Metal Casting. Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No.

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1 Metal Casting

2 Important factors in casting Solidification of the metal from its molten state and accompanying shrinkage Flow of the molten metal into the mold cavity Heat transfer during solidification and cooling of the metal in the mold Mold material and its influence on the casting operation

3 Solidification of Metals Pure metals have clearly defined melting or freezing points and solidification takes place at a constant temperature. The latent heat of fusion is released during the freezing leading to this fixed temperature of melting/freezing After solidification the solid metal contracts a it cools down to room temperature

4 Alloys, on the other hand, solidify over a range of temperatures (freezing range) between the Liquidus and the Solidus In this range the alloy is in a mushy or pasty state

5 Temperature & Density for Castings FIGURE 5.1 (a) Temperature as a function of time for the solidification of pure metals. Note that freezing takes place at a constant temperature. (b) Density as a function of time.

6 Cast Structures Pure Mretals A typical grain structure of a solidified pure metal consists of the following zones: A chill zone (skin) as the shell in contact with the mold walls solidify. This is characterized by fine grained shell around the casting due to the initially high cooling rates.

7 Columnar grains which have a preferential growth direction due to the fact that solidification proceeds in opposite direction to heat transfer Grains having substantially different direction of growth are blocked from further growth

8 FIGURE 5.5 Schematic illustration of three cast structures of metals solidified in a square mold: (a) pure metals, with preferred texture at the cool mold wall. Note in the middle of the figure that only favorable oriented grains grow away from the mold surface; (b) solid-solution alloys; and (c) structure obtained by heterogeneous nucleation of grains. Texture in Castings

9 Cast Structures / Alloys As the alloy enter the mushy state within its freezing range, it develops columnar dendritic grains The alloys tend to develop a third zone of equi-axed grains in the middle of the casting If heterogeneous nucleation is used then a fully equi-axed grained structure may be obtained

10 Alloy Solidification & Temperature FIGURE 5.6 Schematic illustration of alloy solidification and temperature distribution in the solidifying metal. Note the formation of dendrites in the semi-solid (mushy) zone.

11 Solidification Patterns for Gray Cast Iron FIGURE 5.7 Schematic illustration of three basic types of cast structures: (a) columnar dendritic; (b) equiaxed dendritic; and (c) equiaxed nondendritic. Source: After D. Apelian.

12 Effect of Cooling Rate Slow cooling rates (100 K/s) or long solidification times result in coarse dendritic structures with large spacing between the dendrite arms Higher cooling rates (10000 K/s) or short solidification times result in coarse dendritic structures with smaller spacing between the dendrite arms

13 For even higher cooling rates ( K/s) solidification proceeds with the formation of amorphous structures (without any ordered crystalline structure)

14 Cast Structures FIGURE 5.8 Schematic illustration of three basic types of cast structures: (a) columnar dendritic; (b) equiaxed dendritic; and (c) equiaxed nondendritic. Source: After D. Apelian. FIGURE 5.9 Schematic illustration of cast structures in (a) plane front, single phase, and (b) plane front, two phase. Source: After D. Apelian.

15 Structure Property relationships As the structure becomes more fine-grained: The strength and ductility increase Microporosity (intedendritic shrinkage voids) decrease) Tendency for cracking (hot tearing) decreases

16 A lack of uniformity in grain size and distribution results in anisotropic properties. Slow cooling is more likely, however, to result in uniform composition of the dendrites, while fast cooling is likely to result in cored dendrites

17 The surface of the dendrites having compositions different to their core due to solute rejection in the liquid is known as microsegregation

18 Macrosegregation Differences in composition throughout the casting itself

19 Normal segregation when the solidification front moves as a plane front (see figure 5.9), lower melting point constituents move towards the center.

20 Inverse Segregation When the center of the casting has lower concentration of alloying elements as in the case of solid-solution alloys

21 Gravity Segregation Higher density inclusions and compounds sink while lighter ones float to the surface

22 Innoculants Nucleating agents added to the casting to enhance heterogeneous nucleation and extend the equi-axed grains zone (see figure 5.5b) An example is TiB2 in Aluminum alloys to refine grain patterns and improve mechanical properties

23 Rheocasting Breaking dendrites by mechanical or electromagnetic action to promote heterogeneous nucleation (Fig. 5.8-b)

24 Fluid Flow Consider a basic gravity casting system The molten metal is poured through a pouring basin it then flows through the sprue to the well and into the runners to the mold cavity Risers (also known as feeders) serve as reservoirs of molten metal to supply the metal necessary to substitute for shrinkage

25 Successful casting requires proper design and control of the solidification process to ensure adequate fluid flow during casting

26 Requirements of gating system Contaminants trapping; causing the contaminants (oxides and other inclusions) to adhere to the gating system walls and prevent their reach to the mold cavity Avoid or minimize problems such as premature cooling, turbulence and gas entrapment and introduction of impurities into the molten metal

27 Fluidity of the molten metal The ability of the molten metal to fill mold cavities Fluidity depends on: Molten metal characteristics and Casting parameters

28 Molten metal characteristics Viscosity. Fluidity decrease as viscosity Increase Surface tension. A higher surface tension of the liquid metal (such as the presence of oxide film on the metal surface) significantly affects fluidity in an adverse manner

29 Inclusions. The presence of inclusions significantly affects fluidity in an adverse manner (observe the flow of a liquid through sand particles) Solidification pattern of the alloy. Fluidity is inversely proportional to the freezing range

30 Casting Parameters Mold design. The design and dimensions of the gating system, risers, etc., Mold material and its surface characteristics. The higher the thermal conductivity of the mold material the lower the fluidity Higher degree of super heat improves fluidity Heat transfer directly affects the molten metal viscosity and, hence, fluidity

31 Test for Fluidity A common test is to let molten metal flow along a channel that is at room temperature The distance the metal travels before it solidifies and stops running is an indication of its fluidity

32 Mold Features FIGURE 5.10 Schematic illustration of a typical sand mold showing various features.

33 Temperature Distribution FIGURE 5.11 Temperature distribution at the mold wall and liquid-metal interface during solidification of metals in casting

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