Manufacturing Processes: Metal casting — Pouring, Solidification and Shrinkage
How molten metal flows, freezes and shrinks in a mold, and how foundries design gates, risers and patterns to get sound castings.
Manufacturing Processes · 23 questions
Try 3 questions
1. Why is casting often the preferred process for parts like engine blocks?
- It always gives the strongest material
- It needs no machining afterward
- It can produce complex internal cavities
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Answer: It can produce complex internal cavities
Molten metal fills any shape the mold and cores define, including internal passages that machining or forging could not reach.
2. How does a pure metal solidify, compared with most alloys?
- At one temperature, not over a range
- Only under applied pressure
- Over a wider range of temperatures
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Answer: At one temperature, not over a range
Pure metals freeze at a single melting point; alloys freeze between the liquidus and solidus temperatures.
3. In a casting of a pure metal, what grain structure forms right against the cold mold wall?
- Long columnar grains along the wall
- A single large crystal
- A thin layer of fine, equiaxed grains
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Answer: A thin layer of fine, equiaxed grains
Rapid cooling at the wall creates many nuclei at once, giving a fine-grained chill zone; columnar grains then grow inward.
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