In metalworking, casting involves pouring a liquid metal into a mold, which contains a hollow cavity of the desired shape, and then is allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.
The casting process is subdivided into two main categories: expendable and non-expendable casting. It is further broken down by the mold material, such as sand or metal, and pouring method, such as gravity, vacuum, or low pressure.
Some specialized processes, such as die casting, use additional terminology.
==Theory== Casting is a solidification process, which means the solidification phenomenon controls most of the properties of the casting. Moreover, most of the casting defects occur during solidification, such as gas porosity and solidification shrinkage.
Solidification occurs in two steps: nucleation and crystal growth. In the nucleation stage solid particles form within the liquid. When these particles form their internal energy is lower than the surrounded liquid, which creates an energy interface between the two. The formation of the surface at this interface requires energy, so as nucleation occurs the material actually undercools, that is it cools below its freezing temperature, because of the extra energy required to form the interface surfaces. It then recalescences, or heats back up to its freezing temperature, for the crystal growth stage. Note that nucleation occurs on a pre-existing solid surface, because not as much energy is required for a partial interface surface, as is for a complete spherical interface surface. This can be advantageous because fine-grained castings possess better properties than coarse-grained castings. A fine grain structure can be induced by grain refinement or inoculation, which is the process of adding impurities to induce nucleation.
All of the nucleations represent a crystal, which grows as the heat of fusion is extracted from the liquid until there is no liquid left. The direction, rate, and type of growth can be controlled to maximize the properties of the casting. Directional solidification is when the material solidifies at one end and proceeds to solidify to the other end; this is the most ideal type of grain growth because it allows liquid material to compensate for shrinkage.
Note that before the thermal arrest the material is a liquid and after it the material is a solid; during the thermal arrest the material is converting from a liquid to a solid. Also, note that the greater the superheat the more time there is for the liquid material to flow into intricate details.
The above cooling curve depicts a basic situation with a pure alloy, however, most castings are of alloys, which have a cooling curve shaped as shown below.
Note that there is no longer a thermal arrest, instead there is a freezing range. The freezing range corresponds directly to the liquidus and solidus found on the phase diagram for the specific alloy.
The local solidification time can be calculated using Chvorinov's rule, which is:
:
Where t is the solidification time, V is the volume of the casting, A is the surface area of the casting that contacts the mold, n is a constant, and B is the mold constant. It is most useful in determining if a riser will solidify before the casting, because if the riser does solidify first then it is worthless.
===The gating system===
The gating system serves many purposes, the most important being conveying the liquid material to the mold, but also controlling shrinkage, the speed of the liquid, turbulence, and trapping dross. The gates are usually attached to the thickest part of the casting to assist in controlling shrinkage. In especially large castings multiple gates or runners may be required to introduce metal to more than one point in the mold cavity. The speed of the material is important because if the material is traveling too slowly it can cool before completely filling, leading to misruns and cold shuts. If the material is moving too fast then the liquid material can erode the mold and contaminate the final casting. The shape and length of the gating system can also control how quickly the material cools; short round or square channels minimize heat loss.
The gating system may be designed to minimize turbulence, depending on the material being cast. For example, steel, cast iron, and most copper alloys are turbulent insensitive, but aluminium and magnesium alloys are turbulent sensitive. The turbulent insensitive materials usually have a short and open gating system to fill the mold as quickly as possible. However, for turbulent sensitive materials short sprues are used to minimize the distance the material must fall when entering the mold. Rectangular pouring cups and tapered sprues are used to prevent the formation of a vortex as the material flows into the mold; these vortices tend to suck gas and oxides into the mold. A large sprue well is used to dissipate the kinetic energy of the liquid material as it falls down the sprue, decreasing turbulence. The choke, which is the smallest cross-sectional area in the gating system used to control flow, can be placed near the sprue well to slow down and smooth out the flow. Note that on some molds the choke is still placed on the gates to make separation of the part easier, but induces extreme turbulence. The gates are usually attached to the bottom of the casting to minimize turbulence and splashing.
