Preface

Casting processes are the most efficient and economical methods of shaping a component. Creating the most suitable part to perform the function effectively requires a combination of multiple disciplines. The design for function necessitates an understanding of the service loads and the assembly constraints. The assurance of performance demands an intimate knowledge of the diverse alloy and heat treatment options, their metallurgical characteristics, and the working environment. Ensuring the manufacturability and integrity of products requires expertise in alternative process capabilities and limitations.

Cast irons and steels are the two groups of metals that are most extensively studied, researched, and documented. It is gratifying to see the vast quantity of literature on the principles of metal castings, characterizing alloy developments. This literature has benefitted both academia and industry over several decades.

The purpose of Iron and Steel Castings Engineering Guide is to discuss and illustrate the application of these principles and the interdependence of the multiple disciplines through practical examples. This guide describes engineering details of iron and steel castings in a variety of industries. It highlights the significance of microstructures to the performance of typical castings, working under varied environments.

Casting design-change guidelines for improved castability, strength, and stiffness are illustrated with industrial applications. The influence of design on casting-distortion and internal stresses is addressed. Guidelines to minimize or compensate for inherent distortions are offered.

Process outlines for melting, metal treatment, and molding are offered in this guide for basic orientation. Engineering guidelines for tooling, gating, and feeding designs are detailed, outlining the technological differences among different grades of cast iron and steel. This guide details the concept of directional solidification of steel castings and its influence on casting design and feeding principles.

Also, the guide illustrates the application of metal casting principles with several figures of practical applications, along with many tables and nomograms for easy reference and quick computation. Practical examples of casting defects, problem-solving challenges, and resolution guidelines are highlighted.

The global interest in the development of electric vehicles offers a challenge and an opportunity to the casting industry, compelling a need for review, repositioning of capabilities, and equipment. The impact of electric vehicles on the casting industry on growth and obsolescence is analyzed and presented.

Successful product launches on-time and within targeted costs demand a structured approach in program management. An overview of the product launch process is outlined.

This practical compilation of several decades of experience, illustrating the judicious application of principles and proven practical engineering guidelines, should be of special interest to ferrous product design engineers, casting process engineers, and graduate students pursuing the study of casting technology.

This book is an accompanying guide to my previous publication, Aluminum Castings Engineering Guide (ASM International, 2018).