3: Casting

Question 1

Sand Casting Process (6)

Answer 1

1. Pattern Creation: Make a replica of the final product.
2. Mold Preparation: Mix sand with a binder, Pack sand around the pattern to form the mold, Create and place sand cores for internal cavities.
3. Mold Assembly: Assemble and clamp mold halves with cores.
4. Pouring: Pour molten metal into the mold.
5. Cooling
6. Mold Removal: Break mold to retrieve the casting.

Question 2

Investment Die Casting Process (8)

Answer 2

1. Pattern Creation: Make a wax or plastic replica of the final product.
2. Assembly: Attach patterns to a central wax sprue to form a tree.
3. Shell Building: Dip the tree in ceramic slurry and coat with sand; repeat to build a thick shell.
4. Dewaxing: Heat the shell to melt and drain the wax, leaving a ceramic mold.
5. Preheating: Preheat the ceramic mold to prepare for metal pouring.
6. Pouring: Pour molten metal into the preheated mold.
7. Cooling: Allow the metal to cool and solidify.
8. Shell Removal: Break the ceramic shell to retrieve the casting.

Question 3

Gravity Die Casting Process (5)

Answer 3

1. Mold Preparation: Preheat and coat a metal mold with a release agent.
2. Pouring: Pour molten metal into the mold using gravity.
3. Cooling: Allow the metal to cool and solidify in the mold.
4. Mold Opening: Open the mold and remove the casting.
5. Finishing: Trim excess material and clean the casting.

Question 4

Hot Chamber Pressure Die Casting Process (6)

Answer 4

1. Mold Preparation: Preheat and close the die casting machine’s mold.
2. Injection: Molten metal is forced into the mold cavity under high pressure.
3. Cooling: Allow the metal to cool and solidify within the mold.
4. Ejection: Open the mold and remove the casting.
5. Trimming: Remove excess material and trim the casting.
6. Finishing: Polish and clean the casting.

Question 5

Plaster of Paris Casting Process (9)

Answer 5

1. Pattern Creation: Make a pattern of the object to be cast.
2. Mold Preparation: Place the pattern in a container & mix plaster of Paris with water to form a slurry.
3. Pour the slurry over the pattern to create the mold.
4. Setting: Allow the plaster to set and harden
5. Pattern Removal: Remove the pattern from the hardened plaster mold.
6. Casting: Pour molten metal or other material into the mold cavity.
7. Cooling and Solidification
8. Mold Breakage: Break the plaster mold to retrieve the casting.
9. Finishing: Remove any excess material and smooth the casting.