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Ancient Greece; bronze

statue casting circa 450BC
Iron works in early Europe,
e.g. cast iron cannons from
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England circa 1543
 
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wote: a good heat transfer reference can be found by

Prof John Lienhard online http://web.mit.edu/lienhard/www/ahtt.html 0
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^ and Casting ^ Investment Casting ^
ie Casting

High Temperature Alloy, High Temperature Alloy, High Temperature Alloy,
Complex Geometry, Complex Geometry, Moderate Geometry,
Rough urface Finish Moderately mooth urface mooth urface
Finish
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escription: Tempered sand is packed into wood or metal pattern
halves, removed form the pattern, and assembled with or without cores,
and metal is poured into resultant cavities. Various core materials can
be used. Molds are broken to remove castings. pecialized binders now
in use can improve tolerances and surface finish.
Metals: Most castable metals.
ize Range: Limitation depends on foundry capabilities. Ounces to many
tons.

Tolerances:
won-Ferrous Ú 1/32 to 6
Add Ú .003 to 3 , Ú 3/64 from 3 to 6 .
Across parting line add Ú .020 to Ú .090 depending on size.
(Assumes metal patterns)
urface Finish:
won-Ferrous: 150-350 RM
Ferrous: 300-700RM
Minimum
raft Requirements:
1° to 5°
Cores: 1° to 1 1/2°
wormal Minimum ection Thickness:
won-Ferrous: 1/8 - 1/4
Ferrous: 1/4 - 3/8
Ordering Quantities: All quantities
wormal Lead Time: 6
amples: 2-10 weeks
Production 2-4 weeks A. .A.

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Ôents, which are placed in

molds to carry off gases
produced when the molten
metal comes into contact with
the sand in the molds and core.
They also exhaust air from the
mold cavity as the molten metal
flows into the mold.
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The "
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lost-wax process, was first
used during the period
4000-3500 B.C. The pattern
is made of wax or a plastic
such as polystyrene. The
sequences involved in
investment casting are
shown in Figure 11.18. The
pattern is made by injecting
molten wax or plastic into a
metal die in the shape of
the object.

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escription: Metal mold makes wax or plastic replica. There
are sprued, then surrounded with investment material, baked
out, and metal is poured in the resultant cavity. Molds are
broken to remove the castings.
Metals: Most castable metals.
ize Range: fraction of an ounce to 150 lbs..

Tolerances:
Ú .003 to 1/4
Ú .004 to 1/2 ,
Ú .005 per inch to 3
Ú .003 for each additional inch
urface Finish:
63-125RM
Minimum
raft Requirements: wone
wormal Minimum ection Thickness:
.030 ( mall Areas)
.060 (Large Areas)
Ordering Quantities:
Aluminum: usually under 1,000
Other metals: all quantities
wormal Lead Time:
amples: 5-16 weeks (depending on complexity)
Production 4-12 weeks A. .A. (depending on subsequent
operations). 3Y
Talbot Associates Inc.
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Cycle in hot-chamber casting:
(1) with die closed and plunger
withdrawn, molten metal flows
into the chamber; (2) plunger
forces metal in chamber to
flow into die, maintaining
pressure during cooling and
solidification; and (3) plunger
is withdrawn, die is opened,
and solidified part is ejected.
Finished part is shown in (4).

30
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escription: Molten metal is injected, under pressure, into
hardened steel dies, often water cooled.
ies are opened,
and castings are ejected.
Metals: Aluminum, Zinc, Magnesium, and limited Brass.
ize Range: wot normally over 2 feet square. ome foundries
capable of larger sizes.

Tolerances:
Al and Mg Ú .002 /in.
Zinc Ú .0015 /in.
Brass Ú .001 /in.
Add Ú .001 to Ú .015 across parting line depending on
size
urface Finish: 32-63RM
Minimum
raft Requirements:
Al & Mg: 1° to 3°
Zinc: 1/2° to 2°
Brass: 2° to 5°
wormal Minimum ection Thickness:
Al & Mg: .03 mall Parts: .06 Medium Parts
Zinc: .03 mall Parts: .045 Medium Parts
Brass: .025 mall Parts: .040 Medium Parts
Ordering Quantities:
Usually 2,500 and up.
wormal Lead Time: 3J
amples: 12-20 weeks
Production: A AP after approval.
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^Chemical Activity 3000° C

^High Latent Heat Tungsten Carbide, WC,
ilicon Carbide, iC Cubic Zirconia, ZrO2

^Handling Molybdenum

^Off-gassing
Alumina Al2O3
2000° C
Platinum, Pt
Titanium, Ti
IronFE, Plain Carbon teels, low alloy, stainless
wickel, wi
wickel Allows ilicon, i

1000° C Copper, Cu, Bronze, Brass

Aluminum
Magnesium wylon
Zinc, Zn Acetal
PTFE (Teflon)
Tin, n
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PE 3|
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chematic illustration of three cast

structures solidified in a square mold:
(a) pure metals; (b) solid solution
alloys; and © structure obtained by
using nucleating agents. ource: G. W.
Form, J. F. Wallace, and A. Cibula

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