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Casting is the process of pouring a molten component into a mold cavity and freezing to obtain the desired component.
Conditions involved in casting
-> drag the box
-> Cope Box
-> Ceramic Plate
-> Mold Cavity
-> pour basin
-> locking pin
-> rolling pin
-> Parting Line
-> Sand Casting
The pattern is a replica of the final product that is desired.
1. The pattern should maintain its shape
2. The pattern should be easily at hand
3. Pattern should be light in weight
4. Paternas should have a smooth surface.
5. Pattern should be non-observer of moisture
6. The pattern should be easily machined
7. Pairn should be easily economical
Patterns can be made from different types of materials. Depending on the materials used to make the pattern, it will be used in various applications.
Ex: wood, metal, plastic, wax, mercury
Type of pattern
Patterns are classified based on their structure and usability.
1. Integrated / Single Piece Pattern
2. Two Pieces / Split Piece Pattern
3. Multi piece pattern
4.Cope and drag patterns
6. Plate Plate Pattern
7. Sweep Type Pattern
8 oversized patterns
9. Piece by piece pattern
Type of casting
Castings are classified based on the lifetime of the product.
Temperry is a type of casting in which the product can be taken as the base material. In this, the final shape can be obtained from the final product using different typed methods depending on the original material and the composition of the final product.
Permanent casting is a type in which the original product cannot be recovered from the final product. In this process the originally manufactured end product is using the original material.
A casting / pressure casting
In the cold chamber die casting process, the metal mold must have a high melting point. And the metal mold must have high metal thermal conductivity. Adding molten metal creates oxides for the interpretation of molecular gases. To reduce this, hot chamber die casting is used for low melting points of metals.
In centrifugal casting, when the mold cavity penetrates the molten metal the mold will be thrown towards the periphery of the cavity. By this process we will get the shape of the hollow component. The thickness of the component depends on the speed of rotation. And the centrifugal force depends on the mass of the molten metal. In this, heavy mass particles will move towards the perimeter due to the high applied centrifugal force on them.
The pinhole is sometimes called porcity. Pinholes are very thin holes. These are usually found in parts of the mold in poorly organized pockets. They appear in large numbers either on the surface or below the casting surface. They always appear to the naked eye. No equipment is required to identify them.
2. Surface Blow Hole
Blowholes or simply pores are larger pores than pinholes. A subsurface appears toward the flying cast and is usually not visible until after the match.
3. Open hole
These blow holes appear on the surface of the cast and are simpler than surface blowholes.
Causes and prevention of gas vents
-> Mold and core deterioration.
-> Inadequate drying of molds and cores