C- Shell Molding and Die Casting

Question 1

What is the casting process of developing a mold cavity surrounded only by a very thin layer of refractory material to then fill with molten metal?

Answer 1

SHELL MOLDING

Question 2

What must the PATTERNS used in SHELL MOLDING be made of?

Answer 2

METAL, only used if large numbers of the part are to be produced.

Question 3

How are the METAL PATTERNS made?

Answer 3

SAND CASTING

Question 4

What is a box containing the sand and resin mixture, which is attached to the METAL PATTERN?

Answer 4

DUMP BOX

Question 5

What are the pins on the pattern plate are used to remove the shell from the plate?

Answer 5

EJECTOR PINS

Question 6

What are the ADVANTAGES of SHELL MOLDING (over sand casting)?

Answer 6

Thin shells (fast cooling, flexible, good gas permeability), low sand volume (compared to sand casting), surface finish, lightweight, fewer flaws.

Question 7

An EXPENDABLE MOLD process that involves wax. Investment means to “DIP”.

Answer 7

INVESTMENT/LOST WAX CASTING

Question 8

What is a process to make wax patterns. Usually for making items such as rings and jewelry with organic shapes.?

Answer 8

WAX CARVING

Question 9

What is a method of creating plastic parts and wax patterns in very large numbers?

Answer 9

INJECTION MOLDING

Question 10

What is an assembly of wax elements including the patterns, which will eventually become an entire casting system with a pouring basin, sprue, runners, and mold cavities.?

Answer 10

TREE

Question 11

What are the TREES dipped into?

Answer 11

STUCCO or CERAMIC SLURRY

Question 12

What is the process of removing the wax from their surrounding ceramic shells?

Answer 12

MELT OUT

Question 13

What is a method of separating the ceramic shell and the metal tree?

Answer 13

SHAKE OUT

Question 14

What is a process similar to lost wax/ investment casting, but with STYROFOAM.

Answer 14

LOST FOAM CASTING/ EVAPORATIVE FOAM CASTING/ EXPANDED POLYESTERENE PROCESS

Question 15

What is one of the best aspects of LOST FOAM CASTING?

Answer 15

Hollow parts can be made WITHOUT CORES.

Question 16

What are casting processes where the mold can be utilized over and over again?

Answer 16

PERMANENT MOLD CASTING (usually made of tool steel or graphite)

Question 17

What is the process of using metal molds for permanent mold casting?

Answer 17

DIE CASTING

Question 18

What is a metal mold used in CASTING?

Answer 18

A DIE

Question 19

What are retractable metal CORES that are pushed into the die cavity to inject out the metal parts?

Answer 19

CORE PULLS

Question 20

What are mechanical plungers used to pop out the walls of the die cavity and kick out the part?

Answer 20

EJECTOR PINS

Question 21

What is used in conjunction with the hydraulically actuated CLAMPING SYSTEM required to keep the two die halves closed?

Answer 21

TOGGLE LOCK

Question 22

Which method requires the metal CHARGE to be placed in the SHOT TUBE (chamber) ahead of the piston?

Answer 22

COLD CHAMBER

Question 23

Which die casting method maintains a reservoir of molten metal as part of the machine?

Answer 23

HOT CHAMBER

Question 24

How is the PRESSURIZED INPUT of metal achieved?

Answer 24

By using a PISTON (straight cylinder) or PLUNGER (gooseneck system)

Question 25

What are the six attributes required for successful DIE CASTING?

Answer 25

PRESSURIZED METAL INPUT (shot charge)
VENTING/VALVE SYSTEM
CLAMPING/LOCKING SYSTEM
EJECTOR PIN SYSTEM
CORE PULLS
COOLING SYSTEM