Squeeze Casting

The process is suitable for components with relatively thick wall sections with high mechanical properties, as for example required of safety components in automotive engineering. The cast components can be welded and heattreated, and they can be produced with near net shape. Aluminum alloys can be used which are difficult or impossible to produce by standard die casting.

Buhler selectively utilizes the advantages of the horizontal shot sleeve system.
Advantages using Buhler machines

• The velocity and pressure intensification profile matched to the component geometry can be programmed in very many discrete steps. Real time control maintains these parameters constant.
• Depending on the type of shot unit selected, it is possible to generate high pressure intensification values during the solidification phase.

Your benefits
• Low capital investment, as no special-purpose machines are required.
• Entering of future-oriented market segments using existing SC machines.
• Low maintenance and training requirements thanks to unified machine and die ranges.

Cold Chamber Process

The essential feature of this process is the independent holding and injection units. In the cold chamber process metal is transferred by ladle, manually or automatically, to the shot sleeve. Actuation of the injection piston forces the metal into the die. This is a single-shot operation. This procedure minimizes the contact time between the hot metal and the injector components, thus extending their operating life. However, the turbulence associated with high-speed injection is likely to entrain air in the metal, which can cause gas porosity in the castings. The cold chamber process is used for the production of aluminum and copper base alloys and has been extended to the production of steel castings. Next to zinc aluminum is the most widely used die-casting alloy. The primary advantage is it light weight and its high resistance to corrosion. Magnesium alloy die-castings are also produced and are used where a high strength–to–weight ratio is desirable.
The mold has sections, which include the “cover” or hot side and the “movable” or ejector side. The die may also have additional moveable segments called slides or pulls, which are used to create features such as undercuts or holes which are parallel to the parting line. The machines run at required temperatures and pressures to produce a quality part to near net-shape.






 
Some application for Aluminum Die Castings:
o Automotive industry
o Home Appliances
o Communication Equipment
o Sports & Leisure

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Sandy loam soils

Sandy loam soils are dominated by sand particles, but contain enough clay and sediment to provide some structure and fertility. There are four different types of sandy loam soil that are classified based on the size of the sand particles in the soil. You can determine whether your yard has this kind of soil using a simple test.

Classification

Sandy loam soils are broken down into four categories, including coarse sandy loam, fine sandy loam, sandy loam and very fine sandy loam. The size of the sand particles is measured in millimeters and their concentration in the soil is used to determine which category a soil falls under. Sandy loam soils are made of approximately 60 percent sand, 10 percent clay and 30 percent silt particles.

Characteristics

Sandy loam soils have visible particles of sand mixed into the soil. When sandy loams soils are compressed, they hold their shape but break apart easily. Sandy loam soils have a high concentration of sand that gives them a gritty feel. In gardens and lawns, sandy loam soils are capable of quickly draining excess water but can not hold significant amounts of water or nutrients for your plants. Plants grown in this type of soil will require more frequent irrigation and fertilization than soils with a higher concentration of clay and sediment. Sandy loam soils are often deficient in specific micronutrients and may require additional fertilization to support healthy plant growth.

Identification

You can quickly identify sandy loam soil based on its physical characteristics. Pick up a handful of dry soil and slowly dribble water onto it. Work the water into the soil with your hand until it has a smooth consistency similar to putty. Hold the soil in your hand as though you are holding a pipe straight up and down and squeeze it. Sandy loam soils have a very gritty texture. If your soil is a sandy loam, it will form a cohesive ribbon of soil as it squeezes out between your thumb and finger that will fall apart before it reaches one inch in length.

Considerations

Plants that are grown in a sandy loam soil need frequent irrigation and fertilization to maintain healthy growth. The best way to improve a sandy loam soil for gardening is to mix organic matter into the soil. Incorporating a 2- to 4-inch layer of compost or peat moss over the area can significantly improve the ability of your sandy loam soil to hold nutrients and water.

