The gravity permanent mold (GPM) process produces castings of high strength and integrity with good surface finish and consistent dimensions. This chapter lists castings produced using GPM and semipermanent mold (SPM). It illustrates the basic elements of a conventional tilt pour machine. The chapter also provides an overview of the high-volume rotary table, high-volume production rotary manufacturing cell, cycle time planning, sizes of tilt pour machine and table, and improvement of turntable uptime. It also presents some of the common semipermanent molded castings.

A test flight was cut short after a fire warning came on indicating a problem with one of the four engines on an aircraft. A visual examination following the precautionary landing revealed several burned hoses, a melted bolt, and fuel leaking from the base of the main burner. The fuel nozzle was also damaged, and based on its microstructure, came very close to melting. Investigators determined that the burner was mounted backwards, facing the compressor rather than the turbine. They also recommended a redesign to prevent the fuel nozzle from being reversed.

This report describes the failure of a gas turbine in a combined-cycle power plant and the examination and tests that were conducted to determine the cause. Based on microstructural analysis, hardness measurements, and tensile tests, the failure was attributed to inadequate clearances in the seal land region between two stages in the compressor section of the rotor. The report also recommends changes to remediate the problem.

This chapter presents guidelines for product designers to choose the best process and alloys while designing a casting. The discussion covers some of the factors pertinent to the selection of the best process for the product function and performance, namely geometric factors, mechanical properties, tooling cost per piece, and overall cost factors. The chapter contains tables listing several markets, products, popular processes, and common alloys and the common processes used for a variety of markets and products.

This chapter discusses some of the ways that the lessons learned from failures have benefitted society, leading to improved product designs, better materials, safer industrial processes, and more robust codes and standards. It also provides several examples of how the technology and procedures associated with aviation security have been upgraded in the wake of air disasters.

This chapter discusses the crystal structures of steel and cast iron, the iron-iron carbide equilibrium diagram, microconstituents or phases in the iron-iron carbide phase diagram, the iron-carbon carbide-silicon equilibrium diagram of cast irons, and the influence on microstructure by base elements and alloying elements. Graphitization, cooling rates, and heat treatment effects are covered. There also is discussion on inoculation benefits, flake graphite types and typical applications, evolution of cast iron types, ASTM specification A247 for graphite shapes, and selection of the best molding process. A large table lists typical material choices for various applications.

This chapter discusses the advantages, limitations, and applications of various aluminum casting processes, namely green sand casting process, air set or no-bake molding process, vacuum molding process, evaporative foam casting process, and die casting process. The processes covered also include gravity permanent molding, low-pressure permanent molding, counter pressure, squeeze casting, investment casting, rapid prototype casting, cast forge hybrid, and semisolid metal processes.

Most iron and steel castings are produced by casting into sand molds. Sand cores are needed primarily to form hollow cavities in castings for collapsibility and ease of cleaning. This chapter begins with an overview of the classification of molding and core-making systems. This is followed by a section discussing the process involved in shell molding, along with its applications. A brief description of the special casting processes is then presented. Next, the chapter discusses the processes involved in core making. Further, it provides an overview of casting manufacturing. Finally, the chapter provides information on the factors that influence a casting facility layout.

Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides information on the process of conversion of steel and iron parts to aluminum.

Malleable iron has unique properties that justify its application in the metal working industry. This chapter discusses the advantages, limitations, and mechanical properties of malleable iron; provides a description of the malleabilization process; and presents manufacturing guidelines for malleable iron castings.

This chapter covers mechanical properties, microstructures, chemical compositions, manufacturing processes, and engineering of gating practices for several applications of gray, white, and alloyed cast irons. It begins with a description of material standards, followed by a section providing information on the practice of stress relieving. Next, the chapter details various ways of eliminating slag entrainment while designing gating and venting systems. Several factors related to the establishment of the optimum pouring rate and time are then covered. Further, the chapter discusses the technology of unalloyed or low-alloyed gray iron castings and white iron and high-alloyed cast irons. Finally, it describes the casting defects that are associated with cast iron and the processes involved in solving these defects. The article includes a number of figures illustrating the topics discussed.

This chapter provides an overview of the state of the art in high-pressure cold spray equipment, including both spray systems and gas supply systems. The chapter describes the commercial cold spray systems developed by companies such as Cold Gas Technology (CGT) GmbH, Plasma Giken Company Ltd, Impact Innovations GmbH, and ASB Industries. Typical helium and nitrogen gas systems used in high-pressure cold spray processing are reviewed.

Ductile iron has far superior mechanical properties compared to gray iron as well as significantly improved castability and attractive cost savings compared to cast steel. This chapter begins with information on graphite morphology and matrix type. It then discusses the advantages and applications of ductile iron. Next, the effects of various factors on the grades, chemistry, matrix, and mechanical properties of ductile iron are covered. This is followed by a section detailing the ductile iron treatment methods and the quality control methods used. Guidelines for gating and feeder design are then provided. Further, the chapter addresses the technology of ductile iron castings, including the performance and geometric attributes, molding and core-making processes used, material grades, mechanical properties, and chemical compositions of a few applications. Finally, it describes ductile iron casting defects and presents practical cases of problem-solving.

The die casting process is a widely applied technique used by a variety of industries. This chapter reviews the casting design and engineering requirements for optimizing the characteristics of die castings.

This chapter explains how powder metallurgy technologies are being leveraged for the production of automotive components, electric motors, rare-earth permanent magnets, and the infrastructure for high-speed rail transport.