Casting Flashcards

1
Q

What is the 1st key part of sand casting?

A
  1. Pattern creation - pattern, usually made of wood or metal, is made into the shape of the desired final product
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2
Q

What is the 2nd key part of sand casting?

A
  1. Mould preparation - two-part mould box is created around the pattern forming an impression in the sand. The pattern is then removed leaving a cavity
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3
Q

What is the 3rd key part of sand casting?

A
  1. Core formation - cores are made from sand or other materials to create internal shapes within the final casting
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4
Q

What is the 4th key part of sand casting?

A
  1. Meting and pouring - metal, brass or iron is poured into the cavity through a sprue
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5
Q

What is the 5th key part of sand casting?

A
  1. Solidification - metal cools and solidifies within the sand mould, taking the shape of the cavity and patterns design
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6
Q

What is the 6th key part of sand casting

A
  1. Cooling and removal - the sand mould is broken apart after the metal has cooled, excess material is removed and the final piece undergoes finishing processes
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7
Q

What are some advantages of sand casting?

A
  • versatile
  • cost-effective
  • material flexibility
  • suitable for high and low volume production
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8
Q

What are some disadvantages of sand casting?

A
  • may require additional processes to achieve a good surface finish
  • limited detailing
  • environmental impact
  • gas pockets or air entrapment in the mould
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9
Q

What is die casting? What are the two different types?

A

A process used to create metal parts by forcing molten metal into a mould under high pressure. The two types are:
- hot chamber die casting (ideal for metals with low melting points)
- cold chamber die casting (ideal for metals with high melting points)

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10
Q

What is the 1st part of the die casting process?

A
  1. Die preparation - two halves of the die are prepared which are made of hardened steel and are precisely machined to form desired shape of the final part
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11
Q

What is the 2nd part of the die casting process?

A
  1. Melting - the metal is melted in a furnace at high temps.
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12
Q

What is the 3rd part of the die casting process?

A
  1. Injection - for hot chamber, molten metal is automatically fed into the die using a piston system. For cold chamber, molten metal is ladled into the shot chamber and then injected into the die under high pressure
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13
Q

What is the 4th part of the die casting process?

A
  1. Cooling & solidification - once the metal fills the cavity, it is allowed to cool and solidify in the mould
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14
Q

What is the 5th part of the die casting process?

A
  1. Ejection - the two halves of the die are separated and the newly formed part is ejected. Excess material is trimmed.
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15
Q

What is the 6th part of the die casting process?

A
  1. Finishing - any necessary additional processes are carried out
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16
Q

What are some advantages of die casting?

A
  • high efficiency
  • excellent surface finish
  • cost effective for high volumes
  • strength and durability
  • reduced waste
17
Q

What are some disadvantages of die casting?

A
  • high initial tooling costs
  • material and design limitations
  • surface imperfections
18
Q

What is resin casting?

A

The pouring of liquid resin into a prepared mould, allowing it to solidify and take the shape of the mould.

19
Q

What is the 1st part of the resin casting process?

A
  1. Mould preparation - often made of silicone and is created from an existing object
20
Q

What is the 2nd part of the resin casting process?

A
  1. Resin mixing - resin is mixed with a hardening agent or catalyst. The mixture can include dyes or additives.
21
Q

What is the 3rd part of the resin casting process?

A
  1. Pouring - the mixture is carefully poured into the mould and vacuum chambers may be used to get rid of air bubbles and ensure the resin completely fills the mould.
22
Q

What is the 4th part of the resin casting process?

A
  1. Curing - the resin is left to cure and harden
23
Q

What is the 5th part of the resin casting process?

A
  1. Demoulding - once hardened, the solidified resin is removed from the mould and finishing touches may be required
24
Q

What are some advantages of resin casting?

A
  • easy to use
  • intricate detailing
  • colour customisation
  • lightweight
25
Q

What are some disadvantages of resin casting?

A
  • Low durability
  • can be sensitive to high temps
  • can be brittle
  • UV sensitive