Metal Casting and Welding

Introduction:

Manufacturing is a process of converting raw materials into finished product. It

includes design and manufacturing of goods using various production methods and
techniques. Every product requires material from which the product is made and also
requires a method to convert raw material into desired product. We need machines to
convert the materials to get desire shape and size. To convert the raw material into the
product using machine and methods we require men to operate the machines and to apply
the methods. Money is the essential input required for purchasing raw materials,
machines and man power.

Classification of manufacturing process:

a. Casting
b. Forming
c. Machining
d. Joining

a. Casting:
In casting process, the molten metal is poured into a mould cavity and is allowed to
solidify after solidification, the casting is removed from the mould and cleaned, finally
machined to the required shape and size and inspected before use. They are further
classified into 2 types:
1. Expandable mould
2. Permanent mould

1. Expandable mould:
Here, the mould is prepared from sand, plaster or any other similar material which can
break easily to remove the solidified part, in other words a new mould has to be prepared
for each new casting. Eg: Green sand, dry sand, plaster, etc.
2. Permanent mould:
Here, the mould is fabricated out of steel and can be used repeatedly to produce many
castings. Eg: Gravity die casting, continuous casting, pressure die casting, centrifugal
casting.
b. Forming:
In forming process, the desired shape and size are obtained through the plastic
deformation of material. The type of loading may be tensile, compressive, shearing or
combination of these loads, unlike machining technique. In this process no material is
removed and wasted.

1. Hot working
In this process deformation of metal takes place above its re-crystallization
temperature.Eg: Forging, rolling, extrusion, etc.

2. Cold working
In this process deformation of metal takes place below its re-crystallization
temperature.Eg: Bending, wire drawing, etc.

c. Machining process
The process of removing the unwanted material from a given work piece to give it to a
required shape and size is known as machining. The unwanted material is removed in the
form of chips from the blank material by a harder tool, so as to obtain a final desired
shape.

1. Traditional or conventional machine

In this process a cutting tool is used to remove excess material from the work piece.
Thetool is rigidly mounted on the machine. Eg: Turning, milling, drilling, grinding, etc.

2. Non-Traditional or non-conventional machine

In this process, a layer of electron beam, chemical erosion, electric discharge and
electrochemical energy is used instead of traditional cutting tool.

d. Joining
In this process, two or more pieces are joined together to produce the required
shapeand size of the product. The joint can be either permanent or temporary.

1. Permanent joint:
In this joining, it can be done by pouring metals together i.e. welding, gas welding, etc.

2. Temporary joint:
In this, it can be done by nuts, bolts, screws, adhesive (gum) bonding, soldering, brazing,
etc.
 Schematic representation of the classification of manufacturing process.

Selection of a process for production:

Selection of a particular process for manufacturing to produce a given component
depends onseveral factors. Some of the important factors to be considered are:
1. Shape to be produced

2. Quantity to be produced
3. Type of material
4. Surface finish and dimensional tolerance

5. Technical viability of the process

6. Economic consideration
Introduction to Casting:

In this process, components are produced by pouring molten metal into a contoured cavity
followed by cooling to a solid mass.

1. The cold solid mass represents the configuration of the cavity and is the required shape of
the component.

2. The components thus produced are called as casting.

3. The cavity compound to shape of the component is called mould.

4. The mould can be made of refractory material or metal.

5. The mould made out of refractory material is called sand moulds and that of made out

of metal is called metal moulds or dies.

6. Cooling of liquid metal to solid metal is termed as phase transformation. The place where
this activity is carried out is referred to as foundry.

7. In short, casting process involves shaping of the metal by using a mould cavity and hot
metal.

8. In this process, the final shape is realized without using any other mechanism unlike in other
processes, except the conversion of liquid metal to solid metal.

Steps involved in making a casting:

1. Pattern and Mould preparation

2. Core making

3. Melting and pouring

4. Cleaning and Inspection

1. Pattern:

A pattern is a replica of the object is to be cast. It is used to prepare a cavity into which the
molten metal is poured. A skilled pattern maker prepares the pattern using wood, metal, plastic
or any other material. Many factors like durability, allowance for shrinkage and machining, etc.,
are considered when making a pattern.

Mould preparation: It involves for making a cavity by packing sand around a pattern enclosed
in a supporting metallic frame. When the pattern is removed from the mould an exact shaped
cavity remains into which the molten metal is poured. Gating and risering are provided at
suitable locations in the mould.

2. Core making:

In some cases a hole or a cavity is required in the casting. This is obtained by placing a core in
the mould cavity. The shape of the core corresponds to the shape of the hole required. The
mould is cleaned & finished before metal pouring.

3. Melting and pouring:

Metals or alloys of the required composition are melted in a furnace and poured in to the
mould cavity. Many factors like temperature of molten metal, pouring time, turbulence, etc
should be considered while making & pouring.

