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casting Flashcards

1
Q

cope

A

the top part of the mould

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2
Q

drag

A

the bottom part of the mould

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3
Q

pouring cup

A

the entrance for the moulten metal

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4
Q

sprue

A

channel used to deliver moulten metal

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5
Q

gating system

A

channel used to deliver material to mould cavity

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6
Q

riser

A

extra void

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7
Q

parting line

A

interface seperati g cope and drag

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8
Q

core

A

sand or metal shape used tpo produce internal feature of a casting

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9
Q

mould cavity

A

the space to be filled with moulten mmaterial

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10
Q

draft

A

tapers on the cast that permits casting to be withdrawn

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11
Q

sand casting

A

uses pattern of final casting pressed into sand to create a mould caVITY WITH A RISER AND A SPRUE

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12
Q

sand casting pro

A

low cost, almost all types of materials can be cast, no limit on max wieght, complex shapes,

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13
Q

sandcasting cons

A

HIGH POROSITY ROUGH SURFace finish , llow dimensional accuracy

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14
Q

invessstment casting

A

a type of disposable mould casting where wax pattern is made from a modified replica of product that is coated in ceramic powder the wax is then melted away and MM is filled in the shel is then broken off usually with vibration

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15
Q

investment casting pro

A

excellent surface finish ,high dimensional accuracy almost unlimited intricasey most metals can be used no parting line concerns

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16
Q

investment casting cons

A

costly patterns and moulds high labour time consuming

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17
Q

slush casting

A

moulertn metal is poured into a metal mould the when the desired thickness of the skin is obtained mould is inverted and remaining MM poured out then casting is removed

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18
Q

slush casting app,iscations

A

used to create thin walled objects that are often decorational oftenused in theatre for props

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19
Q

pressure castingg

A

MM forced upward by gas pressure of vaccuum and this pressure is maintained intil solidification see(https://vle.shef.ac.uk/bbcswebdav/pid-3159519-dt-content-rid-8843518_1/courses/MEC130.A.180071/Man%20Tech%20Lecture%203%20%28PJS%29%202017.pdf) page 7

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20
Q

pressure casting pro

A

avoids rapin oxidisaton promotes directioonal cooling ( top down)

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21
Q

pressure casting con

A

long cycle time

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22
Q

die casting hot chamber

A

injection syustem forces MM out of hot chamber through a gooseneck uinto the die cavity where mm rapidly solidifies dies are usually cooled with liquid to improve die life

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23
Q

hot chamber pro

A

no open tranfer of MM fast cycle time goood product strength , exellent dimensional accuracey and Surface finish,

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24
Q

hot chamber cons

A

expensive requires a high production rate cannot be used for mTERIALS WITH A VERY HIGH MP

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25
die casting cold chamber
injection syustem forces MM through a gooseneck into the die cavity where mm rapidly solidifies dies are usually cooled with liquid to improve die life. the differenec is that the mm is transported from a seperate melting place
26
cold chamber pro
good dimensional presision | good surfavec finish
27
cold chamber cons
expensive dies requires a high production rate trabsport of MM required
28
centrefugal casting
MM poured into a rotating mould inertial force distriobutes mm into the mold cavitys metal helld against waall till cooling takes place
29
true centrefugal cadsting
inner surface remains cylindrical used to produce hollow objects like pipeds or gun barrels https://www.youtube.com/watch?v=ZxVA-htTunU
30
semi centrefugal casting
used to cast parts with rotaitonal symetry
31
centriguging
spins forcing mm into die on outside of centriguge
32
centrifuging pro
wide range of cylindrical parts | good dimensional accuracy
33
centrifuging con
shape limited to cylindrical stuff mostly | expensive spinning equiptment
34
single crystal caasting
czochraiski proccess in wich a seed of a single crystal of sillicon contacts the topp of molten sillicon as seed is raised atoms of the ms sooolidify in the seeds pattern
35
single crystal pro
very low thermal creepused for high tempreture stuff
36
single crystal con
slow and expensive
37
powder metalurgy
powdered metals are blwnded then compacted (hot compaction=isostatic) then sintered.
38
powder metalurgy pro
no waste material only need semi skilled labour requires little to no finishing
39
atomisation
liquid metall broken up by jets of inert gas or water. size of particle producd depends on jet flow characteristic and temp of mm
40
reduction
metal oxides reduced by gas like co or h2 to produce uniformly spongy porous powder
41
electrolytic deposition
uses aquius solution or fused salts to produce a very pure poweder
42
comminution
mechanical proccess involving crushingg milling or grinding
43
blending (for powder metalurgy
powders are mixed with lubricants or other metals and blended to create uniform sized particless with desirable mechaniceal propertys
44
cold isostatic pressing
metal powders placed in rubber mould and pressed hydrostaticlaly
45
hot isostatic pressing
inert gAS USED AS a pressurising medium to produce excellent density ND good metalurgic bonding so good mechanical properties
46
powder rolling
powders pressed between gap with rollers compacting into a continous strip
47
extrusion
powders are placed inn a metal die and extruded
48
injection mouldiing
very fine metal powder blended with polymer or wax then pressed into shape then put in oven to remove polymer binder complex shapes easily produced
49
sintering
compressed metal powder heated ib controlled temp below melting point to increse strength and density and electrical and termal conductivity however the compact does shrink
50
forging
a workpiecce is shaped by compressive forces
51
coining
a type of forging proccess where a slug is completely inclosed in the die used to increse strength and surface finish
52
infiltration
slug of lower mp placed against the sintered metal infiltrates pores with capillary action
53
plating
a coating proccess that impaets resistance to were and corrosion
54
economics of powder mettalurgty
eliminates need for many secondary finishng initial die and equiptment cost is high generally at least 10,000 production rate required
55
continous casting
https://www.youtube.com/watch?v=SgAhwgyBsyM
56
tundish
bith where molten metal in continous casting is poured reduce inclusion by maximising residence time
57
mould for coniuos casting
copper and water coold lubricated with a mould flux and is the primary source of heat extraction
58
mould powder / flux
provides uniform cooling protects ffrom oxidisation and absorbs inclusions
59
gross cracks
up to 400mm long assosiated with poor mould level control
60
sub surface cracks
prevelent in medium carbon steal thermal shrinkage results in a uneven shell

manufacturing techniques (3 decks)

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