Facing Sand

A sand casting facing composition comprises a dry mixture of about 77% fine sand, 5% binder, 6% green system sand and 12% burned system sand. The fine sand is mulled with 5.8% wt/wt oil per total dry mixture and catalyst at about 0.5% wt/wt. Preferably, fine sand and binder are mulled with oil, catalyst, green system sand and screened burned system. The mulled mixture is rested, mulled again and rested again before use as facing sand for achieving accurate reproduction of the pattern's fine detail. A method of preparing the mold and preserving fine detail comprises riddling the pattern with a thin layer of the facing sand composition, compacting, riddling with dry system sand and riddling with system sand before compacting about the periphery of the pattern. Final layers of system sand are applied and compacted over the entire pattern.

 

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Green Sand

Greensand is a naturally occurring mineral mined from ocean deposits from a sedimentary rock known as "Glauconite". It is often an olive-green colored sandstone rock found in layers in many sedimentary rock formations.

Origin of Greensand
Greensand forms in anoxic (without oxygen) marine environments that are rich in organic detritus and low in sedimentary inputs. Some greensands contain marine fossils (i.e. New Jersey Greensand). Greensand has been found in deposits all over the world.
The greenish color comes from the mineral glauconite and iron potassium silicate that weathers and breaks down releasing the stored minerals. The color may range from a dark greenish gray, green-black to blue-green depending on the minerals and water content. It often weathers easily and forms nodules that have been oxidized with iron bearing minerals that has a reddish brown or rust color.
The major chemical description is ((K,Na)(Fe+3, Al, Mg)2(Si,Al)4O10(OH)2)
General chemical information:

Iron (Fe)	12-19%
Potassium (K)	5-7%
Silicon (Si)	25.0%
Oxygen (O)	45%
Magnesium (Mg)	2-3 %
Aluminum (Al)	1.9 %
Sodium (Na)	0.27%
Hydrogen (H)	0.47%

Over 30 other trace minerals and many micronutrients.

Types of Greensand
Glauconite is the name given to a group of naturally occurring iron rich silica minerals that may be composed of pellets or grains.
When glauconite is mined the upper layers that have weathered and become oxidized and minerals are released. These sometimes form pyrite a iron sulfide (FeS2) when oxygen is absent. In the deeper layers or reduced zone pyrite crystals often form. Other minerals found by magnetic separation are Zn, Ni, Cu, and many trace minerals and micronutrients.
The potassium (K) is often found in potassium saturated layers of mica, vermiculite and montmorillonite. Greensand is often considered a clay mineral due to the presence of chlorite, kaolinite, vermiculite, and other clay minerals that may be present.
Greensand is a very heavy mineral with a density of approximately 90 pounds per cubic foot (over 1 ton per cubic yard). The minerals are normally released slowly over time but occur much faster in organic rich soils full of beneficial microbes (microbes produce organic acids as they break down organic matter which facilitates the release of the minerals for plant absorption).
The pH of greensand varies from slightly acidic to slightly alkaline depending on the source and has little effect on soils.

Sources of Greensand
Greensand deposits are found all over the world with the largest and most numerous deposits in the United States and in Great Britain. The original deposits used in Horticulture were from the New Jersey area. In recent years several deposits have been found scattered from East Texas near Lufkin to West of San Antonio and in Arkansas.

Uses of Greensand
Greensand has been used for over 100 years as a natural source of slow release fertilizer and soil conditioner. The slow release of potash and phosphate does not burn plants and the minerals improve the moisture holding properties of soil. The best deposits of greensand contain at least 90% of the mineral glauconite and less than 2-3% clay minerals.
The cation exchange capacities (CEC) of soils were found to increase as the weathering of the greensand increased. The mineral glauconite is used as a water softener and it very beneficial to fight chlorosis in iron deficient soils.
Greensand often has the consistency of sand but is able to absorb 10 times more moisture which makes it a good amendment for use in agriculture and horticulture for many soils types. Greensand does not burn plants and helps for beneficial microbes to grow in the soil. It also has been found to be a good conditioner to help loosen heavy and tight soils and help bind loose soils.
Greensand is often used in compost piles to increase the nutrient content and diversity of beneficial microbes.
Recommended application is 2-4 pounds of greensand per 100 square feet or 1 ton per acre. For potting soils 5-20 pounds per cubic yard can be beneficial.
A field test by Rutgers University in a sandy loam soil with greensand applied in the row at the time of planting, found that the application of greensand increased the yield of potatoes by 16%.
The benefits of greensand, largely unexplained by scientific research are far more than a laboratory analysis would indicate. However numerous greenhouse and field studies have shown significant improvement in the growth of plants. Other studies have shown that the use of greensand improves the taste, color, nutritional value, the health of plants and the health of soils.