4. Cleaning and Inspection:

After the molten metal is solidified and cooled, the rough casting is removed from the mould,
cleaned and dressed (removing cores, adhered sand particles, gating, risering system, fins,
blisters, etc from the casting surface) and then sent for inspection to check for dimensions or
defects like blow holes, crakes, etc.

Procedure for making a casting:

a. Mould box:

It is usually a metallic frame used for making for holding a sand mould. The mould box has two
parts. The upper part is called “Cope” and the lower part is called “Drag”.

b. Parting line:
It is the zone of separation between a cope & drag position of the mould in sand casting.

c. Sprue/Runner:

It is a vertical passage through which the molten metal will enter the gate.

d. Pouring basin:

The enlarge position of the sprue with its top into which the molten metal is poured.

e. Gate:

It is a short passage way which carries the molten metal from the runner sprue in to the

mould cavity.

f. Riser:

A riser or a feed head is a vertical passage that stores the molten metal ands supplies the

same to the casting as it solidifies.

g. Mould cavity:

The space in a mould that is filled with molten metal to form the casting upon solidification.

h. Core:

A core is performed by using a mass of sand placed in the mould cavity to form hollow

cavity in the castings.

i. Core print:

It is a projection attached to the pattern to help for support and correct location of core in

the mould cavity.

The mold is made of two parts, the top half is called the cope, and bottom part is the drag.
• The liquid flows into the gap between the two parts, called the mold cavity. The geometry
of the cavity is created by the use of a wooden shape, called the pattern. The shape of the
patterns is (almost) identical to the shape of the part we need to make.
• A funnel shaped cavity; the top of the funnel is the pouring cup; the pipe-shaped neck of
the funnel is the sprue– the liquid metal is poured into the pouring cup, and flows down the
sprue.
• The runners are the horizontal hollow channels that connect the bottom of the sprue to
the mould cavity. The region where any runner joins with the cavity is called the gate. Some
extra cavities are made connecting to the top surface of the mold. Excess metal poured into
the mould flows into these cavities, called risers. They act as reservoirs; as the metal
solidifies inside the cavity, it shrinks, and the extra metal from the risers flows back down to
avoid holes in the cast part.
• Vents are narrow holes connecting the cavity to the atmosphere to allow gasses and the
air in the cavity to escape.
Varieties of Components produced by casting process:

Casting is the 1st step and the primary process for shaping any material.
All materialshave to be cast before it is put in use.
The ingots produced by casting process are used as raw material for
secondary processeslike machining, forging, rolling, etc.
To list the components produced by casting is an endless process, a
few majorcomponents produce by casting are given below:

a. Automotive sector: A few parts like brake drum, cylinder, cylinder

linings, pistons, engine blocks, universal joints, rocker arms, brackets,
etc.
b. Aircraft: Turbine blades, casting, etc.
c. Marine: Propeller blades

d. Machining: Cutting tools, machine beds, wheels and pulleys, blocks, table
for supports,etc.
e. Agriculture & rail road equipment’s: Pumps and compressor, frames,
valves, pipesand fittings for construction.
f. Camera frame, parts in washing machine, refrigerator & air-conditioners
g. Steel utensil & a wide variety of products.

Advantages and limitations of casting process:

Advantages:

1. Casting is the basic and versatile (flexible) manufacturing process.

2. Difficult shapes can be easily cast.

3. Large, hollow & intricate shapes can be easily cast.

4. Casting provides freedom of design with respect to shape, size and quality of the product.
5. Some metals that cannot be machined can be produced by casting to the required shape.

6. Heavy objects can be produced only by casting process.

7. Controlled mechanical & metallurgical properties can be obtained.

8. Casting process is most suitable for mass production.

9. A large variety of alloying composition & properties can be obtained.

10. Directional properties can be obtained in certain cases by controlled cooling.

11. Parts with close dimensional tolerance & ready to use can be produced by special casting
methods.

Disadvantages OR Limitations:

1. Casting process is an elaborate process and involves operations.

2. It requires large infrastructure like casting section, melting, pattern, core section, cleaning,
finishing, and inspection.

3. Very high investment is required.

4. Casting process is not economical & viable for small scale operations.

5. The man power requirement is large.

6. High care is required in handling chemicals and molten metal.

7. The actual casting operation cannot be automated.

8. Generally most operations may be casting or one of type i.e. mould has to be prepared for
each casting.

9. Great care is required in controlling the cooling rate to obtain defect free casting.

10. Very difficult to cast thin sections.

PATTERNS:
Definition: Pattern is a tool used to produce the mould cavity. It is a mould
making tool. The shape of the pattern is the same as that of the component or
casting, but the size will be slightly larger than the casting. Pattern is also referred
to as the positive replica of the casting. A number or castings can be made using a
single pattern.
The following materials are used for making patterns:-

a) Wood
b) Metal
c) Wax
d) Plastics
e) Plaster
Classification of patterns: Patterns are of various types. But the selection of a
particular type of pattern depends upon the type of moulding process employed,
shape and size of the castingrequired. Some of the commonly used patterns are:
a. Single piece pattern.

b. Two-piece pattern.

c. Multi-piece pattern.

d. Match plate pattern.

e. Gate pattern.

f. Sweep pattern.

g. Skeleton pattern.

h. Loose piece pattern.

