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1. Introduction To Casting
Processes by Stead Fast
Engineers Pvt Ltd – part 1
one of the leading Induction heating system
manufactures

2. History of Casting

3. Advantages
• Complex forms, low cost
• Certain shapes cannot be
machined
• One piece parts vs. multiple
piece parts
• Design changes are easily
incorporated
• High volume, low skilled labor
• Large, heavy parts can be made
easily

4. Disadvantages
• Problems with internal
porosity
• Dimensional variations due
to shrinkage
• Trapped impurities, solids
and gasses
• High-tolerance, smooth
surfaces not possible
• More costly than stamping
or extruding in some cases

5. Expendable Molds
• Green Sand
• Dry Sand
• Shell
• Investment
• Plaster

6. Expendable Molds
• Pattern must be produced
• New mold for every cycle

7. Permanent Molds
• Die
• Centrifugal
• Pressure
• Injection

8. Permanent Molds
• Made of durable material
• Multiple use
• Built-in Alignment

9. Cupola Furnaces
Five Zones
• Stack
• Charging Zone
• Melting Zone
• Tuyers (Air Intake)
• Crucible or Hearth

10. Induction Furnaces
• Magnetic field
• Rapid melting rate
• Low pollution

11. Foundries
• Pattern and Mold Making
– Computer Aided
Design
– Manufacturing
– Rapid Prototyping
• The Casting Process
– Metal Melting
– Metal Compositions
– Impurities
– Pouring into molds

12. Foundries

13. Foundry Automation
• Pouring into Molds
• Cleaning
• Heat Treatment
• Inspection
• Automated Guided
Vehicles
– Automatic Storage
– Moving Cores and
patterns
– Etc.

14. Reasons For Automation
• Increased Manufacturing
Efficiency
• Reducing Costs
• Reliability in Harsh
Environments
• Release of Skilled Man
Power
• Maximize Space
• Improved Quality

15. Why Fluid Flow?
• When Heated Metal
Becomes Liquid
• Important in Cast Design
- Sprue
- Well
- Runner
- Gate

16. Fluidity of Metals
• Viscosity
• Surface Tension
• Inclusions
• Mold Design
• Degree of Super Heat
• Mold Material
- Thermal Conductivity
- Surface Roughness
• Heat Transfer

17. Tests for Fluidity
• There are several
different fluidity tests
• All use the same principle
• Useful in simulating how
metal will react
• See how far the metal will
travel before solidification

18. Heat Transfer
• Heat transfer is important
in many aspects of
casting
- Pouring
- Solidification
- Cooling rate
- Rate is a function
of Volume and
surface area