Fundamentals of Casting

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Casting
Lily Chapman
Flashcards by Lily Chapman, updated more than 1 year ago
Lily Chapman
Created by Lily Chapman over 6 years ago
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Question Answer
Key steps in casting 1) Melt the metal 2) Pour into a mould 3) Let molten metal freeze 4) Remove from mould
Advantages of casting - Creates relatively complex geometries - Can create both internal and external shapes - Produces very larges shapes - Can be suited to mass production (if the geometry is less complex)
Disadvantages of casting - Material limits mechanical capabilities - Poor dimensional accuracy and surface finish - Excess material - Safety issues
What are the two forms of mould? Open mould and closed mould
Closed mould casting Has a complex geometry, requires a gating system leading into the cavity.
Features in a closed mould casting - Risers: A reservoir built to prevent cavities due to shrinkage - Core: Used to create an internal cavity - Runners: Connected channels that transport the molten metal
What is an expendable mould process? The mould must be destroyed in order to remove the casting
What is a permanent mould process? -One where the mould can be reused many times - Open moulds used
How does volume to surface ratio affect the casting? A casting with a higher volume-to-surface area ratio cools and solidifies more slowly than one with a lower ratio
How do you minimise the effects of shrinkage? Design the riser to have a larger volume-to-surface area ratio so that the main casting solidifies first
Solidification shrinkage Shrinkage of a cylindrical casting during solidification and cooling. Causes a reduction in level of the casting
Directional solidification The regions most distant from the molten metal should freeze first. To do this Locate sections of the casting with lower V/A ratios away from the riser, so freezing occurs first in these regions.
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