Centrifugal casting

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Centrifugal casting or rotocasting is a casting technique which has application across a wide range of industrial and artistic applications.

Processes

Centrifugal casting is used as a means of casting small, detailed parts or jewelry. An articulated arm is free to spin around a vertical axle, which is driven by an electric motor or a spring. The entire mechanism is enclosed in a tub or drum to contain hot metal should the mold break or an excess of metal be used. Single use molds are prepared using the lost wax method. A small amount of metal in a crucible (a sort of ceramic pan) next to the mold is heated with a torch. When the metal is molten the arm is released, forcing (by centrifugal force) the metal into the mold. The high forces imposed on the metal overcome the viscosity, resulting in a finely detailed workpiece. A similar advantage is obtained by vacuum casting.

For industrial casting of small parts using poured hot metal, a disk shaped mold is contained within a rotating drum, and molten metal is poured into the center.

It is applied to the fabrication of large telescope mirrors, where the natural curve followed by the molten glass greatly reduces the amount of grinding required. Rather than being cast by pouring glass into a mold an entire turntable containing the peripheral mold and the back pattern (a honeycomb pattern to lighten the finished product) is contained within a furnace and charged with the glass material used. The assembly is then heated while spun at slow speed until the glass is liquid, then gradually cooled over a period of months.

The technique is known in the glass industry as "spinning". The centrifugal force pushes the molten glass against the mold wall, where it solidifies. This cooling process takes anywhere between 16 to 72 hours depending on the impurities or volume of material. Typical products made using this process are television picture tubes and missile nose cones.

Applications

Centrifugal casting is commonly used to shape glass into spherical objects such as marbles.

In centrifugal casting, a permanent mold is rotated about its axis at high speeds (300 to 3000 rpm) as the molten metal is poured. The molten metal is centrifugally thrown towards the inside mold wall, where it solidifies after cooling. The casting is usually a fine grain casting with a very fine-grained outer diameter, which is resistant to atmospheric corrosion, a typical situation with pipes. The inside diameter has more impurities and inclusions, which can be machined away.

Centrifugal casting is also applied to the casting of disk and cylindrical shaped objects such as railway carriage wheels or machine fittings where the grain, flow, and balance are important to the durability and utility of the finished product. It is used by UFIP for casting cymbals.

Machinery

Many machines are available which can perform centrifugal casting, and they are relatively simple to construct. All that is required is an arm which rotates with an adequate amount of centrifugal force, a container on the end of said arm to hold both a mold and the material to be cast into the mold.

Materials

Typical materials that can be cast with this process are iron, steel, stainless steels, glass, and alloys of aluminum, copper and nickel. Two materials can be cast by introducing a second material during the process. Typical parts made by this process are pipes, boilers, pressure vessels(see autofrettage), flywheels, cylinder liners and other parts that are axi-symmetric.

See also

• Spin casting

References

• Manufacturing Engineering and Technology 5th ed. Serope Kalpakjian, Steven R. Schmid p. 525

External links

• Castcraft site with light industrial spin casting machine using a rotating mold
• Efunda site page with centrifugal casting fundamentals
• Johnson Brass & Machine Foundry with movies of the centrifugal casting process

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