Defectformationincastiron

LennartElmquist
SchoolofEngineering
JnkpingUniversity
Sweden
Tammerfors,Finland,November8,2012
Introduction
Casting
Mouldcavity
Meltingprocess
Pouring
Solidification
Mouldremoval
Cleaningandfinishing
Advantages
Complexshapes
Holesandinnercavities
Widerangeofalloys
Melttreatment
Economical
Lennart Elmquist
Tammerfors 2012-11-08
2
Introduction
Commondefects:
Blowholes
Pinholes
Shrinkage
Penetration
Inclusions
etc
Lennart Elmquist
Tammerfors 2012-11-08
DEFECTS!
Shrinkageporosity
Metalexpansionpenetration
Slaginclusiondefect
Carbonmonoxideblowhole
3
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
4
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
5
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
6
(Source: Torsten Sjgren)
Gasdefects Introduction
Lennart Elmquist
Tammerfors 2012-11-08
Source: Diszegi, 2005 Source: UAB Casting Engineering Laboratory (CEL), 2005
7
Gasdefects Introduction
Degradationofbindermaterial
Gasprecipitateduringsolidificationdueto
decreasedsolubility
Gasmaybepickedupbythemeltduring
mouldfilling
Slagconstituentscanreactwithalloying
additionsinthemetalandformgaseous
reactionproducts
Lennart Elmquist
Tammerfors 2012-11-08
8
Gasdefects Introduction
Hydrogenpinholes
Nitrogenpinholes
Blowholes
Fissures
Carbonmonoxide
Slagblows
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
9
Pinholes
Hydrogen,nitrogen,CO
Revealedaftermachining
Usuallysmall
Roundshape
Graphitelining
Remedies
LowlevelsofAlandTi
Controlofsteelscrap
Coresandwaterbased
coatingsfullycuredand
dried
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
10
Pinholes
Hydrogenpinholes
Waterandorganicmaterials
Airhumidity
Rustychargematerial
Damprefractorymaterial
Moistureinmoldandcore
Corebinder
Lennart Elmquist
Tammerfors 2012-11-08
Nitrogenpinholes
Resinbondedcoresand
molds
Sandadditives
Coatingsandglues
Chargematerials
Source: http://www.objet.sk/content/products/sand_casting_a4.pdf
11
Pinholes
Carbonmonoxidepinholes
Reactionofcarbonandoxygen
Liquidslagrichinironoxide
CO
2
reactwithiron
Carbonreactwithwater
Nographitelining
MnSandslaginclusions
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
12
Blowholes
Largecavities
Normallyirregularinshape
Smoothwalls
Graphitelining
Highturbulenceduring
moldfilling
Highgaspressureinthe
mold
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
13
Blowholes
Castingdesign
Gating
Sandpermeability
Coreprintarea
Typeofresinsystem
Extentofcureanddrying
Pouringtemperature
Rustychaplets
Cloggedvents
etc
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
14
Fissures
Narrowcracklikecavities
Frequentlyhavedendritic
structures
Excessivenitrogenmain
cause
Hydrogenmayintensifythe
defect
Sources
Nitrogencontenthigh
Highnitrogencontentin
corebinder
Poorcoreventing
Lennart Elmquist
Tammerfors 2012-11-08
15
Source: www.ikominerals.de
Solubilityofgases
1. Diffusionofgastothesurface
2. Chemicalreactiononthe
surface
3. Diffusionofoneormore
reactionproductsawayfrom
thesurface
Lennart Elmquist
Tammerfors 2012-11-08
( ) H g H 2
2

| | ( )
2
H P K H
H
=
Source: Svensson et al, 1980
16
Solubilityofgases
Hydrogen Nitrogen
Lennart Elmquist
Tammerfors 2012-11-08
Influenceofalloyingelementsonsolubility
Source: Weinstein et al, 1963 Source: Dawson et al, 1965
17
Solubilityofgases
Thesolubilityofhydrogen
andnitrogenaffecteach
other
Cumulativeeffectthat
increasetheriskfor
porosity
Lennart Elmquist
Tammerfors 2012-11-08
| | ( )
2
N P K N
N
=
2
2
N H TOT
P P P + =
Source: Svensson et al, 1980
18
Gaslevelsinproduction
Meltingmethods
Differentfoundries
Differentfurnaces
Longperiodoftime
Lennart Elmquist
Tammerfors 2012-11-08
19
Gaslevelsinproduction
Hydrogen
Preheating
Holdingtime
Nitrogen
Meltingmethod
Chargematerial
Lennart Elmquist
Tammerfors 2012-11-08
1250 1300 1350 1400 1450 1500 1550
Temperature [C]
40
80
120
160
N
i
t
r
o
g
e
n

