Precision Casting Processes for Automotive & Aerospace Components

Date: 19 Oct 2004 - 20 Oct 2004

Venue: SIMTech, Seminar Room, Valley Block, Level 1


Metal casting is the most effective and economical way of producing shaped metal components. However, it is essential that component designers and casting producers understand how to get the best performance from both the castings and the processes used to produce them. The unique feature of the casting process is the transformation of a liquid metal into a solid casting. The process of solidification is crucial to the structure, properties and integrity of the casting and, therefore, to its performance in the application for which it is intended. The production of a perfect casting requires that it be designed with an understanding of the influence that both the process of production and the design have upon solidification and the occurrence of defects such as porosity and inclusions. Customers seek castings that are dimensionally accurate, have a good surface and have as thin a section thickness as possible. Furthermore, they expect these castings to be free from defects that would adversely affect the mechanical properties and subsequent performance of the cast components. To meet these expectations, it is necessary that designers and producers fully understand the implications of the solidification process and the capabilities and limitations of the alternative casting production processes available.

The workshop will describe the range of casting processes suitable for producing precision castings in terms of dimensional accuracy, surface quality and metallurgical integrity. The emphasis will be on those processes suitable for the production of castings for automotive and aerospace components.
The casting processes that will be covered by the workshop include: precision sand casting processes (shell moulding and the Cosworth process); the ‘Lost Foam’ process (also known as EPC process); the ‘Lost Wax’ process (also known as investment casting); the die casting processes (to include gravity, low-pressure and high-pressure processes) and squeeze casting.

The workshop will also consider casting design from the perspectives of solidification and the avoidance of casting defects. In particular, the steps necessary to avoid porosity and inclusion defects will be described. Besides, how CAE technology can help casting product development will also be included in this workshop.

Workshop Leaders :

Dr Allen J Clegg holds a part-time post at Loughborough University where he has long-standing experience in teaching and research in cast metals. He is the author of a book entitled ‘Precision Casting Processes’ and has been involved in the development and presentation of short courses for industry for major clients that include Ford Motor Company and Rolls-Royce plc. Over the last 10 years, he has extended his interests to include environmental matters. With the support of the Royal Academy of Engineering, he has been responsible for developing and teaching modules to support ‘Engineering Design for Sustainable Development’. In 2004, Allen Clegg was appointed as a Visiting Senior Scientist at SIMTech where he provides support to the Forming Technology Group.

Dr Fu Ming Wang is a Senior Research Engineer of the Forming Technology Group, SIMTech, working on metal forming technology and metal forming product design and development. His R&D activities focus on metal forming process, integrated CAE simulation and analysis, dies and moulds CAD, and bulk nanostructured materials processing. Over the past ten years, he has been conducting extensive research on how CAD technology and CAE simulation help metal forming product development. Dr Fu is also the co-author of a book entitled “Computer-aided injection mould design and manufacture” published by Marcel Dekker, Inc., New York.