Casting Design

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Learning Outcomes

  • Describe the effect of different alloy characteristics on a finished casting product.
  • Identify material property factors to be considered when choosing a casting alloy.
  • Identify how production and service requirements affect the casting method chosen.
  • Choose an appropriate casting process based on the complexity and manufacturability of a part.
  • Identify the secondary operations that affect casting design.
  • Identify factors that control casting tolerance.
  • Describe the benefits of simulation in casting design.

Course Introduction

This course delves into the major factors that affect final part design. Participants will explore alloy selection, metalcasting process capabilities and limitations and their effects on casting design, and the impact of secondary operations. Other major topics will include design for manufacturability, fab to casting design conversions, dimensional control, and the importance of casting simulation. Discussion and case studies will be used throughout this two-day course to illustrate effective and practical casting design principles. Participants should have knowledge and experience in designing engineered components prior to attending this course.

Module 1: Introduction

Module 2: Approach to Design

  • Understanding the End Product You are Designing
  • Design Approach

Module 3: Casting Materials

  • Selecting a Casting Alloy
  • Comparison of Alloy Selection

Module 4: Selecting a Metalcasting Process

  • Selection Considerations
  • Casting Methods
  • Additive Manufacturing

Module 5: Practical Casting Design

  • Dimensional Control
  • Considerations of Secondary Operations in Design
  • Casting Simulation
  • Design Conversions

Module 6: Conclusion Activities

 

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