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    Ch10 1

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    abeljhonson98

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    Ch10 1

    Uploaded by

    abeljhonson98
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    Ch10_1

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    5 views6 pages

    Ch10 1

    Uploaded by

    abeljhonson98

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    Solidification Contraction for Various Cast

    Metals
    TABLE 10.1
    Volumetric Volumetric
    solidification solidification
    Metal or alloy contraction (%) Metal or alloy contraction (%)
    Aluminum Al– 6.6 70%Cu–30%Zn 4.5
    4.5%Cu Al– 6.3 90%Cu–10%Al 4
    12%Si 3.8 Gray iron Expansion to 2.5
    Carbon steel 1% 2.5–3 Magnesium 4.2
    carbon steel 4 White iron Zinc 4–5.5
    Copper 4.9 6.5
    Source: After R. A. Flinn.
    Hot Tears

    Figure 10.11 Examples of hot tears in castings. These defects occur because the
    casting cannot shrink freely during cooling, owing to constraints in various
    portions of the molds and cores. Exothermic (heat-producing) compounds may
    be used (as exothermic padding) to control cooling at critical sections to
    avoid hot tearing.
    Casting Defects
    Figure 10.12 Examples of common defects in castings. These defects can be minimized or eliminated by
    proper design and preparation of molds and control of pouring procedures. Source: J. Datsko.
    Casting Defect
    Casting defects are classified by International Committee of Foundry
    Technical Associations. They mentioned seven basic categories of casting
    defects.
    A. Metallic projections: consisting of fins, flash or massive projections such
    as- swells and rough surfaces
    B. Cavities: consisting of rounded internal or exposed cavities, including
    blow-holes, pinholes and shrinkage cavities
    C. Discontinuities: such as- cracks, hot tearing and cold shut. If the
    solidifying metal is constrained from shrinking freely, cracking and
    tearing can occur. Cold shut is an interface in a casting that lacks
    complete fusion because of meeting of two streams of liquid metal from
    different gates
    D. Defective surface: such as- surface folds, laps, scars, adhering sand layers
    and oxide scale
    Casting Defect
    E. Incomplete casting: such as – misruns due to premature solidification,
    insufficient volume of metal poured and run out ( loss of metal from
    mold after pouring). Incomplete casting can result from the molten
    metal being at too low temperature or from pouring the metal too
    slowly
    F. Incorrect dimension or shape: Due to improper shrinkage allowance,
    pattern mounting error, irregular construction, deformed pattern
    G. Inclusion: Form during melting, solidification and molding. Generally
    non-metallic and they are regarded as harmful, because they act as
    stress riser and reduce strength. Inclusion may form during melting by
    reacting with O2 or crucible or mold materials. Slags and other foreign
    materials entrapped in the molten metal also become inclusions.
    Spilling of the mold or core surfaces also produce inclusions.
    Internal and External Chills
    Figure 10.13
    Various types of
    (a)internal and
    (b)external chills
    (dark areas at
    corners), used in
    castings to
    eliminate porosity
    caused by
    shrinkage. Chills
    are placed in
    regions where
    there is a larger
    volume of metals,
    as shown in (c).

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