Failures Related to Castings

2021 ◽  
pp. 177-222
Author(s):  
George M. Goodrich ◽  
Richard B Gundlach ◽  
Robert B. Tuttle ◽  
Charles V. White
Keyword(s):  
Ductile Iron ◽  
Casting Process ◽  
Production Method ◽  
Gray Iron ◽  
Mold Material ◽  
Copper Base ◽  
Material Production ◽  
Metal Type ◽  
Metal Group ◽  
Causes Of Failure

Abstract The information provided in this article is intended for those individuals who want to determine why a casting component failed to perform its intended purpose. It is also intended to provide insights for potential casting applications so that the likelihood of failure to perform the intended function is decreased. The article addresses factors that may cause failures in castings for each metal type, starting with gray iron and progressing to ductile iron, steel, aluminum, and copper-base alloys. It describes the general root causes of failure attributed to the casting material, production method, and/or design. The article also addresses conditions related to the casting process but not specific to any metal group, including misruns, pour shorts, broken cores, and foundry expertise. The discussion in each casting metal group includes factors concerning defects that can occur specific to the metal group and progress from melting to solidification, casting processing, and finally how the removal of the mold material can affect performance.

Design and Development of a Mold for Patternless Casting Using AM/3D Printing

2021 ◽  
Vol 1033 ◽  
pp. 98-102
Author(s):  
Taha Waqar ◽  
Muhammad Azhar Ali Khan ◽  
Muhammad Asad ◽  
Faramarz Djavanroodi ◽  
Jamal Nayfeh
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Casting Process ◽  
Mold Material ◽  
Mold Design ◽  
3D Design ◽  
Casting Mold ◽  
Direct Printing ◽  
Cad Modelling

Additive manufacturing is a technology that is influencing every facet of manufacturing such as casting. 3D printing in particular has the potential to revolutionize castings in terms of precision and time taken in production. Patternless molds increase the efficiency of the casting process for large scale manufactured components. Therefore, ceramic based molds can be utilized for low temperature alloy parts such as mounting brackets. Nowadays, 3D printing technologies allow the direct printing of these molds. This is possible with the aid of CAD modelling of the casting mold which allows instant printing of patternless molds. The aim of this work is to introduce an approach to prepare a 3D design for a casting mold that can be manufactured using 3D printing technology. Mold design was made using Solidworks software according to standardized calculations from which cope and drag components were extracted. Candidates for potential mold material are highlighted along with advantages & limitations of utilizing 3D printing methodology.

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