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MECH 423 Casting, Welding, Heat
Treating and NDT
Introduction
Lecture 2
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Solidification/Freezing
Casting is a process where
Many defects gas porosity and shrinkage also happen this time
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Solidification/Freezing
Nucleation:- formation of stable particle of solid material within
the molten liquid.
New surfaces are created at the interface between solid and liquid
called super or
undercooling
Solidification/Freezing
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Solidification/Freezing
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Cooling Curves
Study temperature of cooling metal:- thermal analysis
melting point
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Cooling Curves
Cooling rate is the rate at which liquid solidifies. It is the slope of
the cooling curve at a given point T/ t
At thermal arrest heat is being removed from the mould comes
from latent heat due to solidification
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Cooling Curves
Alloys (non-eutectic) usually have freezing range; change in
slope of T/ t.
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Cooling Curves
If undercooling required for nucleation, heat of fusion increases
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Solidification Time: Chvorinovs Rule
ts = total solidification time
n
V
t s B
n = constant (1.5 - 2.0)
A
V = volume of casting
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Solidification Time: Chvorinovs Rule
This value can be used for computing Ts of other castings
before riser
FIGURE 13.6 Cross-sectional structure of a cast metal bar showing the chill
zone at the periphery, columnar grains growing toward the center, and
central shrinkage cavity.
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Cast Structure
Columnar zone at the end of chill zone as
large grains).
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Cast Structure
Equiaxed zone in many materials nucleation
directions) properties
Preferable structure
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Molten Metal Problems
Liquid metals tend to be REACTIVE. (Atmosphere, crucible, mould
surface finish
machinability
dross or slag
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Molten Metal Problems
Dross or slag can be controlled by good foundry practice
(titanium).
Let oxides float on surface; take liquid metal from below so that the
oxide stays back and does not go into the casting. (figure 13.7)
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Molten Metal Problems
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Molten Metal Problems
Gas Porosity liquid metals contain
gas porosity
atmospheric contact
environment
argon, chlorine in Al). Dissolved gas enters this flushing gas and is
carried away.
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Surface Films
Some gases enter liquid and diffuse into bulk (hydrogen in al) but
Ductile cast iron - more difficult than gray cast iron due to Mg.
High Temp. alloys (many elements which can form oxides Al etc.)
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Surface Films
POURING -This should be carried out to minimize turbulence.
Use filters.
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Surface Films
Figure 1.11 The effect of increasing Figure 1.14 Confluence geometries: (a) at the side of a
height on a falling stream of liquid round core; (b) randomly irregular join on the top of a
illustrating: ( a) the oxide film remaining bottom-gated box; and ( c) a straight and reproducible join
intact; (b) the oxide film being detached on the top of a bottom-gated round pipe ( Campbell, 1988) .
and accumulating to form a dross ring;
and (c) the oxide film and air being
entrained in the bulk melt.
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Effect of Surface Films
Machining - Oxide particles in Al alloys
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Effect of Surface Films
Mechanical Properties
resistance.
Fluidity
Cleaner melts are more fluid and can be cast at lower temps.
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Fluidity
require good flow of molten metal to all
affects interactions
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Gating Systems
Gating system distributes molten metal to all parts of cavity
CSA of various channels can regulate flow shape and length can control
Gating can also prevent dross from entering the cavity. Long flat
runners with more time for dross to raise will do it, but material will
cool faster
Ceramic filters can be added to trap dross and other foreign bodies
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Gating Systems
Figure 2.8 (a) A simple funnel pouring cup, not recommended in general; (b) a
weir bush of excellent design, whose upward circulation will assist in the
separation of slag and dross, but which would need to be carefully matched to the
entrance diameter of the sprue in the cope; and (c) an offset bush with an open
base recommended for general use.
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Gating Systems
Figure 2.14 Various
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Gating Systems & Filters
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Gating System Design
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Gating Systems - Pressure
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Gating Systems - Gravity
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Solidification Shrinkage
Three stages of shrinkage (volumetric contraction)
temperature
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Solidification Shrinkage
Eject casting immediately in die
casting to avoid cracking ?
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Risers and Riser Design
Added reservoirs to feed liquid metal to solidifying casting.
Rules:
them
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Risers and Riser Design
Top Riser - sits on top of casting (short feeding
distance)
Dead (cold) Riser - filled before or concurrent with cavity by metal that
has flown through the mould. (top riser dead riser)
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Risers and Riser Design n
V
Use Chvorinovs Rule. ts B
Mould constant, B is the same, Assume n = 2. A
Make riser take 25% longer to freeze, i.e.; triser = 1.25tcasting
2 2
Vriser Vcasting
1.25
Ariser Acasting
Insert modulus of casting and then calculate riser size.
Note: Only use riser areas that allow heat loss - discount
common surfaces.
shapes
a surface
solidify last
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Risers and Riser Design
Riser has to be removed from casting (as well as runner/gate)
Note: Risers are not always required. For alloys with large freezing
common.
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Risering Aids
Generally done by
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Risering Aids
CHILLS - External and Internal
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Risering Aids
To slow cooling of a riser:
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Risers and Riser Design
General design rules
iron castings;
a. general riser
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Gating System Design
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Gating System Design
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Gating System Design
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Gating System Design
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Gating System Design
A - gates
B - runner
System is often designed to
C - Sprue exit (Choke)
follow ratio of (CSA) 1:2:2, or
1:4:4 WRT:
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