c
o
n
c
e
n
t
r
a
t
i
o
n

[
p
p
m
]
Cup. melt, sampling 1
Cup. melt, sampling 2
Ind. melt, sampling 1
Ind. melt, sampling 2
1250 1300 1350 1400 1450 1500 1550
Temperature [C]
0
0.5
1
1.5
2
2.5
3
3.5
H
y
d
r
o
g
e
n

c
o
n
c
e
n
t
r
a
t
i
o
n

[
p
p
m
]
Cup. melt, sampling 1
Cup. melt, sampling 2
Ind. melt, sampling 1
Ind. melt, sampling 2
20
Source: Orlenius, Elmquist, Diszegi, 2007
Gaslevelsinproduction
Oxygen
Dissolvedoxygen
Oxygenfound inoxides
Totalamount of oxygen
Difference between
processes
Lennart Elmquist
Tammerfors 2012-11-08
21
1250 1300 1350 1400 1450 1500 1550
0
0.5
1
1.5
2
2.5
3
3.5
4
Temperature [C]
D
i
s
s
o
l
v
e
d

o
x
y
g
e
n

[
p
p
m
]
Source: Elmquist, Orlenius, Diszegi, 2007
1280 1320 1360 1400 1440 1480
Temperature [C]
0
4
8
12
T
o
t
a
l

o
x
y
g
e
n

[
p
p
m
]
Cupola furnace
Induction furnace
Aftermoldfilling
Gaslevelsinproduction
Lennart Elmquist
Tammerfors 2012-11-08
1 2
Sample No
0
20
40
60
80
100
120
140
N
i
t
r
o
g
e
n

