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    IE 337 W10 Lecture 7.casting 1

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    This document provides an overview of metal casting processes and concepts. It discusses the basic casting process which involves pouring molten metal into a mold and allowing it to solidify. It describes expendable and permanent mold casting and focuses on sand casting. Key concepts covered include gating systems, risers, heating metal, pouring calculations, solidification of pure metals and alloys, phase diagrams, and sources of shrinkage. Solidification time is also discussed using Chvorinov's rule.

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    IE 337 W10 Lecture 7.casting 1

    Uploaded by

    linkinun
    187 views48 pages
    This document provides an overview of metal casting processes and concepts. It discusses the basic casting process which involves pouring molten metal into a mold and allowing it to solidify. It describes expendable and permanent mold casting and focuses on sand casting. Key concepts covered include gating systems, risers, heating metal, pouring calculations, solidification of pure metals and alloys, phase diagrams, and sources of shrinkage. Solidification time is also discussed using Chvorinov's rule.

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    IE 337 W10 Lecture 7.Casting 1

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    This document provides an overview of metal casting processes and concepts. It discusses the basic casting process which involves pouring molten metal into a mold and allowing it to solidify. It describes expendable and permanent mold casting and focuses on sand casting. Key concepts covered include gating systems, risers, heating metal, pouring calculations, solidification of pure metals and alloys, phase diagrams, and sources of shrinkage. Solidification time is also discussed using Chvorinov's rule.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    187 views48 pages

    IE 337 W10 Lecture 7.casting 1

    Uploaded by

    linkinun
    This document provides an overview of metal casting processes and concepts. It discusses the basic casting process which involves pouring molten metal into a mold and allowing it to solidify. It describes expendable and permanent mold casting and focuses on sand casting. Key concepts covered include gating systems, risers, heating metal, pouring calculations, solidification of pure metals and alloys, phase diagrams, and sources of shrinkage. Solidification time is also discussed using Chvorinov's rule.

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    of 48

    IE 337: Materials & Manufacturing

    Processes
    Lectures 7&8:
    Introduction to Metal
    Casting
    Chapters 10 & 6

    Assignment
    HW

    2 due today

    CH 21,22 and 24 Problems


    In Assignments folder

    This Time
    Basic

    Process
    Casting Terminology
    Heating
    Pouring
    Phase diagrams
    Solidification

    Casting
    Common process attributes:
    Flow

    of Molten Liquid
    Requires Heating

    Heat

    Transfer of Liquid in
    Mold Cavity During and
    After Pouring

    Solidification

    into Component

    Metal Casting Processes Categories


    1.

    Expendable mold processes - mold is


    sacrificed to remove part

    2.

    Permanent mold processes - mold is made of


    metal and can be used to make many castings

    Advantage: more complex shapes possible


    Disadvantage: production rates often limited by
    time to make mold rather than casting itself

    Advantage: higher production rates


    Disadvantage: geometries limited by need to open
    mold

    Overview of Sand Casting


    Most

    widely used casting process, accounting


    for a significant majority of total tonnage cast
    Nearly all alloys can be sand cast, including
    metals with high melting temperatures, such as
    steel, nickel, and titanium
    Parts ranging in size from small to very large
    Production quantities from one to millions

    Sand Casting

    Sand casting mold

    Gating System
    Channel through which molten metal flows into
    cavity from outside of mold
    Consists of a downsprue, through which metal
    enters a runner leading to the main cavity
    At top of downsprue, a pouring cup is often
    used to minimize splash and turbulence as the
    metal flows into downsprue

    Riser
    Reservoir in the mold which is a source of liquid
    metal to compensate for shrinkage during
    solidification
    The riser must be designed to freeze after the
    main casting in order to satisfy its function

    Heating the Metal

    Heating furnaces are used to heat the metal to


    molten temperature sufficient for casting
    The heat required is the sum of:
    1. Heat to raise temperature to melting point
    2. Heat of fusion to convert from solid to liquid
    3. Heat to raise molten metal to desired temperature
    for pouring

    10

    Heating the Metal


    1. Heat to melting point: VCs(Tm-To)
    2. Heat of fusion to convert from solid to liquid: VHf
    3. Heat molten metal to pouring temp.: VCl(Tp-Tm)
    density, V = volume, Cs = specific heat,
    Hf = latent heat of fusion, T = temperature
    Properties vary with temperature and phase
    Melting may occur over a temperature range
    Heat loss to the ambient

    11

    Pouring the Molten Metal


    For

    this step to be successful, metal must flow


    into all regions of the mold, most importantly
    the main cavity, before solidifying
    Factors that determine success:
    Pouring temperature
    Pouring rate
    Turbulence

