INNOVATIVE CASTING USING MAGNETIC MATERIALS

Abstract

Casting is a manufacturing process, which is used directly or indirectly in almost every industry. It is a primary process having effect on the properties of resultant product. The history of molding and casting traces back to earlier century. It has been observed that in first and oldest generation mold was made by means of squeezing/jolting green sand, second generation binders were used in sand molding process, i.e., clay or organic resins to enhance the properties. It progressed to the third generation where physical means like gravity, vacuum, lost foam were adopted. Of the late the magnetic field is being attempted which has observed to stabilize free flowing dry molding materials. This development of unbounded casting process is to improve flexibility and enhances mold ability. The concept of unbounded casting is to change the kind of binder or to avoid substantial binder. Magnetic molding uses an expandable pattern surrounded by steel shots which are bound together by the action of an induced magnetic field. The present work has been carried to study the effect of the magnetic field and on properties of the casting. A preliminary study was carried with the „sand cast‟, „die cast‟ and Magnetic molding of Aluminum alloy. It‟s observed that the magnetic mold casting exhibited reasonably enhanced „yield strength‟ compared to other molding processes, with fine grain micro-structure monitoring the properties of casting, process being environment friendly and materials are reusable