METAL CASTING AND MOLDING PROCESSES

Question 1

involve shaping molten metal by
pouring it into molds, which determine the final form after cooling and solidification.

Answer 1

Metal casting and Molding processes

Question 2

Molten metal poured into a
sand mold to form complex shapes.

Answer 2

Sand Casting

Question 3

refers to the sand molds formed from wet sand and is sometimes referred to as clay. The disadvantage is that sand is a soft mold that can collapse or shift during casting.

Answer 3

Green sand casting

Question 4

Sand mold is baked at a given temperature to make it stronger. (form of green sand)

Answer 4

Dry sand casting

Question 5

molding material is a blend of quartz sand and resin sand. When resin sand is mixed and heated, it hardens into a solid, smooth mold. A solid mold produces fewer faulty castings, but it comes at a greater cost and a slower production rate.

Answer 5

Resin Sand Casting

Question 6

Molten metal is poured into a rotating mold, using centrifugal force for uniform distribution.
EXAMPLES:
1. Cylindrical parts for oil and gas.
2. High-precision machine
components.

Answer 6

Centrifugal Casting

Question 7

Types of Centrifugal Casting (3)

Answer 7

1. True centrifugal casting: Pipes,
   tubes, rings.
2. Semi-centrifugal casting:
   Gears, pulleys, wheels.
3. Centrifugal shell casting:
   Turbine blades, thin-walled parts.

Question 8

Molten metal is poured into reusable molds for high-volume production.
EXAMPLES:
1. Automotive (e.g., pistons,
engine blocks).
2. Aerospace structural parts.
3. Consumer goods and
cookware.

Answer 8

Permanent Mold Casting

Question 9

using molds made of plaster to create detailed shapes, ideal for small-scale production of complex parts.

Answer 9

Plaster-Mold casting

Question 10

EXAMPLES:
1. Prototypes: Aircraft and
automotive prototypes.
2. Complex parts: Lock parts, gears,
and housings.
3. Artistic items: Sculptures and
decorative objects.

Answer 10

Plaster-Mold Casting

Question 11

Also called lost-wax casting, it involves creating a wax pattern, coating it with ceramic, removing the wax, and pouring molten metal. It delivers high
precision and complexity.

Answer 11

Investment Casting

Question 12

EXAMPLES
1. Aerospace: Turbine blades and
structural components.
2. Engine components like rocker
arms.
3. Surgical instruments and
implants.
4. Intricate gold and silver pieces.
5. Valve components and machine
parts.

Answer 12

Investment Casting