    12

    Pouring Calculations 1
    Minimum mold filling time, MFT
    MFT =V/Q
    Q: volumetric flow rate, cm3/s
    V: mold cavity volume, cm3

    13

    Pouring Calculations 2
    Volumetric flow rate remains constant
    Q =v1A1 = v2A2
    Q: volume rate of flow cm3/s
    v: velocity of the liquid metal
    A: cross-sectional area, cm2
    CONTINUITY EQUATION
    14

    Increase in area results in decrease in velocity

    Pouring Calculations 3
    Flow of liquid metal through gating system & mold
    v = (2gh)1/2
    v: velocity of the liquid metal at base of sprue
    g = gravitational acceleration, 981 cm/s2
    h = height of sprue, cm
    15

    Example 1
    The

    downsprue leading into the runner of a


    certain mold has a length = 175 mm.
    The cross-sectional area at the base of the
    sprue is 400 mm2.
    The mold cavity has a volume = 0.001 m3.
    Determine: (a) the velocity of the molten metal
    flowing through the base of the downsprue, (b)
    the volumetric flow rate, and (c) the time
    required to fill the mold cavity.
    16

    Example 1: Solution
    (a)

    Velocity v = (2gh)0.5
    = (2 x 9810 x 175)0.5
    = 1853 mm/s
    (b) Volume flow rate Q = vA
    = 1853 x 400
    = 741,200 mm3/s
    (c) Time to fill cavity MFT = V/Q

    17

    Solidification of Pure Metals

    18

    A pure metal solidifies at a constant temperature


    equal to its freezing point (same as melting point)

    Solidification and Cooling

    Figure 10.8 Shrinkage of a cylindrical casting during solidification


    and cooling: (0) starting level of molten metal immediately after
    pouring; (1) reduction in level caused by liquid contraction during
    cooling (dimensional reductions are exaggerated for clarity).

    Microstructure: I

    20

    Characteristic grain structure in a casting of a pure metal,


    showing randomly oriented grains of small size near the mold
    wall, and large columnar grains oriented toward the center of the
    casting

    Solidification of Alloys

    Most alloys freeze over a temperature range rather


    than at a single temperature

    21

    Microstructure: II

    Micro-segregation
    Characteristic grain structure in an alloy casting, showing
    segregation of alloying components in center of casting

    22

    Microstructure: II

    Macro-segregation
    Characteristic grain structure in an alloy casting, showing
    segregation of alloying components in center of casting

    23

    Phase Diagrams
    A graphical means of representing the phases of
    a metal alloy system as a function of
    composition and temperature
    A phase diagram for an alloy system consisting
    of two elements at atmospheric pressure is
    called a binary phase diagram
    Other forms of phase diagrams are
    discussed in texts on metallurgy and
    materials science

    Phase Diagrams
    Composition is plotted on the horizontal axis
    and temperature on the vertical axis
    Any point in the diagram indicates the overall
    composition and the phase or phases present
    at the given temperature under equilibrium
    conditions

    Copper-Nickel Phase Diagram

    Figure 6.2 Phase diagram for the coppernickel alloy


    system.

    CopperNickel (Cu-Ni) Alloy System


    Solid solution alloy throughout entire range of
    compositions below the solidus
    No intermediate solid phases in this alloy
    system
    However, there is a mixture of phases (solid +
    liquid) in the region bounded by the solidus and
    liquidus

    Chemical Compositions of Phases


    The overall composition of the alloy is given by
    its position along the horizontal axis
    However, the compositions of liquid and solid
    phases are not the same
    These compositions can be found by
    drawing a horizontal line at the temperature
    of interest
    Where the line intersects the solidus and
    liquidus indicates the compositions of solid
    and liquid phases, respectively

    Example
    Determine compositions of liquid and solid phases
    in the Cu-Ni system at an aggregate composition
    of 50% nickel and a temperature of 1316oC
    (2400oF)

    Inverse Lever Rule Step 1


    The phase diagram can be used to determine
    the amounts of each phase present at a given
    temperature
    Using the horizontal line that indicates
    overall composition at a given temperature,
    measure the distances between the
    aggregate composition and the intersection
    points with the liquidus and solidus,
    identifying the distances as CL and CS,
    respectively

    Inverse Lever Rule Step 2


    The proportion of liquid phase present is given
    by
    L phase proportion =

    CS
    (CS CL )

    And the proportion of solid phase present is


    given by
    CL
    S phase proportion =
    CS CL

    Applications of the Inverse Lever Rule


    Methods for determining chemical composition
    of phases and amounts of each phase are
    applicable to the solid region of the phase
    diagram as well as the liquidussolidus region
    Wherever there are regions in which two phases
    are present, these methods can be utilized
    When only one phase is present, the
    composition of the phase is its aggregate
    composition under equilibrium conditions, and
    the inverse lever rule does not apply

    Tin-Lead Phase Diagram

    Figure 6.3 Phase diagram for the tinlead alloy system.