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Casting Process Quiz

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Continuous casting

Continuous casting, also referred to as strand casting, is a process used in manufacturing industry to cast a continuous length of metal. Molten metal is cast through a mold, the casting takes the two dimensional profile of the mold but its length is indeterminate. The casting will keep traveling downward, its length increasing with time. New molten metal is constantly supplied to the mold, at exactly the correct rate, to keep up with the solidifying casting. Industrial manufacture of continuous castings is a very precisely calculated operation. Continuous casting can produce long strands from aluminum and copper, also the process has been developed for the production of steel.

The Process

Molten metal, from some nearby source, is poured into a tundish. A tundish is a container that is located above the mold, it holds the liquid metal for the casting. This particular casting operation uses the force of gravity to fill the mold and to help move along the continuous metal casting. The tundish is where the operation begins and is thus located high above ground level, as much as eighty or ninety feet. As can be seen, the continuous casting operation may require a lot of space.
It is the job of the tundish to keep the mold filled to the right level throughout the manufacturing operation. Since the metal casting is constantly moving through the mold, the tundish must always be supplying the mold with more molten metal to compensate.
The supplying of metal to the mold is not only going on throughout the entire manufacturing operation, it must be carried out with accuracy. A control system is employed to assist with this task. Basically the system can sense what the level of molten metal is, knows what the level should be, and can control the pouring of the metal from the tundish to ensure the smooth flow of the casting process. Although the tundish can typically hold several thousand pounds of metal, it too must be constantly supplied from the source of molten material.
The tundish also serves as the place where slag and impurities are removed from the melt. The high melting point and reactive nature, at high temperatures, has always made steel a difficult material to cast. When a manufacturing operation is continuously casting steel, the reactivity of the molten steel to the environment needs to be controlled. For this purpose, the mold entrance may be filled with an inert gas such as argon. The inert gas will push away any other gases, such as oxygen, that may react with the metal. There is no need to worry about the inert gas reacting with a molten metal melt, since inert gases do not react with anything at all.
The metal casting moves quickly through the mold, in the continuous manufacture of the metal part. The casting does not have time to solidify completely in the mold. As can be remembered from our discussion on solidification, a metal casting will first solidify from the mold wall, or outside of the casting, then solidification will progress inward. The mold in the continuous casting process is water cooled, this helps speed up the solidification of the metal casting. As stated earlier, the continuous casting does not completely harden in the mold. It does, however, spend enough time in the water cooled mold to develop a protective solidified skin of an adequate thickness on the outside.
The long metal strand is moved along at a constant rate, by way of rollers. The rollers help guide the strand and assist in the smooth flow of the metal casting out of the mold and along its given path. A group of special rollers may be used to bend the strand to a 90 degree angle. Then another set will be used to straighten it, once it is at that angle. Commonly used in manufacturing industry, this process will change the direction of flow of the metal strand from vertical to horizontal.





The continuous casting can now travel horizontally as far as necessary. The cutting device, in manufacturing industry, is typically a torch or a saw. Since the metal casting does not stop moving, the cutting device must move with the metal casting, at the same speed, as it does its cutting. There is another commonly used setup for cutting lengths of metal casting strand from a continuous casting operation. This particular manufacturing setup eliminates the need for bending and straightening rollers. It does, however, limit the length of metal casting strand that may be produced, based in a large part on the height of the casting floor where the mold is located.






