Sixth National Foundry Conclave
01-02 March 2013 : Hotel Le Meridien : Coimbatore
Topic : Design & Methoding Of Steel Castings
Presented By : Mr. V.S. Jayabal , M.Tech.,
Managing Director , JRE Valves & Pumps (P) Ltd.,

The Birth of the casting
By V.S.J

My IIT Programme , in the Foundry Technology ,
M.Tech , Started with this story , as told by my respected Professor in the year of Aug 1970.
By V.S.J

Fundamentals of Casting
Casting processes basically involve the introduction of a molten metal into a mold cavity, where upon solidification, the metal takes on the shape of the mold cavity.
Simple and complicated shapes can be made from any metal that can be melted.
Example of cast parts: frames, structural parts, machine components, engine blocks, valves, pipes, statues, ornamental artifacts…..
Casting, one of the oldest manufacturing processes, dates back to 4000 B.C. when copper arrowheads were made.
By V.S.J

Product Design Considerations
 Geometric simplicity:
– Although casting can be used to produce complex part geometries, simplifying the part design usually improves castability
– Avoiding unnecessary complexities:
 Simplifies mold-making
 Reduces the need for cores
 Improves the strength of the casting
 Corners on the casting:
– Sharp corners and angles should be avoided, since they are sources of stress concentrations and may cause hot tearing and cracks
– Generous fillets should be designed on inside corners and sharp edges should be blended
By V.S.J

Product Design Considerations
 Minor changes in part design can reduce need for coring
Design change to eliminate the need for using a core:
(a) original design, and (b) redesign.
By V.S.J

Product Design Considerations
By V.S.J

Gating System
By V.S.J

5.
6.
3.
4.
1.
2.
7.
8.
The Following Points Shall be considered , before selecting the parting line
Dimensional consistency
Padding & Feeder Locations .
Reduce the no. Of cores as much as possible.
The Fettling shop work , must be minimized as much as possible.
Preferable to go for a aluminum Patterns .
Wherever not possible , wood / Aluminum construction can be used.
Ex. Ribs , bosses , changeable flanges can be made with
Aluminum.
Multiple patterns depending up – on the quantum requirements.
By V.S.J

1.
2.
3.
4.
5.
It’s Preferable to match plate the patterns with runners , risers incl. filters & Integral test bars , wherever reqd.
It’s always a good idea to have the integral test bars for the castings weighing ex. 700 Kg’s & above.
Chill Pattern need to be made for each & every application.
Suitable Colour coding is Preferable.
Method Drgs must be referred every time.
By V.S.J

1. Design suitability for the foundry purpose.
2. The Application of the casting
3. Working Medium.
By V.S.J

 Preparing a mold cavity of the desired shape with proper allowance for shrinkage.
 Melting the metal with acceptable quality and temp.
 Pouring the metal into the cavity and providing means for the escape of air or gases.
 Solidification process, must be properly designed and controlled to avoid defects.
 Mold removal.
 Finishing, cleaning and inspection operations.
By V.S.J

 Most widely used casting process, accounting for a significant majority of total tonnage cast
 Nearly all alloys can be sand casted, including metals with high melting temperatures, such as steel, nickel, and titanium
 Castings range in size from small to very large
 Production quantities from one to millions

Buoyancy in Sand Casting Operation
 During pouring, buoyancy of the molten metal tends to displace the core, which can cause casting to be defective
 Force tending to lift core = weight of displaced liquid less the weight of core itself
F b
= W m
W c where F b
= buoyancy force;
W m
= weight of molten metal displaced; and
W c
= weight of core
This Buoyancy effect can be avoided , with the proper design of the Core Print ; In worst cases by Chaplet.

Fluidity of Molten Metal
Fluidity :
The capability of a molten metal to fill mold cavities
Viscosity :
Higher viscosity decreases fluidity
Surface tension :
Decreases fluidity; often caused by oxide film
Inclusions :
Insoluble particles can increase viscosity, reducing fluidity
Solidification pattern :
Fluidity is inversely proportional to the freezing temperature range
By V.S.J

Fluidity of Molten Metal
Mold design :
The design and size of the sprue, runners, and risers affect fluidity
Mold material and surface :
Thermal conductivity and roughness decrease fluidity
Superheating :
The temperature increment above the melting point increases fluidity
Pouring :
Lower pouring rates decrease fluidity because of faster cooling
Heat transfer :
Affects the viscosity of the metal
Increasing Fluidity :
The fluidity of the Steel can be increased by Micro level additions of Cerium Mishmetal.
By V.S.J

Types Of Solidification
1. Mushy Formation
2. Directional Solidification
By V.S.J

Solidification contraction for various cast metals
Metal or alloy
Aluminum
Al-4.5% Cu
Al-12% Si
Carbon steel
1% Carbon steel
Copper
Volumetric solidification contraction %
6.6
Metal or alloy
70% Cu-30% Zn
Volumetric solidification contraction %
4.5
6.3
90% Cu-10% Al 4
3.8
2.5-3.0
Gray Iron
Magnesium
Expansion to 2.5
4.2
4
4.9
White iron
Zinc
4.0-5.5
6.5
By V.S.J

