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manufacturing techniques > casting > Flashcards

casting Flashcards

1
Q

cope

A

the top part of the mould

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2
Q

drag

A

the bottom part of the mould

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3
Q

pouring cup

A

the entrance for the moulten metal

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4
Q

sprue

A

channel used to deliver moulten metal

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5
Q

gating system

A

channel used to deliver material to mould cavity

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6
Q

riser

A

extra void

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7
Q

parting line

A

interface seperati g cope and drag

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8
Q

core

A

sand or metal shape used tpo produce internal feature of a casting

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9
Q

mould cavity

A

the space to be filled with moulten mmaterial

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10
Q

draft

A

tapers on the cast that permits casting to be withdrawn

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11
Q

sand casting

A

uses pattern of final casting pressed into sand to create a mould caVITY WITH A RISER AND A SPRUE

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12
Q

sand casting pro

A

low cost, almost all types of materials can be cast, no limit on max wieght, complex shapes,

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13
Q

sandcasting cons

A

HIGH POROSITY ROUGH SURFace finish , llow dimensional accuracy

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14
Q

invessstment casting

A

a type of disposable mould casting where wax pattern is made from a modified replica of product that is coated in ceramic powder the wax is then melted away and MM is filled in the shel is then broken off usually with vibration

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15
Q

investment casting pro

A

excellent surface finish ,high dimensional accuracy almost unlimited intricasey most metals can be used no parting line concerns

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16
Q

investment casting cons

A

costly patterns and moulds high labour time consuming

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17
Q

slush casting

A

moulertn metal is poured into a metal mould the when the desired thickness of the skin is obtained mould is inverted and remaining MM poured out then casting is removed

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18
Q

slush casting app,iscations

A

used to create thin walled objects that are often decorational oftenused in theatre for props

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19
Q

pressure castingg

A

MM forced upward by gas pressure of vaccuum and this pressure is maintained intil solidification see(https://vle.shef.ac.uk/bbcswebdav/pid-3159519-dt-content-rid-8843518_1/courses/MEC130.A.180071/Man%20Tech%20Lecture%203%20%28PJS%29%202017.pdf) page 7

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20
Q

pressure casting pro

A

avoids rapin oxidisaton promotes directioonal cooling ( top down)

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21
Q

pressure casting con

A

long cycle time

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22
Q

die casting hot chamber

A

injection syustem forces MM out of hot chamber through a gooseneck uinto the die cavity where mm rapidly solidifies dies are usually cooled with liquid to improve die life

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23
Q

hot chamber pro

A

no open tranfer of MM fast cycle time goood product strength , exellent dimensional accuracey and Surface finish,

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24
Q

hot chamber cons

A

expensive requires a high production rate cannot be used for mTERIALS WITH A VERY HIGH MP

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25
Q

die casting cold chamber

A

injection syustem forces MM through a gooseneck into the die cavity where mm rapidly solidifies dies are usually cooled with liquid to improve die life. the differenec is that the mm is transported from a seperate melting place

26
Q

cold chamber pro

A

good dimensional presision

good surfavec finish

27
Q

cold chamber cons

A

expensive dies
requires a high production rate
trabsport of MM required

28
Q

centrefugal casting

A

MM poured into a rotating mould
inertial force distriobutes mm into the mold cavitys
metal helld against waall till cooling takes place

29
Q

true centrefugal cadsting

A

inner surface remains cylindrical used to produce hollow objects like pipeds or gun barrels https://www.youtube.com/watch?v=ZxVA-htTunU

30
Q

semi centrefugal casting

A

used to cast parts with rotaitonal symetry

31
Q

centriguging

A

spins forcing mm into die on outside of centriguge

32
Q

centrifuging pro

A

wide range of cylindrical parts

good dimensional accuracy

33
Q

centrifuging con

A

shape limited to cylindrical stuff mostly

expensive spinning equiptment

34
Q

single crystal caasting

A

czochraiski proccess in wich a seed of a single crystal of sillicon contacts the topp of molten sillicon as seed is raised atoms of the ms sooolidify in the seeds pattern

35
Q

single crystal pro

A

very low thermal creepused for high tempreture stuff

36
Q

single crystal con

A

slow and expensive

37
Q

powder metalurgy

A

powdered metals are blwnded then compacted (hot compaction=isostatic) then sintered.

38
Q

powder metalurgy pro

A

no waste material
only need semi skilled labour
requires little to no finishing

39
Q

atomisation

A

liquid metall broken up by jets of inert gas or water. size of particle producd depends on jet flow characteristic and temp of mm

40
Q

reduction

A

metal oxides reduced by gas like co or h2 to produce uniformly spongy porous powder

41
Q

electrolytic deposition

A

uses aquius solution or fused salts to produce a very pure poweder

42
Q

comminution

A

mechanical proccess involving crushingg milling or grinding

43
Q

blending (for powder metalurgy

A

powders are mixed with lubricants or other metals and blended to create uniform sized particless with desirable mechaniceal propertys

44
Q

cold isostatic pressing

A

metal powders placed in rubber mould and pressed hydrostaticlaly

45
Q

hot isostatic pressing

A

inert gAS USED AS a pressurising medium to produce excellent density ND good metalurgic bonding so good mechanical properties

46
Q

powder rolling

A

powders pressed between gap with rollers compacting into a continous strip

47
Q

extrusion

A

powders are placed inn a metal die and extruded

48
Q

injection mouldiing

A

very fine metal powder blended with polymer or wax then pressed into shape then put in oven to remove polymer binder complex shapes easily produced

49
Q

sintering

A

compressed metal powder heated ib controlled temp below melting point to increse strength and density and electrical and termal conductivity however the compact does shrink

50
Q

forging

A

a workpiecce is shaped by compressive forces

51
Q

coining

A

a type of forging proccess where a slug is completely inclosed in the die used to increse strength and surface finish

52
Q

infiltration

A

slug of lower mp placed against the sintered metal infiltrates pores with capillary action

53
Q

plating

A

a coating proccess that impaets resistance to were and corrosion

54
Q

economics of powder mettalurgty

A

eliminates need for many secondary finishng
initial die and equiptment cost is high
generally at least 10,000 production rate required

55
Q

continous casting

A

https://www.youtube.com/watch?v=SgAhwgyBsyM

56
Q

tundish

A

bith where molten metal in continous casting is poured reduce inclusion by maximising residence time

57
Q

mould for coniuos casting

A

copper and water coold lubricated with a mould flux and is the primary source of heat extraction

58
Q

mould powder / flux

A

provides uniform cooling protects ffrom oxidisation and absorbs inclusions

59
Q

gross cracks

A

up to 400mm long assosiated with poor mould level control

60
Q

sub surface cracks

A

prevelent in medium carbon steal thermal shrinkage results in a uneven shell

manufacturing techniques (3 decks)

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