There needs to be an initial setup for a continuous casting operation, since you can not just pour molten metal through an empty system to start off the process. To begin continuous casting manufacture, a starter bar is placed at the bottom of the mold. Molten material for the metal casting is poured into the mold and solidifies to the bar. The bar gives the rollers something to grab onto initially. The rollers pull the bar, which pulls along the continuous casting.





In the manufacture of a product, often two or more different kinds of operations may need to be performed. Such as a metal casting operation followed by a metal forming operation. In modern commercial industry, the continuous casting process can be integrated with metal rolling. Do not confuse the rolling operation with the rolls used to guide the casting. The rolling operation is a forming process and it will change the metal it processes. Rolling of the metal strand, is the second manufacturing process and it must be performed after the casting operation. Continuous casting is very convenient in that the rolling mill can be fed directly from the continuously cast metal casting strand. The metal strand can be rolled directly into a given cross sectional shape such as an I beam. The rate of the rolling operation is synchronized with the speed that the continuous metal casting is produced and thus the two operations are combined as one.

Properties And Considerations Of Manufacturing By Continuous Casting

• Continuous casting manufacture is different from other metal casting processes, particularly in the timing of the process. In other casting operations, the different steps to the process such as the ladling of metal, pouring, solidification, and casting removal all take place one at a time in a sequential order. In continuous casting manufacture, these steps are all occurring constantly and at the same time.
  


• This process is used in commercial manufacture as a replacement to the traditional process of casting ingots.
  


• Piping, a common problem in ingot manufacture, is eliminated with the continuous casting process.
  


• Structural and chemical variations in the metal of the casting, often present in ingots, have been eliminated. When manufacturing with the continuous metal casting process, the casting's material will possess uniform properties.
  


• When employing continuous metal casting manufacture, the castings will solidify at 10 times the rate that a casting solidifies during ingot production.
  


• With less loss of material, cost reduction, higher productivity rate, and superior quality of castings, continuous casting manufacture is often the choice over ingot production.
  


• A continuous casting manufacturing process will take considerable resources and planning to initiate, it will be employed in only very serious industrial operations.

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SLUSH MOLDING PROCESS

Slush molding is an excellent method of producing open, hollow objects,including rain boots, shoes, toys, dolls and automotive products, such as protective skin coatings on arm rests, head rests and crash pads. The basic process of slush molding involves exposing a hollow mold to heat, filling a hollow mold with vinyl plastisol or vinyl powder compound, gelling an innerlayer or wall of plastisol or partially fused powder  compound in the mold, inverting the mold to pour out the excess liquid plastisol or unfused powder
compound and then heating the mold again to fuse the vinyl compound which remains in the mold. The mold is then cooled and the finished part is removed.

Slush molding can be a simple hand operation for limited production, or an elaborate conveyorized system for long runs. This process can be a one pour method, where finished or semi-finished products can be made by one slushing step, or a multiple-pour method where two or more slushing steps are used.

The wall thickness of the slush molded part, made from powder compound at a given oven temperature, is determined by several factors: the thickness of the metal wall of the mold, the length of time the mold is preheated, and the amount and type of plasticizer in the compound.

Molds used in slush molding are produced from spun, machined or electroformed aluminum. Vinyl
powder compound will reproduce the surface finish of the mold, whether matte or glossy. Mold porosity, depending upon severity, may cause such detrimental effects as surface gloss reduction, pinholing, and voids in the molded part.

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Vacuum Casting

Vacuum mold casting, also known in manufacturing industry as the V process, employs a sand mold that contains no moisture or binders. The internal cavity of the mold holds the shape of the casting due to forces exerted by the pressure of a vacuum. Vacuum molding is a casting process that was developed in Japan around 1970.

The Process

A special pattern is used for the vacuum mold casting process. It is either a match-plate or a cope and drag pattern with tiny holes to enable a vacuum suction. A thin plastic sheet is placed over the casting pattern and the vacuum pressure is turned on, causing the sheet to adhere to the surface of the pattern.




