Casting Process, Casting Defects and Mechanical Properties. Mechanical Engineering. Finite Element Analysis, Modeling & Simulations. LS DYNA Work, Hypermesh, Abaqus, CAE, CFD, CATIA V5, & SOLID WORKS Linear Analysis, Non - Linear Analysis, Statics Analysis, Dynamics Analysis, Thermal Analysis, Fluid Analysis, Metal Forming, Stress Analysis, Crash Box Analysis, Structure Analysis, & Automotive Analysis. Note: Real Engineering for Students & Employee. Learn Mechanical with Software Analysis. Raj Kumar, Research Fellow in IIT – Roorkee, Research Organization. Top 5th Rank in India. M.Tech – Industrial & Production Engineering, B.Tech – Mechanical Engineering, Filed & Background: 1. Research & Development Deptt. – LS - DYNA, Hypermesh, CFD & Abaqus CAE Software, 2. Operations & Maintenance Deptt. - SAP – PM, & ERP Software, Experiences: 7–Year.

1. Casting Process

2. Casting Process
“Casting is a manufacturing
process in which a liquid
material is usually poured
into a mold”

3. Casting Process
Liquid
Metal
Filling
Solidification
Shrinkage
Casting

4. 1. Sand Casting:
A casting method for producing casting in a sand mold.
Sheet, iron, and most non-ferrous alloy casting can be
obtained by sand casting.
Application:
Automotive engine block, Cylinder head, Crankshaft and
Other Casting.
Types of Casting Process

6. 2. Investment Casting:
To making patterns in fusible materials, covering the surface of the
pattern with several layers of refectory materials and then melting the
pattern out of the mold shell to obtain a mold without a parting surface,
which can be filled after baking at high temperature.
Application:
Turbine engine blades, and small parts with complex shapes.
Types of Casting Process

8. 3. Die Casting:
The high pressure metal liquid is pressed into a precision metal
mold cavity at high speed, and the metal liquid is cooled and
solidified under pressure to form a casting.
Application:
Automotive Industry, Instrument Industry, Agriculture Machinery,
Machine Tool Industry, Electronics Industry, Defence Industry,
Medical Equipments, Computers, Clocks, Cameras and Daily
Hardware.
Types of Casting Process

10. 4. Low Pressure Casting:
That method of making liquid metal fill a mold under a low
pressure (0.02 – 0.06 MPa) and crystallize under process to form a
casting.
Application:
Traditional product like Cylinder head, Hub, and Cylinder frame
etc.
Types of Casting Process

12. 5. Centrifugal Casting:
In which molten metal is poured into a rotating mold, and the
mold is filled and solidified under the action of centrifugal force.
Application:
Pipes, Metallurgy, Mining transportation, Irrigation & Drainage
machinery, Aviation, Steel, Iron, Non-ferrous metal carbon alloy
etc.
Types of Casting Process

14. 6. Gravity Die Casting:
In which liquid metal is filled with a metal mold under the action
of gravity and cooled and solidified in the mold to obtain a casting.
Application:
Aluminium alloy, magnesium alloy, iron etc.
Types of Casting Process

16. 7. Vacuum Die Casting:
That improve mechanical properties and surface quality of die
casting parts by removing or significantly reducing the pores and
dissolved gas in the die casting part by extracting the gas in the die
casting mold cavity during the die casting process .
Types of Casting Process

18. 8. Squeezing Die Casting:
It’s a method for solidifying a liquid or semi solid metal under high
pressure and following forming to directly obtain the product or
blank.
Application:
Aluminium Alloy, zinc alloy, copper alloy, and nodular cast iron
etc.
Types of Casting Process

20. 9. Lost foam Casting:
That a combination of paraffin or foam models similar to the size
and shape of the casting to form a models cluster.
Application:
Gray cast iron engine box, and high manganese steel elbow etc.
Types of Casting Process

22. 10. Continual Casting:
It’s principle is to continuously pour molten metal into a special
metal mold called a crystallizer .
Application:
Cast steel, Iron, Copper alloys, aluminium alloys, magnesium
alloys, slabs, pipes, rod billets etc.
Types of Casting Process

24. Casting Defects

25. It is an unwanted irregularities that appear in the casting during metal
casting process.
Gas Porosity
Shrinkage
Mold Material
Metallurgical
Pouring
Casting Shapes
Casting Defects

26. Casting Defects
• Pinhole
• Subsurface Blowhole
• Open Holes
1. Gas Porosity:

27. Casting Defects
• Open Shrinkage
• Close Shrinkage
2. Shrinkage:

28. Casting Defects
3. Mold Material:
Cuts & Washes
Fusion
Run Out

29. Casting Defects
3. Mold Material:
Swells
Drops

30. Casting Defects
3. Mold Material:
Rat Tails, Veins &
Buckles
Metal
Penetration

31. Casting Defects
4. Metallurgical:
• Hot Tear & Crack
1.
• Hot & Hard Spot
2.

32. Casting Defects
5. Pouring:
Cold Shot
Slag Inclusion

33. Casting Defects
5. Pouring:
Cold Shut & Lap
Misruns are closely related to
cold shuts

34. Casting Defects
6. Casting Shapes:
Shift Mismatch
Flash, Fin & Burrs
Warping

35. Mechanical
Properties

36. Mechanical Properties
Strength is the mechanical property that enables a metal to
resist deformation load.
1.Strength:

37. The elasticity of a material is its power of coming back to its
original position after deformation when the stress or load
is released.
Mechanical Properties
2. Elasticity:

38. 3. Plasticity: The plasticity of a material is its ability to undergo some
permanent deformation without rupture(brittle).
Mechanical Properties

39. 4. Hardness: The hardness is the ability of a material to resist scratching,
abrasion, cutting or penetration.
Mechanical Properties

40. 5. Toughness: Toughness is the opposite condition of brittleness.
Mechanical Properties

41. 6. Brittleness: The brittleness of a property of a material which enables it to
withstand permanent deformation.
Mechanical Properties

42. 7. Stiffness: The stiffness is the resistance of a material to elastic
deformation or deflection.
Mechanical Properties

43. 8. Ductility: The ductility is a property of a material which enables it to be
drawn out into a thin wire.
Mechanical Properties

44. 9. Malleability:
The malleability is a property of a material which permits
it to be hammered or rolled into sheets of other sizes and
shapes
Mechanical Properties

45. 10. Impact Strength: The impact strength is the ability of a metal to resist suddenly
applied loads.
Mechanical Properties

46. 11. Fatigue: The fatigue is the long effect of repeated straining action
which causes the strain or break of the material.
Mechanical Properties