Page 311 - Manufacturing Engineering and Technology - Kalpakjian, Serope : Schmid, Steven R.

290 Chapter 11 Metal-Casting Processes and Equipment
In permanent-mold casting, die and equipment costs are relatively high, but the
processes are economical for large production runs. Scrap loss is low, dimensional
accuracy is relatively high, and good surface detail can be achieved.
Other casting processes include squeeze casting (a combination of casting and
forging), semisolid-metal forming, rapid solidification (for the production of
amorphous alloys), and the casting of single-crystal components (such as turbine
blades and silicon ingots for integrated-circuit manufacture).
Melting processes and their control also are important factors in casting opera-
tions. They include proper melting of the metals; preparation for alloying; re-
moval of slag and dross; and pouring the molten metal into the molds. Inspection
of castings for possible internal or external defects also is important.
Castings are generally subjected to additional processing (such as heat treat-
ment and machining operations) to produce the final desired shapes and sur-
face characteristics and to achieve the required surface finish and dimensional
accuracy.

KEY TERMS

Binders Expendable mold Parting agent Rheocasting
Centrifugal casting Expendable-pattern casting Patterns Sand casting
Ceramic-mold casting Fluxes Permanent mold Semisolid-metal forming
Chaplets Foundry Permanent-mold casting Shell-mold casting
Composite mold Green molding sand Plaster-mold casting Slush casting
Core print Insert molding Precision casting Sodium-silicate process
Cores Investment casting Pressure casting Squeeze casting
Crystal growing Levitation melting Rammed-graphite molding Thixotropy
Die casting Lost-foam process Rapid prototyping Vacuum casting
Evaporative-pattern casting Lost-wax process Rapid solidification

BIBLIOGRAPHY

Allsop, D.F., and Kennedy, D., Pressure Die Casting-Part II: Clegg, A.]., Precision Casting Processes, Pergamon, 1991.
The Technology of the Casting and the Die, Pergamon, Investment Casting Handbook, Investment Casting Institute,
1983. 1997.
Ammen, C.W, Metalcasting, McGraw-Hill, 2000. Martin, A., The Essential Guide to Mold Making SC Slip
An Introduction to Die Casting, American Die Casting Casting, Lark Books, 2007.
Institute, 1 9 8 1. Otooni, M.A. (ed.), Elements of Rapid Solidification:
Andresen, W, Die Cast Engineering: A Hydraulic, Thermal Fundamentals and Applications, Springer, 1999.
and Mechanical Process, CRC Press, 2005. Product Design for Die Casting, Diecasting Development
ASM Handbook, Vol. 15: Casting, ASM International, 2008. Council, 1988.
Beeley, P., Foundry Technology, Butterworth-Heinemann, Sias, ER., Lost-Wax Casting, Woodsmere Press, 2006.
2002. Steel Castings Handbook, 6th ed., ASM International, 1995.
Brooks, N., Mouldmaking and Casting, Crowood Press, 2005. The Metallurgy of Die Castings, Society of Die Casting
Campbell, ]., Castings, 2nd ed., Butterworth-Heinemann, Engineers, 1986.
2003. Viarcik, E.]., High Integrity Die Casting, Wiley, 2002.
Chastain, S., Metal Casting: A Sand Casting Manual for the Young, K.P., Semi-solid Processing, Chapman 86 Hall,
Small Foundry (2 vols), Chastain Publishing, 2004. 1997.