A special flask is used for this manufacturing process. The flask has holes to utilize vacuum pressure. This flask is placed over the casting pattern and filled with sand.





A pouring cup and sprue are cut into the mold for the pouring of the metal casting.





Next, another thin plastic sheet is placed over the top of the mold. The vacuum pressure acting through the flask is turned on, and the plastic film adheres to the top of the mold.





In the next stage of vacuum mold casting manufacture, the vacuum on the special casting pattern is turned off and the pattern is removed. The vacuum pressure from the flask is still on. This causes the plastic film on the top to adhere to the top and the plastic film formerly on the pattern to adhere to the bottom. The film on the bottom is now holding the impression of the casting in the sand with the force of the vacuum suction.





The drag portion of the mold is manufactured in the same fashion. The two halves are then assembled for the pouring of the casting. Note that there are now 4 plastic films in use. One on each half of the internal casting cavity and one on each of the outer surfaces of the cope and drag.





During the pouring of the casting, the molten metal easily burns away the plastic.

Properties And Considerations Of Manufacturing By Vacuum Mold Casting

• In vacuum mold casting manufacture there is no need for special molding sands or binders.
  


• Sand recovery and reconditioning, a common problem in metal casting industry, is very easy due to the lack of binders and other agents in the sand.
  


• When manufacturing parts by vacuum mold casting the sand mold contains no water, so moisture related metal casting defects are eliminated.
  


• The size of risers can be significantly reduced for this metal casting process, making it more efficient in the use of material.
  


• Casting manufacture by vacuum molding is a relatively slow process.
  


• Vacuum mold casting is not well suited to automation.

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Plaster Mold Casting

Plaster mold casting is a manufacturing process having a similar technique to sand casting. Plaster of Paris is used to form the mold for the casting, instead of sand. In industry parts such as valves, tooling, gears, and lock components may be manufactured by plaster mold casting.

The Process

Initially plaster of Paris is mixed with water just like in the first step of the formation of any plaster part. In the next step of the manufacture of a plaster casting mold, the plaster of Paris and water are then mixed with various additives such as talc and silica flour. The additives serve to control the setting time of the plaster and improve its strength. The plaster of Paris mixture is then poured over the casting pattern. The slurry must sit for about 20 minutes before it sets enough to remove the pattern. The pattern used for this type of metal casting manufacture should be made from plastic or metal. Since it will experience prolonged exposure to water from the plaster mix, wood casting patterns have a tendency to warp. After striping the pattern, the mold must be baked for several hours, to remove the moisture and become hard enough to pour the metal casting. The two halves of the mold are then assembled for the casting process.

Properties and Considerations of Manufacturing by Plaster Mold Casting

• When baking the casting mold just the right amount of water should be left in the mold material. Too much moisture in the mold can cause metal casting defects, but if the mold is too dehydrated, it will lack adequate strength.
  


• The fluid plaster slurry flows readily over the pattern, making an impression of great detail and surface finish. Also due to the low thermal conductivity of the mold material the casting will solidify slowly creating more uniform grain structure and mitigating casting warping. The qualities of the plaster mold enable the process to manufacture parts with excellent surface finish, thin sections, and produces high geometric accuracy.
  

Castings of high detail and section thickness as low as .04 - .1 inch, (2.5 - 1 mm), are possible when manufacturing by plaster mold casting

• There is a limit to the casting materials that may be used for this type of manufacturing process, due to the fact that a plaster mold will not withstand temperature above 2200F (1200C). Higher melting point metals can not be cast in plaster. This process is typically used in industry to manufacture castings made from aluminum, magnesium, zinc, and copper based alloys.
  


• Manufacturing production rates for this type of metal casting process are relatively slow, due to the long preparation time of the mold.
  


• The plaster mold is not permeable, which severely limits the escape of gases from the casting. 

