Casting Defects and Design Issues - Precision Die Casting

Casting Defects and Design Issues ver. 2. ME 6222: Manufacturing Processes and Systems 1. Prof. Colton GIT 2011. Overview Processes Analysis Defects Design rules Economics ME 6222: Manufacturing Processes and Systems 2. Prof. Colton GIT 2011. Issues in Casting Shrinkage Porosity Piping Microstructure ME 6222: Manufacturing Processes and Systems 3. Prof. Colton GIT 2011. Shrinkage Can amount to 5-10% by volume Gray cast iron expands upon solidification due to phase changes Need to Design part and mold to take this amount into consideration ME 6222: Manufacturing Processes and Systems 4. Prof. Colton GIT 2011. Shrinkage TABLE Volumetric Volumetric solidification solidification Metal or alloy contraction (%) Metal or alloy contraction (%). Aluminum 70%Cu 30%Zn Al 90%Cu 10%Al 4. Al 12%Si Gray iron Expansion to Carbon steel 3 Magnesium 1% carbon steel 4 White iron 4 Copper Zinc Source: After R. A. Flinn. ME 6222: Manufacturing Processes and Systems 5.

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2011 1 Casting Defects and Design Issues ver. 2

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