MFE 230

CASTING I

David Berdahl
Cal Poly
Pomona
MFE 230
WHAT IS CASTING?

Casting is a manufacturing process in which a

liquid material is usually poured into a mold,
which contains a hollow cavity of the desired
shape, and then allowed to solidify.
Process:
Make a hole -> melt metal -> pour it into the hole ->
solidify -> remove and clean
THE SOLIDIFICATION PROCESS

3 Stages
Stage 1
Liquid

Stage 2
Liquid + Solid
Stage 3
Solid
 SOLIDIFICATION: GRAIN FORMATION
Nucleation
The 3 Zones
Solid/Chill (TS)
Mushy Zone
Liquidus (TL)

Freezing Range
F = TL - TS
SOLIDIFICATION: COOLING RATE AND TIME

Slow Cooling Rate

Result in course/large dendritic grain structure
Less ductile and less strength and more porosity
High Cooling Rate
Result in finer grain structure
Higher ductility, more strength, less voids, less porosity
Solidification Time
Chvorinovs Rule
T = C (Volume/ Surface Area)^n
C is the casting constant and n is usually 2
SOLIDIFICATION: MICRO/ MACROSEGREGATION
When material cools at a fast rate, alloyed
materials have:
Microsegregation
Core of dendrite is different than its outer
edges
Macrosegregation
Differences in the alloy are throughout the
casting
Can combat by adding a inoculant to the
alloy so that the alloy does not sepparate
PARTS OF A CASTING
SOLIDIFICATION AND ISSUES

Shrinkage
Worst phase is liquid to solid
Porosity
Discontinuities/ Tears

Cavities

Incomplete casting/ Cold Shut

FLUID FLOW AND CASTING DESIGN
Gating design
Bernoullis Theorem
2
+ + =
2
h = height above reference level
p = pressure at height
= density of metal
v = velocity of fluid

Law of Continuity
Q = v1A1 = v2A2
USE OF THE 2 EQUATIONS AND SPRUE DESIGN

Fluid flow is essential to mold fill

If path is not designed properly, fluid can
aspirate/ cause turbulence or have air infused
This can cause porosity

Can be combated by a tapered sprue or

choking the sprue
FLUIDITY/ FILLABILITY

Temperature and superheat affect viscosity of

liquid and amount of heat to be removed
mold design-V/SA ratios and, mold material
(sand vs. metal) affect heat transfer rates,
pouring rate
Spiral Test
SHRINKAGE

Can cause
Partdimensional change
Porosity

Can be minimized by optimizing gating and

strategically sizing and placing risers
Use mold design software
PROCESS SIMULATION (CASTING)
THE RESULT