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Workshop Technology

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Flask Technology

This casting technology was originally developed for the jewellery and dental industries, for the production of comparatively small parts. As the production time is relatively short compared to conventional shell building, it is also being applied more and more for Rapid Prototyping.  In the embedding machine a chalky powder is mixed with water under vacuum and poured over the wax part, housed in a small metal container, the so-called flask.


This casting technology was originally developed for the jewellery and dental industries, for the production of comparatively small parts. As the production time is relatively short compared to conventional shell building, it is also being applied more and more for Rapid Prototyping.  In the embedding machine a chalky powder is mixed with water under vacuum and poured over the wax part, housed in a small metal container, the so-called flask.This casting technology was originally developed for the jewellery and dental industries, for the production of comparatively small parts. As the production time is relatively short compared to conventional shell building, it is also being applied more and more for Rapid Prototyping.  In the embedding machine a chalky powder is mixed with water under vacuum and poured over the wax part, housed in a small metal container, the so-called flask.

After solidification of the plaster, the flask is heated to a casting temperature of 300 – 500 °C, step by step. It is then cooled down depending on the material.

After the cast the part is de-bedded by means of a high-pressure water-jet to release the part from the plaster. The part is then sent for finishing.
Advantages:
Very good surface quality
Material is only mixed if required
No cores are necessary
Easy de-bedding by water
Disadvantages:
Only small and medium-sized parts are possible
Only low melting alloys e.g. aluminium can be cast, no steel
High material usage and lot of waste
No perfect casting quality because of the long solidification process, depending on the size of the flask
Burning takes up to several days, depending on flask size
Oven is blocked for many hours / days with (one) flask, as soon as the tempering process has been started

After solidification of the plaster, the flask is heated to a casting temperature of 300 – 500 °C, step by step. It is then cooled down depending on the material.

After the cast the part is de-bedded by means of a high-pressure water-jet to release the part from the plaster. The part is then sent for finishing.
Advantages:
Very good surface quality
Material is only mixed if required
No cores are necessary
Easy de-bedding by water
Disadvantages:
Only small and medium-sized parts are possible
Only low melting alloys e.g. aluminium can be cast, no steel
High material usage and lot of waste
No perfect casting quality because of the long solidification process, depending on the size of the flask
Burning takes up to several days, depending on flask size
Oven is blocked for many hours / days with (one) flask, as soon as the tempering process has been started

After solidification of the plaster, the flask is heated to a casting temperature of 300 – 500 °C, step by step. It is then cooled down depending on the material.

After the cast the part is de-bedded by means of a high-pressure water-jet to release the part from the plaster. The part is then sent for finishing.



Advantages:
Very good surface quality
Material is only mixed if required
No cores are necessary
Easy de-bedding by water


Disadvantages:
Only small and medium-sized parts are possible
Only low melting alloys e.g. aluminium can be cast, no steel
High material usage and lot of waste
No perfect casting quality because of the long solidification process, depending on the size of the flask
Burning takes up to several days, depending on flask size
Oven is blocked for many hours / days with (one) flask, as soon as the tempering process has been started


This casting technology was originally developed for the jewellery and dental industries, for the production of comparatively small parts. As the production time is relatively short compared to conventional shell building, it is also being applied more and more for Rapid Prototyping.  In the embedding machine a chalky powder is mixed with water under vacuum and poured over the wax part, housed in a small metal container, the so-called flask.

After solidification of the plaster, the flask is heated to a casting temperature of 300 – 500 °C, step by step. It is then cooled down depending on the material.

After the cast the part is de-bedded by means of a high-pressure water-jet to release the part from the plaster. The part is then sent for finishing.
Advantages:
Very good surface quality
Material is only mixed if required
No cores are necessary
Easy de-bedding by water
Disadvantages:
Only small and medium-sized parts are possible
Only low melting alloys e.g. aluminium can be cast, no steel
High material usage and lot of waste
No perfect casting quality because of the long solidification process, depending on the size of the flask
Burning takes up to several days, depending on flask size
Oven is blocked for many hours / days with (one) flask, as soon as the tempering process has been started

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