Most materials shrink as they solidify, but, as the table to the right shows, a few materials do not, such as gray cast iron. For the materials that do shrink upon solidification the type of shrinkage depends on how wide the freezing range is for the material. For materials with a narrow freezing range, less than , a cavity, known as a pipe, forms in the center of the casting, because the outer shell freezes first and progressively solidifies to the center. Pure and eutectic metals usually have narrow solidification ranges. These materials tend to form a skin in open air molds, therefore they are known as skin forming alloys.
For the materials that have narrow solidification ranges pipes can be overcome by designing the casting to promote directional solidification, which means the casting freezes first at the point farthest from the gate, then progressively solidifies towards the gate. This allows a continuous feed of liquid material to be present at the point of solidification to compensate for the shrinkage. Note that there is still a shrinkage void where the final material solidifies, but if designed properly this will be in the gating system or riser.
Risers, also known as feeders, are the most common way of providing directional solidification. It supplies liquid metal to the solidifying casting to compensate for solidification shrinkage. For a riser to work properly the riser must solidify after the casting, otherwise it cannot supply liquid metal to shrinkage within the casting. Risers add cost to the casting because it lowers the yield of each casting; i.e. more metal is lost as scrap for each casting. Another way to promote directional solidification is by adding chills to the mold. A chill is any material which will conduct heat away from the casting more rapidly that the material used for molding.
Risers are classified by three criteria. The first is if the riser is open to the atmosphere, if it is then its called an open riser, otherwise its known as a blind type. The second criterion is where the riser is located; if it is located on the casting then it is known as a top riser and if it is located next to the casting it is known as a side riser. Finally, if riser is located on the gating system so that it fills after the molding cavity, it is known as a live riser or hot riser, but if the riser fills with materials that's already flowed through the molding cavity it is known as a dead riser or cold riser.
Riser aids are items used to assist risers in creating directional solidification or reducing the number of risers required. One of these items are chills which accelerate cooling in a certain part of the mold. There are two types: external and internal chills. External chills are masses of high-heat-capacity and high-thermal-conductivity material that are placed on an edge of the molding cavity. Internal chills are pieces of the same metal that is being poured, which are placed inside the mold cavity and become part of the casting. Insulating sleeves and toppings may also be installed around the riser cavity to slow the solidification of the riser. Heater coils may also be installed around or above the riser cavity to slow solidification.
The distortion allowance is only necessary for certain geometries. For instance, U-shaped castings will tend to distort with the legs splaying outward, because the base of the shape can contract while the legs are constrained by the mold. This can be overcome by designing the mold cavity to slope the leg inward to begin with. Also, long horizontal sections tend to sag in the middle if ribs are not incorporated, so a distortion allowance may be required. The first patented vacuum casting machine and process dates to 1879.
Low-pressure filling uses 5 to 15 psig (35 to 100 kPag) of air pressure to force liquid metal up a feed tube into the mold cavity. This eliminates turbulence found in gravity casting and increases density, repeatability, tolerances, and grain uniformity. After the casting has solidified the pressure is released and any remaining liquid returns to the crucible, which increases yield.
The chill zone is named so because it occurs at the walls of the mold where the wall chills the material. Here is where the nucleation phase of the solidification process takes place. As more heat is removed the grains grow towards the center of the casting. These are thin, long columns that are perpendicular to the casting surface, which are undesirable because they have anisotropic properties. Finally, in the center the equiaxed zone contains spherical, randomly oriented crystals. These are desirable because they have isotropic properties. The creation of this zone can be promoted by using a low pouring temperature, alloy inclusions, or . Common inspection methods for aluminum castings are radiography, ultrasonic, and liquid penetrant.
There are a number of problems that can be encountered during the casting process. The main types are: gas porosity, shrinkage defects, mold material defects, pouring metal defects, and metallurgical defects.
A durable plaster intermediate is often used as a stage toward the production of a bronze sculpture or as a pointing guide for the creation of a carved stone. With the completion of a plaster, the work is more durable (if stored indoors) than a clay original which must be kept moist to avoid cracking. With the low cost plaster at hand, the expensive work of bronze casting or stone carving may be deferred until a patron is found, and as such work is considered to be a technical, rather than artistic process, it may even be deferred beyond the lifetime of the artist.
