Introduction to Manufacturing Processes Assignment 2022

Running Head: INTRODUCTION TO MANUFACTURING PROCESSES
Introduction to Manufacturing Processes
Name
Institutional affiliation

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Table of Contents
ASSIGNMENT QUESTION 1...................................................................................................................... 2
INTRODUCTION....................................................................................................................................... 2
CASTING................................................................................................................................................. 2
History................................................................................................................................................ 3
Types of Casting and Applications...................................................................................................... 3
i. Investment Casting................................................................................................................. 4
Advantages and Disadvantages of Investment Casting...................................................................4
ii. Centrifugal Casting.................................................................................................................. 4
Advantages and Disadvantages of Centrifugal Casting...................................................................5
iii. Die Casting.............................................................................................................................. 5
Advantages and Disadvantages of Die Casting............................................................................... 6
iv. Sand Casting........................................................................................................................... 6
Advantages and Disadvantages of Sand Casting............................................................................ 6
CASTING DEFECTS.................................................................................................................................. 7
a) Metallurgical Defect.................................................................................................................... 7
b) Pouring Metal Defect................................................................................................................... 7
c) Gas Porosity................................................................................................................................ 8
d) Shrinkage Defects....................................................................................................................... 9
CONCLUSION.......................................................................................................................................... 9
ASSIGNMENT QUESTION 2.................................................................................................................... 10
INTRODUCTION..................................................................................................................................... 10
CHARACTERISTICS................................................................................................................................ 10
i. Biocompatibility........................................................................................................................ 10
ii. Self-assembly............................................................................................................................ 11
iii. Bioactivity................................................................................................................................. 11
iv. Mechanical Properties............................................................................................................... 11
FABRICATION PROCESS........................................................................................................................ 12
Life-cycle Cost.................................................................................................................................. 13
CHEMICAL AND MECHANICAL PROPERTIES........................................................................................... 13
a) Stiffness................................................................................................................................ 14
b) Strength................................................................................................................................ 14
c) Ductility................................................................................................................................. 14
d) Mass Density......................................................................................................................... 15
e) Thermal Conductivity............................................................................................................ 15
f) Electrical Conductivity........................................................................................................... 15
g) Durability.............................................................................................................................. 15
CONCLUSION........................................................................................................................................ 16
REFERENCES........................................................................................................................................ 17

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ASSIGNMENT QUESTION 1
INTRODUCTION
The aim of this assignment is to gather more knowledge on the process of casting in the
manufacturing industry majorly casting defects and quality test methods, types of casting and
applications as well as history and process of casting. This assignment also discusses emerging
engineering materials with a major focus being on its characteristics, fabrication process, and the
mechanical and chemical properties of the materials.
CASTING
The process of casting can be defined as a manufacturing process in which a liquid material is
normally poured into a mold possessing a hollow cavity of the shape desired and then permitted
to solidify. The part solidified is referred to as casting which is broken or ejected out of the mold
to finish the procedure (Yajun, Wang, Wang, & Huang, 2019). The process of casting is a
process of engineering manufacturing normally used in mass production of complex materials in
which materials in a molten state are poured into a mold to allow for the process of solidification.
Figure 1: Flow Chart of Casting Process (Ringleb & Schlüter, 2014)

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Through the casting process, complex components can be rapidly and economically
manufactured which could have involved a lot of time to manufacture through other approaches
such as cutting or shaping (Ringleb & Schlüter, 2014). This process is used to manufacture
parts like machine tool beds, cylinder blocks, wheels, mill rolls, and pistons.
History
The casting process is one of the ancient manufacturing methods known to humans and a very
direct approach to manufacturing metallic components. The first casting processes can be dated
in the 4th Century BC to ancient China (Pinto & Silva, 2017). Through the process of casting,
molten metal is transferred into a mold which corresponds to the ultimate dimensions of the
completed product. Despite every metal having the ability to be cast, the most dominant include
copper-based alloys, steel, aluminum, and iron.
Figure 2: Casting Process (Salonitis, Jolly, & Zeng, 2017)
Types of Casting and Applications
Different processes of casting are available for application and their suitability is affected by
various factors such as surface finish required, dimensional accuracy required, product material,
manufacturing, and quantity of casting. The major processes of casting used during
manufacturing process include the following: