Casting processes basically involve the introduction of a molten metal into a Mold cavity, where

upon solidification, the metal takes on the shape of the Mold cavity.

Simple and complicated shapes can be made from any metal that can be melted. Example of cast
parts: frames, structural parts, machine components, engine blocks, valves, pipes, statues,
ornamental artifacts…..

Sand casting, also known as sand Molded casting, is a metal casting process characterized by
using sand as the Mold material. The term "sand casting" can also refer to an object produced via the
sand casting process. Sand castings are produced in specialized factories called foundries. Over 70%
of all metal castings are produced via a sand casting process.[1]

Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to
the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is
moistened, typically with water, but sometimes with other substances, to develop strength and
plasticity of the clay and to make the aggregate suitable for Molding. The sand is typically contained in
a system of frames or Mold boxes known as a flask. The Mold cavitiesand gate system are created by
compacting the sand around models, or patterns, or carved directly into the sand.

Casting Steps quick route from raw material to finished

product
•Melt metals
•Pour / force liquid into hollow cavity (mold)
•Cool / Solidify
•Remove
•Finish
Sand Casting steps
Sand Cast Parts
 Casting Processes

Die Casting

Die casting is a metal casting process that is characterized by forcing molten metal under high
pressure into a mould cavity. The mold cavity is created using two hardened tool steel dies which
have been machined into shape and work similarly to an injection mold during the process. Most die
castings are made from non-ferrous metals,
specifically zinc, copper, aluminium,magnesium, lead, pewter and tin based alloys. Depending on the
type of metal being cast, a hot- or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the
process to high volume production. Manufacture of parts using die casting is relatively simple,
involving only four main steps, which keeps the incremental cost per item low. It is especially suited
for a large quantity of small to medium sized castings, which is why die casting produces more
castings than any other casting process.[1] Die castings are characterized by a very good surface
finish (by casting standards) and dimensional consistency.

Vacuum Casting
 FORGING

Cold forging:

These include bending, cold drawing, cold heading, coining extrusion (forward or backward),
punching, thread rolling and others.

Hot forging:

plastically deforming an alloy at a temperature above its recrystallization point, i.e., high enough
to avoid strain hardening.

Open Die Forgings / Hand Forgings:

Made with repeated blows in an open die,

The operator manipulates the workpiece in the die.

Impression Die Forgings / Precision Forgings:

Are further refinements of the blocker forgings.

The finished part more closely resembles the die impression.

1. Drop Hammer
2.Friction Screw Press
3.Crank Press
4.Hydraulic Press
Closed and open die forging
processes
Wheel Example
Most modern performance wheels are
made from aluminum by casting or
forging. Forged wheels are manufactured
in multiple steps compared to the one
step in the casting process.
Cast wheel
Casting has the advantage of allowing
the designer more styling freedom
because the process is a more flexible
method. Until recently, most wheels have
been gravity cast (heavier and thicker).
Today, low pressure die casting
techniques are used to substantially
reduce porosity. Indeed, castings tend to
contain porosity which strongly
influences the mechanical integrity of the
component. Thus, cast wheels are
generally designed larger and heavier in
order to achieve an acceptable structural
strength for a given application.
Forged wheel
The forged wheel, because of the
enormous pressures involved, compacts
the metal, eliminating porosity and the
voids that can be a source for cracks or
corrosion. The result is that less metal is
required to achieve a given strength,
meaning lighter wheels can be made.
Furthermore, due to the density of the
grain structure, the polished forged
wheel will maintain its luster for much
longer than a polished cast wheel which
is very porous.
To summarize, forging yield wheels with
higher strength to weight ratio but the
tooling due to the multiple steps process
and the based alloy are comparatively
more expensive than in casting
processes. Furthermore, with lighter
weight wheels, you will benefit from
increased fuel savings, and better
acceleration due to less amount of
inertial weight at the rotational axis. For
those reasons, usually forged wheels are
only used for high performance
applications

Strength of forging:

- Good Mechanical properties

(yield strength, ductility,

toughness)

- Reliability (used for critical parts)

- No liquid metal treatment

Weakness of forging:

- Defects

- Laps

- Die unfill

- Die failure

- Piping

- Shape limited when undercuts or

cored sections are required

- Overall cost usually higher than

casting

- Multiple steps often required

Strength of casting:

- Large and complex parts

- High production rate

- Design flexibility

Weakness of casting:

- Defects

- Shrinkage porosity

- Metallic projections

- Cracks, hot tearing, cold

shuts

- Laps, oxides

- Misruns, insufficient

volume

- Inclusions

- Requires close process control

and inspections (porosity may

occur)
Mechanical forging presses of the cranks type have found wide application inforging practiceThe
operative units of the press are powered from motor mounted on thepress frame. By means of the v-
belt drive, power is transmitted from pulley toflywheel mounted on the auxiliary shaft .The is stopped
by the auxiliary brake which is automatically engaged whenthe motor is switched off.Used for the
production of rivets, screws ,and nuts where a high operating speed is desired

Upset Forging

What is Upset Forging?

Performed on bar stock, upset forging decreases the length of the stock
and increases its cross-section.

High pressures deform the metal and force material into a designated
area of the bar.

The material is shaped into tools such as bolts, pinions,drill rods, and
other objects where high strength is a necessity.

Upset forging refines the mechanical properties by re-orienting the grain

flow to the shape of the tool.

The result is a component which is inherently stronger than that which

has been cast, welded, or machined.
Upset forging is a metal shaping process in which a heated workpiece of uniform thickness is gripped
between split female dies while a heading die is forced against the workpiece, deforming and
enlarging the need of the workpiece.