In waste molding a simple and thin plaster mold, reinforced by sisal or burlap, is cast over the original clay mixture. When cured, it is then removed from the damp clay, incidentally destroying the fine details in undercuts present in the clay, but which are now captured in the mold. The mold may then at any later time (but only once) be used to cast a plaster positive image, identical to the original clay. The surface of this plaster may be further refined and may be painted and waxed to resemble a finished bronze casting.
Sand casting is one of the most popular and simplest types of casting that has been used for centuries. Sand casting allows for smaller batches to be made compared to permanent mold casting and at a very reasonable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very small size operations. From castings that fit in the palm of your hand to train beds (one casting can create the entire bed for one rail car), it can all be done with sand casting. Sand casting also allows most metals to be cast depending on the type of sand used for the molds.
Sand casting requires a lead time of days for production at high output rates (1–20 pieces/hr-mold) and is unsurpassed for large-part production. Green (moist) sand has almost no part weight limit, whereas dry sand has a practical part mass limit of . Minimum part weight ranges from . The sand is bonded together using clays, chemical binders, or polymerized oils (such as motor oil). Sand can be recycled many times in most operations and requires little maintenance.
Plaster casting is similar to sand casting except that plaster of paris is substituted for sand as a mold material. Generally, the form takes less than a week to prepare, after which a production rate of 1–10 units/hr·mold is achieved, with items as massive as and as small as with very good surface finish and close tolerances. Plaster casting is an inexpensive alternative to other molding processes for complex parts due to the low cost of the plaster and its ability to produce near net shape castings. The biggest disadvantage is that it can only be used with low melting point non-ferrous materials, such as aluminium, copper, magnesium, and zinc.
Shell molding is similar to sand casting, but the molding cavity is formed by a hardened "shell" of sand instead of flask filled with sand. The sand is finer than sand casting sand and is mixed with a resin so that it can be heated by the pattern and harden into a shell around the pattern. Because of the resin it gives a much finer surface finish. The process is easily automated and more precise than sand casting. Common metals that are cast include cast iron, aluminium, magnesium, and copper alloys. This process is ideal for complex items that are small to medium sized.
Investment casting (known as lost-wax casting in art) is a process that has been practised for thousands of years, with the lost-wax process being one of the oldest known metal forming techniques. From 5000 years ago, when beeswax formed the pattern, to today’s high technology waxes, refractory materials and specialist alloys, the castings ensure high-quality components are produced with the key benefits of accuracy, repeatability, versatility and integrity.
Investment casting derives its name from the fact that the pattern is invested, or surrounded, with a refractory material. The wax patterns require extreme care for they are not strong enough to withstand forces encountered during the mold making. One advantage of investment casting is that the wax can be reused.
Industrially, the centrifugal casting of railway wheels was an early application of the method developed by German industrial company Krupp and this capability enabled the rapid growth of the enterprise.
Small art pieces such as jewelry are often cast by this method using the lost wax process, as the forces enable the rather viscous liquid metals to flow through very small passages and into fine details such as leaves and petals. This effect is similar to the benefits from vacuum casting, also applied to jewelry casting.
Continuous casting is a refinement of the casting process for the continuous, high-volume production of metal sections with a constant cross-section. Molten metal is poured into an open-ended, water-cooled copper mold, which allows a 'skin' of solid metal to form over the still-liquid centre. The strand, as it is now called, is withdrawn from the mold and passed into a chamber of rollers and water sprays; the rollers support the thin skin of the strand while the sprays remove heat from the strand, gradually solidifying the strand from the outside in. After solidification, predetermined lengths of the strand are cut off by either mechanical shears or travelling oxyacetylene torches and transferred to further forming processes, or to a stockpile. Cast sizes can range from strip (a few millimetres thick by about five metres wide) to billets (90 to 160 mm square) to slabs (1.25 m wide by 230 mm thick). Sometimes, the strand may undergo an initial hot rolling process before being cut.
Continuous casting is used due to the lower costs associated with continuous production of a standard product, and also increases the quality of the final product. Metals such as steel, copper and aluminium are continuously cast, with steel being the metal with the greatest tonnages cast using this method.
Metalworking Category:Jewellery making Category:History of metallurgy Category:Metallurgy Category:Sculpture techniques
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