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production > Metal Casting > Flashcards

Metal Casting Flashcards

1
Q

What materials can be used in metal casting?

A

1-pure metals: aluminum and magnesium 2-non ferrous alloys: copper 3-ferrous alloys: iron, steal

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2
Q

what are the steps of metal casting?

A

1-Design: material, surface finish, dimensions and volume 2-Casting using mold/pattern 3-inspection

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3
Q

what are the considerations for creating cavity?

A

1-Bigger size for metals 2-Shrinkage for metal removal 3-draft angle

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4
Q

what are the two types of molds? give examples.

A

1-Expendable molds: sand, investment, shell 2-permenant molds: die, continuous, centrifugal

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5
Q

explain the sand casting processes

A

1-replica making: making replica of the object using wood or plastic 2-mold making: by closing cope and drag 3-casting: pouring molten metal using runners 4-cooling: leaving metal to cool at room temp. 5-removal: breaking the mold and extracting the metal

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6
Q

Why is refractory clay used in sand casting?

A

to make the sand more solid

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7
Q

where does the runner system lie in the sand casting process?

A

below the parting line

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8
Q

what are the functions of the riser?

A
  1. indicates complete filling of the mold
  2. venting to reduce humidity in mold
  3. venting gases
  4. compensate for shrinkage
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9
Q

what is the function of the draft angle?

A

allow easy removal of metal from pattern

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10
Q

what are the common defects in sand casting what are their causes?

A
  • mismatch: misallignment between cope and drag
  • incomplete mold filling (misrun): molten metal cooles too quickly, not enough material, problem in ruuners.
  • flashes: excess metal at parting line
  • blowholes: humidity and gases trapped because of lack of venting
  • inclusions: weak sand
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11
Q

what are the applications of sand casting?

A

bulky and low cost products: ex. Machine tool beds • Pistons • Mill rolls • Manhole covers • Wheels • Housings

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12
Q

what are the advantages of sand casting?

A
  1. produce large products
  2. cheap
  3. used with any metal
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13
Q

what are the disadvantages of sand casting?

A
  1. poor surface finish
  2. low dimensional accuracy
  3. lots of waste
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14
Q

describe the investment casting process?

A
  1. dip in ceramic mold
  2. leave to dry
  3. put in oven to remove wax
  4. mold is made of ceramic and pattern made out of wax
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15
Q

what are the applications of investment casting?

A

• Jewelry • Surgical Implants • Aerospace • Military Equipment • Special Automotive Parts

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16
Q

what are the advantages of investment casting?

A
  • produces products which are small and thin and complicated
  • high mechanical accuracy
  • great surface finsih
17
Q

what are the disadvantages of investment casting?

A
  • expensive
  • can’t produce large products
  • requires skill to operate
18
Q

describe shell mold casting?

A
  1. pattern is inserted into sand
  2. the whole thing is flipped
  3. put in the oven to dry
  4. pattern made of metal
  5. mold made out of sand
19
Q

what are the applications of shell mold casting?

A

large copmlex objects: • Cylinder Heads • Bearing Housings

20
Q

advantages of shell mold casting?

A
  • mass production
  • good surface finish
  • high dimensional accuracy
21
Q

disadvantages of shell mold casting?

A
  • expensive equipment and material
  • limited product weight
  • gating must be part of the mold
22
Q

describe pressure die casting?

A
23
Q

advantages of pressure die?

A
  • low cost
  • small products
  • great surface finish
  • high dimensional accuracy
  • economical
24
Q

disadvantages of pressure die?

A
  • expensive
  • limited shapes
  • require high investment cost
25
Q

describe centrifugal casting?

A

uses centrifugal force to form cyrindical shapes

26
Q

applications of centrifugal casting?

A

Pipes for water, gas and sewage • Pulleys • Piston rings • Rolls

27
Q

applications of pressure die?

A

Automotive Parts • Aerospace Castings • Electric Motors housings • Pressure Cookers • Pumps Parts

28
Q
A
29
Q

advantages of centrifugal casting?

A
  • large parts
  • low cost
  • great surface finish
30
Q

disadvantages of centrifugal casting?

A
  • limited length/shape
  • long time
31
Q

continuous casting

A
32
Q

applications of continuous casting?

A

Production of Steel • Aluminum and Copper billets • Blocks and bars

33
Q

advantages of continuous casting?

A
  • cheap and easy
  • unlimited length
34
Q

disadvantages of continuous casting?

A
  • simple geometry
  • Very poor geometrical tolerances

production (8 decks)

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