Casting Methods and Their Characteristics

A manufacturing process where molten metal is poured into a mold, allowed to cool, and solidifies into the desired shape.

The process of making a mold for casting that is destroyed after the casting is complete.

The process of making a mold using two halves of a metal die that are clamped together.

The shrinkage of a casting as it cools from a molten state to solid, creating a smaller dimension than intended.

The process of shaping metal in a mold that creates internal hollow sections and cavities.

The process of casting that allows for intricate designs and complex shapes to be produced.

Casting can produce a wide range of component sizes, from small to very large.

Metals that are difficult to mold with other methods can be cast.

A type of die casting where molten metal is poured into the die using gravity.

A type of die casting where molten metal is forced into the die under high pressure.

Molten metal is poured into the mold, and due to the high thermal conductivity of the die, the metal must flow quickly to all areas before it starts to solidify.

Die Casting is suitable for metals with relatively low melting points.

Piston, connecting rods, and cylinder heads are typical products made with gravity die casting.

Die casting is ideal for producing castings with intricate shapes and complex designs.

Moulds are made of metal to withstand the wear and temperature changes caused by repeated use.

The amount of extra material added to a pattern to compensate for shrinkage during cooling.

A defect in a casting that occurs when the metal solidifies too quickly, leading to uneven cooling and shrinkage in the casting.

A defect in a casting that occurs when air gets trapped in the mold during the pouring process.

A casting defect that occurs when the molten metal does not completely fill the mold cavity, resulting in a thin or incomplete casting.

A type of casting that uses a mold made of a ceramic shell, which is created by dipping a pattern in a slurry of ceramic material.

A type of casting where the molten metal is poured into a mold that rotates, creating a centrifugal force that helps the metal flow evenly into the mold.

Pressure die-casting is limited to low-melting point alloys like aluminum and zinc.

Pressure die-casting allows for complex shapes with internal cavities or hollow sections to be created in a single casting.

The cost of the mold for pressure die-casting is high, making it unsuitable for manufacturing small quantities of products.

The size of pressure die-castings is limited by the size of the tooling and machinery required for the process.

Shrinkage occurs when metals cool and solidify, resulting in dimensional changes, porosity, cavities, and sometimes cracking.

To compensate for shrinkage during the cooling process, allowances must be made in the mold design.

The high finish and surface texture of pressure die-castings minimize the need for additional machining and finishing.

A casting process where a mold is created from a refractory material, like zircon and aluminum oxide, mixed with a bonding agent. This method allows for casting intricate shapes and high-temperature alloys.

The process of ceramic mould casting involves pouring a slurry over a pattern, allowing it to set, drying the mould, and then assembling it for pouring the molten metal.

The ceramic mould casting process is ideal for producing castings in materials like stainless steel, tool steel, and high-temperature alloys due to its high temperature resistance.

Investment casting, also known as the lost wax process, involves creating a wax pattern, covering it with a refractory slurry, and then pouring molten metal into the hardened mould.

The wax pattern in investment casting is produced by injecting molten wax into a metal die, creating a detailed and accurate mold.

To ensure a smooth surface finish and accurate detail, the wax pattern is dipped in a refractory slurry before hardening. This creates a thin layer of smooth refractory material on the pattern.

Investment casting, also known as the lost wax process, is a process where a wax pattern is used to create a mold, resulting in intricate shapes like turbine blades and jewelry.

Investment casting is highly suitable for manufacturing complex and intricate shapes with high precision in high-melting-point metals.

This process involves creating a mold using wax patterns that are coated with a refractory material, then pouring molten metal into the mold. Once the metal solidifies, the wax is melted out and the mold is broken to reveal the casting.

A mold used in centrifugal casting that is typically made of durable materials like iron, steel, or refractory-coated sand to withstand the high temperatures and centrifugal forces.

The process of joining multiple patterns together to create a larger and more complex structure, improving casting efficiency and production speed.

The gradual cooling of the molten metal during investment casting, causing a slight reduction in size as the material solidifies.

A material used in investment casting that protects the wax pattern during heating and also provides a strong base for the metal to solidify against.

The process of removing the wax pattern from the mold after the metal has solidified, allowing the casting to be released from the mold.

A typical application of investment casting that involves creating intricate and complex shapes for various parts, particularly in aerospace and machinery industries.