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Name: (Full name) Date Submitted: (mm/dd/yyyy)
Subject: MTec 121 Workshop Theory and Practice Schedule: M, 9AM-12PM
Laboratory Exercise No. 6:
Foundry and Metal Casting
I. Introduction
Foundry refers to a factory or facility where metals are melted and poured into molds to
create specific shapes or components. Metal casting, also known as foundry work, is one of
the oldest and most versatile manufacturing processes. It involves the creation of metal
objects by pouring molten metal into molds that have the desired shape of the object.
Casting is an essential process used in various industries like automotive, aerospace,
construction, and heavy machinery, as it enables the production of complex shapes that would
be difficult or costly to make using other manufacturing methods. It is particularly useful for
large and intricate components that require durability and strength, such as engine blocks,
turbine blades, and structural components.
II. Theoretical Background
Foundry and metal casting involve the process of pouring molten metal into molds to create
solid components. This process is governed by several theoretical principles drawn from
material science, thermodynamics, and fluid dynamics.
1. Material Behavior and Phase Transformation
Solidification: As molten metal cools, it transitions from liquid to solid, following a
cooling curve influenced by the alloy composition and cooling rate. Slow cooling creates
larger grains and lower strength, while rapid cooling results in finer grains and higher
strength.
Phase Diagrams: Phase diagrams, like the iron-carbon phase diagram, are crucial in
understanding the solidification and properties of alloys during cooling, helping predict
material behaviors and the formation of phases.
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2. Fluid Dynamics and Heat Transfer
Flow of Molten Metal: The molten metal must flow smoothly into the mold to fully fill
the cavity. Factors like mold material, pouring temperature, and viscosity affect this flow.
Poor flow can lead to defects like cold shuts or incomplete filling.
Heat Transfer: During solidification, heat is transferred from the molten metal to the
mold, influencing the cooling rate and the final microstructure. The cooling rate controls
the material properties, such as strength and hardness.
3. Casting DefectsCommon defects include:
Porosity: Air trapped in the metal causes voids, weakening the casting.
Shrinkage: Metal contracts as it solidifies, causing internal voids or cracks.
Cold Shuts: When molten metal streams fail to merge, creating weak spots.
Misruns: Occur when the mold isn't fully filled before the metal solidifies.
4. Casting Design Considerations
Gating System: The design ensures smooth metal flow into the mold.
Risers: These compensate for shrinkage during solidification, preventing defects.
By understanding these principles, foundry engineers can optimize the casting process to
produce high-quality, defect-free components.
III. Materials and Methods
Laboratory guide, pen
YoutTube Video: [Link]
IV. Data Analysis & Discussion
Task1: The Sand molding process Objective:
1. To create a comprehensive procedure for the sand molding process.
Process:
Step 1: Creating Patterns
Making a pattern, or exact duplicate of the intended casting, is the first stage in the sand
casting process. Materials such as wood, metal, or plastic can be used to make it. To
guarantee a high-quality casting, the pattern needs to be precise and flawless.
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Step 2: Putting the Mold Box Together
A flask, which is a two-piece mold box, is used to hold the pattern. The flask is composed of
The cope (top half) and the drag (bottom half) are the two parts. The design is situated within
the drag to form the casting into the required shape.
Step 3: Filling and Preparing the Molding Sand
Sand and a binding agent are combined to create molding sand. It is packed around and wet.
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The mold cavity-forming pattern. Sand
needs to be well packed to guarantee that the molten metal's pressure can be tolerated by the
mold.
Step 4: If required, core assembly
Cores are put into the mold if the casting needs interior holes or cavities. Cores are
composed of sand and are molded to give the casting the appropriate internal characteristics.
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Step 5: Pouring and Mold Assembly
After positioning the cope on the drag, the two pieces are fastened together to create a full
mold. A sprue hole, a conduit that goes to the mold, is filled with molten metal cavity. The
metal fills the mold cavity after passing through the sprue, taking on the shape of the pattern.
Step 6: Cooling and Solidification
The molten metal is left to cool and harden inside the mold. The duration of cooling varies
depending on the casting's size and material.
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Step 7: Mold Removal and Finishing
After the metal has solidified, the mold is broken open, and the casting is taken out. Excess
sand is cleaned off, and the casting may undergo additional finishing steps, such as
machining or polishing.
Safety Considerations
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PPE: Always wear safety glasses, heat-resistant gloves, and protective clothing to avoid
injuries.
Molten Metal Hazards: Be cautious of burns, spills, and explosions; ensure tools and
molds are dry before use.
Procedures: Adhere to all safety guidelines, use equipment correctly, and report any
hazards immediately.
V. Conclusion
Foundry and Metal Casting Foundry and metal casting are essential manufacturing processes
that play a crucial role in creating complex, durable components used in a variety of
industries, including automotive, aerospace, and construction. By understanding the key
principles such as material behavior, solidification, heat transfer, and fluid dynamics,
engineers can optimize casting techniques to produce high-quality, defect-free products.
Proper design considerations, including gating systems and risers, help prevent common
casting defects, while careful pattern making ensures accuracy and precision. As the industry
evolves, advances in technology, materials, and process control continue to improve the
efficiency and quality of metal casting. With its ability to produce intricate shapes and strong
materials, metal casting remains a foundational process in modern manufacturing.
VI. References
[Link]
[Link]
[Link]
[Link]
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