision sand casting method.
5.
6. ADVANTAGES
• No porosity formed therefore the casting are
pressure tight.
• Best suitable for high-integrity aluminium casting.
• Improved metallurgical and mechanical
properties.
• Reduced fettling time and machining required
• Thinner section can be cast allowing the design of
lighter, more robust components.
• High strength and ductility for the casted
products.
7. DISADVANTAGES
• Installation cost is high.
• Not for all metals especially for aluminium
• Vacuum control is not easy task to maintain
• Pre-heat of mould and sprue
• Size restriction
