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Preface ix
1. Introduction 1
1. Introduction 1
2. History of Metalcasting 2
3. Metal casting methods 4
4. Expendable Mold Casting 9
5. Metal casting steps 16
6. Elements of the Gating System 17
7. Advantages and Disadvantages of Metal Casting 18
8. Epilogue 19
References 20
2. Patterns 23
1. Introduction 23
2. Materials of Casting Pattern 24
3. Casting Pattern Allowances 24
4. Materials Used 27
5. Types of Patterns in Casting 27
6. Epilogue 35
References 36
3. Molding Processes and Materials 40
1. Introduction 40
2. Difference Between Molding and Casting 41
3. Various type of Molding 43
4. Epilogue 51
References 52
4. Molding Processes Equipment and Mechanization 56
1. Introduction 56
2. Molding Machines 58
3. Injection Moulding 71
vi Principles of Metal Casting
4. Injection Moulding Machine 83
5. Epilogue 96
References 97
5. Solidification of Metals and Alloys 99
1. Introducton 99
2. Casting and solidification 101
3. Directional Solidification 101
4. Properties of Interfaces 103
5. Nucleation 104
6. Crystal Growth in Vapours 114
7. Mould Feeding Issues 127
8. Freezing characteristics of alloys 129
9. Faceted and Dendritic Solidification Structures 131
10. Epilogue 140
References 141
6. Gating and Risering of Castings 145
1. Introduction 145
2. Elements of Gating System 151
3. Gating Element Design 161
4. Gating Channel Layout 163
5. Epilogue 178
References 179
7. Casting Process Simulation 183
1. Introduction 183
2. Using Casting Process Simulation at a Early Stage 184
3. Casting Simulation Software 185
4. Application of casting simulation software 187
5. CAE (Computer-Aided Engineering) 189
6. Operational Methodology of simulation software 190
7. Epilogue 192
References 193
8. Aluminum and Aluminum Alloys 195
1. Introduction 195
2. Physical characteristics 196
3. Chemistry 198
4. Aluminium Alloy 212
5. Aluminium Casting Techniques 227
6. Epilogue 245
References 245
Contents vii
9. Copper and Copper Alloys 249
1. Introduction 249
2. Occurrence, Uses, And Properties 250
3. Copper Extraction 255
4. Copper Alloys 263
5. Brass Casting 267
6. Brass Die Casting 268
7. Epilogue 270
References 271
10. Magnesium and Magnesium Alloys 275
1. Introduction 275
2. Characteristics 276
3. High pressure die casting 290
4. Vacuum-assisted die casting 295
5. Gravity casting 297
6. Sand casting 297
7. Types and Designation 300
8. Epilogue 304
References 305
Index 309
Metal casting is a modern technique with a long history. Metal shapes are made in the metal casting process by pouring molten metal into a mould cavity, where it cools before being retrieved from the mould. Metal casting is one of history's oldest and most impactful industrial processes. Almost every mechanical equipment we use today, from vehicles to washing machines, is made with metal pieces formed by the casting process. Furthermore, metal casting foundries use metal recycling as a cost-effective supply of raw material, lowering the amount of scrap metal that ends up in landfills. The precision and tolerances that can be reached through the computerised automated design process, as well as current means for making complex cores and moulds, distinguish today's cast metal goods from those created even 100 years ago. Metal casting in the modern era is an example of innovation at work.
This book is an attempt to comprehend and consolidate the scattered knowledge on metal casting. The chapters in this book cover a wide spectrum of scientific disciplines such as patterns, moulding processes, mechanization and solidification of metals. It also narrates key challenges and opportunities in risering of castings, casting process simulation, aluminium alloys and magnesium alloys. The book would not only serve as a reference but also as a guide and inspiration for shaping future research on metal casting. It studies, analyses and upholds the pillars of this subject area and its utmost significance in modern times. The various subfields of engines along with technological progress that have future implications are glanced at in it. The book is appropriate for those seeking detailed information in this area.
Reagan Rush is a Senior Lecturer at Community College, Chichester. He holds Ph.D. in Mechanical Engineering Institute of Technology, Sydney. He has contributed numerous articles and technical papers in international journals, conference proceedings and trade magazines. He has also been an invited speaker at various international production management conferences. His research work in the field of smart materials and alloys has won him several awards.