Pure Metals / Alloys
Pure metals solidify at a constant temperature;
By V.S.J

Pure Metals / Alloys
Alloys solidify within a temperature range
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Directional Solidification Pattern of Quartz
Growth of Dendrites
By V.S.J

Solidification Time
The solidification time is a function of the volume of a casting and its surface area.
Solidification time = C ( volume / surface area) 2 , (1)
Where C is a constant that reflects mold material, metal properties and temperature . Thus large sphere solidifies and cools to ambient temperature at a much slower rate than dose a smaller sphere.
By V.S.J

Solidification Time
Example:
Solidification times for different shapes:
Three pieces being cast have the same volume but different shapes.
One is a sphere ; one is a cube , and the other a cylinder with a height equal to its diameter.
Which piece will solidify the fastest and which one the slowest?
The volume is unity, so we have from equation (1):
Solidification time = 1 / surface area
The respective surface areas are:
Thus the respective solidification time’s t are
Sphere
: V = (4/3) лr 3 , r = (3/4 л) 1/3 ,
And A = 4 лr 2 =4 л (3/4 л) 2/3
= 4.84
; t sphere
= 1 / (4.84
2)

0.043 C ,
Cube: V = a 3 , a = 1,
A = 6a 2 = 6 ; t cube
= 1 / (6 2 )

0.028 C , t cylinder
= 1 / ( 5.54
2) 
0.033 C .
Cylinder: V = лr 2 b = 2 лr 3 , r = (1/2 л) 1/3 , and
A = 2 лr 2 + 2 лrb = 6 лr 2 = 6 л(1/2 л) 2/3
= 5.54
Hence , For Feeding We are using Cylindrical Feeders , instead of Sphere feeders ; Because Sphere is having a Slow Solidification Time.
By V.S.J

Types Of Shrinkages
1. Liquid to Liquid shrinkage
2. Liquid to solid Shrinkage
Risers
Risers
3. Solid Shrinkage Pattern contraction allowance
By V.S.J

Shrinkage
Shrinkage - Feed Metal requirements :
1. The Super Heated steel, more than what is reqd can cause a severe problem.
.
2. The Most scientific form of Calculating the solidification time – Modulus method
By V.S.J

Calculation of the Feeder Dimensions
1. Identify the Locations – Normally the heavy junctions.
2. Try to reduce the no. of locations by connecting them with the pads.
3. The Pads can be either metallic or ins / exo pads.
4. Calculate the solidification time .
5. This is simplified by the Modulus method.
6. Modulus = Volume / Surface Area
By V.S.J

Calculation of the Feeder Dimensions
7. To achieve the directional solidification , the modulus need to be increased progressively to the neck & to the feeder.
8. Ex. Casting Modulus is Mc = 1
Neck – 10% More Mn = 1.1
Feeder - another 10% Mf = 1.2
9. Application of Ins/ Exo Sleeves.
10. The Efficiency of the sleeves is governed by the
Modulus Extension Factor ( MEF ).
By V.S.J

Calculation of the Feeder Dimensions
11. Ex. If MEF is 1.2 then , Mf is = 1.2 / 1.2 = 1
1.3 1.2 / 1.3 = 0.92
1.4 1.2 / 1.4 = 0.85
1.5 1.2 / 1.5 = 0.80
The feeder Dimensions can be calculated based on the
– modulus.
Further , depending up – on the contact area available.
The ratio between the diameter & height can be fixed
Thus , smaller & smaller feeders are reqd with efficient sleeves.
By V.S.J

Calculation of the Feeder Dimensions
12. The No . Of Feeders can also be further reduced by the effective utilization of the external Chills.
13. The Chill thickness shall be Min 80 % of the contact area.
14. In the case of the deep pockets in the casting ,
Sand can be superheated & may cause defects.
15.To avoid this Zircon / Chromite sand can be used , because of their higher density & thermal conductivity , the problem is minimized.
By V.S.J

Use Of Metal Filters
1. Inspite of the best Practices in the melting & moulding system , the metal steel picks up inclusions , as it flows through the pouring cup & sprues.
2. There are different types of ceramic filters are available.
3. The size of the filters reqd , for particular size of casting is recommended by the filter manufacturers.
4. These filters have to be installed in the running system .
5. Our experience shows , remarkable improvement in the defects caused by inclusions.
6. This is more advantage , if used for expensive stainless steels .
By V.S.J

By V.S.J

By V.S.J

Typical Methoding
By V.S.J

Typical Methoding
By V.S.J

Casting defects
A. Metallic Projections
B. Cavities
C. Discontinuities
D. Defective surface
E. Incomplete Casting
F. Incorrect dimensions or shape
G. Inclusions
By V.S.J

By V.S.Jayabal , M.Tech.,
Managing Director , JRE Valves & Pumps (P) Ltd.,