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Lecture 2 Flashcards

(25 cards)

1
Q

Examples of expendable mould casting

A
  • sand
  • investment (lost wax)
  • evaporative pattern (lost foam)
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2
Q

Examples of permanent mould casting

A
  • gravity die
  • pressure die
  • centrifugal
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3
Q

sand casting

A
  • make cavity in sand of desired casting using pattern
  • permeable: still lets gases through
  • allows metal to shrink avoiding heat tears
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4
Q

what are cores

A

in sand casting: core prints used to hold and align the core in the cavity

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5
Q

what are chaplets

A

in sand casting: metal supports to provide extra stability to the core

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6
Q

sand casting advantages:

A
  • no size limit, variety of metals and shapes

- cheap moulds

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7
Q

sand casting disadvantages

A
  • dificult to meet exact engineering requirements e.g. tolerances
  • suited to low production volumes
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8
Q

sand - what type of casting?

A

permanent pattern

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9
Q

investment/lost wax casting

A
  • no split mould

- pattern surrounded by ceramic coating that becomes mould

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10
Q

lost wax process

A
  • produce master pattern, die and wax patterns
  • assemble on tree and coat
  • allow to harden and melt out wax pattern
  • pour molten metal into mould and let it solidify
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11
Q

lost wax casting advantages

A
  • only method for producing precision casting of high melting point materials
  • requires minimal finishing
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12
Q

lost wax - what type of casting

A

expendable mould and pattren

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13
Q

evaporative pattern/lost foam casting

A
  • pattern made from expanded polystyrene
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14
Q

what are permanent mould

A
  • not broken up - designed to be removed from mould
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15
Q

permanent mould advantages

A
  • reusable

- good accuracy and surface finish

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16
Q

permanent mould disadvantages

A
  • suited to lower melting point materials

- wear of mould

17
Q

gravity die casting

A
  • no external force applied other than atmospheric pressure

- involves feeder

18
Q

gravity die advantages

A

long die life, minimal machining

19
Q

gravity die disavantages

A

slow production rates and limited complexity

20
Q

gravity die - what type of casting

A

permanent mould

21
Q

pressure die casting

A

forces molten metal into mould under high pressure

22
Q

pressure die casting process

A
  • lube and lock dies
  • molten metal forced into cavity
  • held under pressure until solidification
23
Q

hot chamber process

A

in pressure die casting:

  • metal maintained molten
  • some metal forced through shaped channel
24
Q

cold chamber process

A

in pressure die casting:

  • molten metal poured into injection cylinder
  • cylinder not heated
25
What is misrun
when molten metal solidifies before it fills the mould