Different Types of Casting Process:

1. Sand Casting Process
2. Gravity Die Casting
3. Pressure Die Casting
4. Investment Casting
5. Plaster Casting
6. Centrifugal Casting
7. Lost-Foam Casting
8. Vacuum Casting
9. Squeezing Casting
10. Continuous Casting
11. Shell Molding
 Welding Processes

Welding definition:
Welding is process of joining two materials (similar or dissimilar) by the
application of heat with or without the application of pressure and addition of filler
material. All metals and alloys can be welded. The materials to be joined are held in
contact together and the required energy is applied mainly in the form of heat. This heat
fuses the material and on cooling the joint solidifies. The joint formed is called welded
joint. Heat is the main source of energy, which can be obtained by electricity, gas or
chemical reaction or friction. Welding isa fabrication process.

Advantages:

• Any metal/alloy can be welded

• Any shape of component can be generated
• Strength of the joint will be the same as that of the base metal.

Disadvantages / Limitations:

Harmful radiation and fumes may be generated during the

process residual stresses may be setup in the welded joint
Skilled operator may be required
Structure of the weld portion will differ from parent metal.

Application:

Fabrication of aircraft and automobile components, bridges, building structures,

ships,pressure vessel, pipes, etc.
Classification of welding processes:

ARC WELDING:

It is a fusion welding process. Here an electric arc is used as the heat source. An
electric arc is a continuous stream of electron flowing between two electrodes into a
medium. This gives rise to intense heat generation. This is used to melt the surface and
deposit the metal from the electrode resulting in a joint on cooling.

Metal Arc Welding (MAW):

• It is also referred as consumable electrode arc welding.

• Arc is struck between the work and electrode which melts and furnishes
therequired feed metal.
• Both the rod and the work melt.
• Both AC and DC supply can be used.
• Arc supplies the required heat.
• The temperature and the heat input can be increased or decreased by
increasingor decreasing the arc current.
• High arc current and low arc length produces high intense heat.
• The metallic rod is normally coated with a flux.
• The flux coating melts and produces slag which covers the molten metal at the joint.
• The slag formed will also give the arc stability.
• An arc length of 0.6 to 0.8 times the electrode diameter yields high quality weld.

Flux Shielded Metal Arc Welding (FSMAW):

The welding is carried out manually, then it is referred to as Manual Metal Arc
Welding (MMAW).

Tungsten inert gas welding (TIG):

An arc is struck between the non-consumable tungsten electrode and the
workpiece in the presence of an inert gas such as helium or argon, which is passed near
the arc thereby creates a shield. This is referred to as Tungsten Inert Gas Welding (TIG).
A filler rod is used to supply molten metal to the joint. Fig. shows the TIG welding.
Pressure of the gas varies between 0.1 to 0.15 N/mm2. Mainly DC supply is used.
Advantages:

Suitable for thin metals

Clear visibility of the arc provides the operator to have greater control over the
weld.Strong and high quality of joints are obtained.
No flux is used, no slag formation, results in clean weld joint.

Disadvantages:

• TIG is most difficult process compared to all the other welding process.
• Skilled operator is required.
• Process is slower.
• Not suitable for thick metals.
Differences between MMAW and TIG welding processes:

Manual Metal Arc welding Tungsten Inert Gas welding.

MMAW utilizes a consumable electrode TIG utilizes a non-consumable electrode.
Filler material is supplied by electrode Filler metal is required to supply additionally
itself. by feeding a filer rod.
Electrode material is usually similar to base Electrode is made of tungsten having some
material. alloying elements. It is irrespective of base
material.
It is suitable for homogeneous welding It is suitable for autogenous welding. Can
only. also be performed in homogeneous and
heterogamous modes.
Electrode is coated with suitable flux. It utilizes bare electrode.
The flux coating of electrode disintegrates Shielding gas is supplied from external
during welding to produce shielding gas. source by means of pipeline and
torch/nozzle.
SMAW produces spatter during welding, TIG welding is free from spatter.
which hampers appearance.
It is comparatively fast process but joint It is not very fast process but can produce
quality is not very good. reliable, sound and good quality joint.
It is commonly employed in household and It is mostly used in industrial sophisticated
general industrial applications. joining requirements.
It is performed manually and the process is It can be performed either manually or using
quite easy. some automatic arrangements.