    Effect of Solidification Rate

    34

    Mechanical properties of 2
    identical composition samples with
    different cooling rates

    Solidification Time
    Solidification

    takes time
    Total solidification time TST = time required for
    casting to solidify after pouring
    TST depends on size and shape of casting by
    relationship known as Chvorinov's Rule

    35

    Chvorinov's Rule

    V
    TST Cm
    A

    where TST = total solidification


    time;
    V = volume of the casting;
    A = surface area of casting;
    n = exponent usually taken to
    have a value = 2; and
    Cm is mold constant

    36

    Mold Constant in Chvorinov's Rule


    Cm

    depends on mold material, thermal


    properties of casting metal, and pouring
    temperature relative to melting point
    Value of Cm for a given casting operation can
    be based on experimental data from previous
    operations carried out using same mold
    material, metal, and pouring temperature, even
    though the shape of the part may be quite
    different
    37

    Example 1
    In

    casting experiments performed using a


    titanium alloy and a zircon sand mold, it took
    155 s for a cube-shaped casting to solidify.
    The cube was 50 mm on a side.
    If the same alloy and mold type were used, find
    the total solidification time for a cylindrical
    casting in which the diameter = 30 mm and
    length = 50 mm.
    38

    Example 1: Solution

    Cube Volume V
    = (50)
    = 125,000 mm3

    Cube Area A
    = 6 x (50)2
    = 15,000 mm2

    = 35,343 mm3

    Cylinder Area A
    = 2D2/4 + DL
    = (30)2/2 + (30)(50)
    = 6126 mm2

    Cylinder (V/A)
    = 35,343/6126
    = 5.77 mm

    Cm = TST/(V/A)2
    = 155/(8.33)2
    = 2.23 s/mm2

    39

    = D2L/4 = (30)2(50)/4

    Cube (V/A)
    = 125,000/15,000
    = 8.33 mm

    Cylinder Volume V

    TST = Cm(V/A)2
    = 2.23 (5.77)2 = 74.3 s

    What Chvorinov's Rule Tells Us


    A casting

    with a higher volumetosurface area


    ratio cools and solidifies more slowly than one
    with a lower ratio

    Since

    riser and casting mold constants will be


    equal, design the riser to have a larger
    volumetoarea ratio so that the main casting
    solidifies first

    40

    Shrinkage in Solidification and Cooling

    Figure 10.8 Shrinkage of a cylindrical casting during solidification


    and cooling: (0) starting level of molten metal immediately after
    pouring; (1) reduction in level caused by liquid contraction during
    cooling (dimensional reductions are exaggerated for clarity).

    Shrinkage in Solidification and Cooling

    Figure 10.8 (2) reduction in height and formation of shrinkage


    cavity caused by solidification shrinkage; (3) further reduction in
    height and diameter due to thermal contraction during cooling of
    solid metal (dimensional reductions are exaggerated for clarity).

    Solidification Shrinkage
    Occurs

    in nearly all metals because the solid


    phase has a higher density than the liquid
    phase
    Thus, solidification causes a reduction in
    volume per unit weight of metal
    Exception: cast iron with high C content
    Graphitization during final stages of freezing causes
    expansion that counteracts volumetric decrease
    associated with phase change

    43

    Shrinkage Allowance
    Patternmakers

    account for solidification


    shrinkage and thermal contraction by making
    mold cavity oversized (See Table 10.1)
    Amount by which mold is made larger relative
    to final casting size is called pattern shrinkage
    allowance

    44

    Example 2
    A mold

    cavity has the shape of a cube, 100


    mm on a side. Determine the volume and
    dimensions of the final cube after cooling to
    room temperature if the cast metal is copper.
    Assume that the mold is full at the start of
    solidification and that shrinkage occurs
    uniformly in all directions.
    For copper, solidification shrinkage is 4.9%,
    solid contraction during cooling is 7.5%.
    45

    Example 2: Solution
    Volume

    of cavity V
    = (100)3
    = 106 mm3
    Volume of casting V
    = 106(1-0.049)(1-0.075)
    = 879,675 mm3
    Dimension on each side of cube
    = (879,675)0.333
    = 95.82 mm
    46

    You should have learned


    Basic

    Process
    Sand Casting Terminology
    Heating
    Pouring
    Phase diagrams
    Solidification

    47

    Next Class
    Casting

    Continued

    Chapter 11

    48

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