c
o
n
c
e
n
t
r
a
t
i
o
n

[
p
p
m
]
Before casting
In the mold
22
Source: Orlenius, Elmquist, Diszegi, 2007
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
23
Gasabsorption
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
24
Gasabsorption
Investigaterelationshipgasabsorption moldfilling
Comparesimulation reality
Turbulenceduringfilling
Permeability
Binders
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
25
Gasabsorption
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
26
Gasabsorption
Fillingvelocity
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
27
Gasabsorption
Turbulentmouldfilling
Lennart Elmquist
Tammerfors 2012-11-08
28
Source: UAB Casting Engineering Laboratory (CEL), 2005
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
29
Mouldandcoregasevolution
Volumeandrateofgasevolution
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
30
Gasevolution
Coregeometry
Volumeequal
Amountofbinderequal
Highestrateforparallelepiped
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
31
Gasevolution
Bindertype
Inorganicbinder
Organicbinder
Amountofbinder
Storagetime
Temperature
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
32
Gasevolution
Coatings
Improvesurface
Aluminiumsilicate
Zircon
Dryingprocess
Lennart Elmquist
Tammerfors 2012-11-08
Source: Orlenius et al, 2008
33
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
34
Inclusions sand
Occuratwidelyvarying
positions
Sandtornawaybymetal
stream
InassociationwithCO
blowholesandslag
Carefullyblowoutmold
cavities
Avoidhighpouringrates
Ensureuniformmold
compaction
Edgedisintegration
Sandcrustformation
Erosion
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
35
Inclusions slag
Irregularshape
Nonmetallicinclusions
Uppercastingsurfaces
FormationofCO
Possiblecauses
Oxidecontentofthecharge
toohigh
Poordissolutionof
inoculants
Poorslagpractice
Lennart Elmquist
Tammerfors 2012-11-08
Source: www.ikominerals.de
36
Inclusions slag
Filter
Designofthegating
system slagtraps
Lennart Elmquist
Tammerfors 2012-11-08
37
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
38
Introduction
Lennart Elmquist
Tammerfors 2012-11-08
39
Source: Elmquist et al, 2008
Shrinkage Introduction
Shrinkagedefects
Openshrinkagedefects
(macroshrinkage)
Closedshrinkagedefects
(shrinkageporosity)
Generally
Liquidcontraction
Liquidtosolidcontraction
Solidcontraction
Lennart Elmquist
Tammerfors 2012-11-08
Castiron graphite
expansion
Source: Stefanescu, 2005
40
Shrinkage Introduction
Factorspromotingshrinkageporosity
Natureandpropertiesofthesandmould
Metalcomposition
Pouringtemperature
Degreeofeutecticnucleationofthemetal
Solidificationmode
Compensatesfortheshrinkage
Feedingofmetal
Graphiteexpansion
Lennart Elmquist
Tammerfors 2012-11-08
Atmosphericgas
Dissolvedgas(hydrogen,
nitrogen)
41
Shrinkage Introduction
Differenttypesof
shrinkage
Relatedtocoolingcurve
Lennart Elmquist
Tammerfors 2012-11-08
42
Source: Soivio, Elmquist, 2012
Shrinkage Introduction
Lennart Elmquist
Tammerfors 2012-11-08
43
Source: Elmquist, Adolfsson, Diszegi, 2008
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
44
Defectcharacterization
Twofoundries
Twodesigns
Productionline
Withandwithoutporosity
Lennart Elmquist
Tammerfors 2012-11-08
Case:CylinderHeads
Economy
Environment
Shrinkageporosity
Characteristicfeatures
Knowledgeaboutmechanisms
45
Defectcharacterization
Similarities
Positiononcasting
Surfacedefect
Connectionsurface
porosity
Lennart Elmquist
Tammerfors 2012-11-08
10mm
Penetratingthroughthe
casting
Enclosingcertainunits
Primarycrystals?
46
Source: Elmquist, Adolfsson, Diszegi, 2008
Defectcharacterization
Borderbetweensurfaceandporosity
Oxidelayer connectionto
atmosphere
Nographitelayer
Lennart Elmquist
Tammerfors 2012-11-08
ShrinkagePorosityvs.
Penetration
47
Source: Elmquist, Adolfsson, Diszegi, 2008
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
48
Heatisremovedduringsolidification
Differentcoolingconditionsindifferentparts
Initialtemperaturesincasting/mold
Partofthecastingthatsolidifieslast
Migratesduringsolidification
Dependsongeometry
Heatremoval
Global/Localhotspots
Migratinghotspot
Lennart Elmquist
Tammerfors 2012-11-08
Y
T
L
49
Migratinghotspot
Thermalcentreatmold/metalinterface
Migratinghotspot
Lennart Elmquist
Tammerfors 2012-11-08
CH1
CH2
50
Source: Elmquist, Adolfsson, Diszegi, 2008
Migratinghotspot
Hotspotmigrates
Casting/moldinterface
Shrinkageporosity
Metalexpansionpenetration
Geometrydevelopedby
simulations
Finalpositionofhotspot
Lennart Elmquist
Tammerfors 2012-11-08
1200
1100
500
800
900
1000
700
600
SOLTIME [s]
51
Source: Elmquist, Adolfsson, Diszegi, 2008
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
52
ShrinkagePorosity
Developacastingthatgeneratesshrinkageporosity
Lennart Elmquist
Tammerfors 2012-11-08
53
Source: Elmquist, Diszegi, 2008
Geometry generating porosity
Migrating hotspot
Lennart Elmquist
Tammerfors 2012-11-08
ShrinkagePorosity
54
Source: Elmquist, Diszegi, 2008
Solidification
Solidificationofgreycastiron
Nucleation
Growth
Primaryaustenite
Eutecticcells
Lennart Elmquist
Tammerfors 2012-11-08
55
Source: Elmquist et al, 2008
Solidification
Lennart Elmquist
Tammerfors 2012-11-08
Equiaxed zone
Columnar
zone
Macrostructure
Microstructure
DendriteArmSpacing(SDAS)
FractionAustenite
Eutecticcellsize
Columnardendrites
Equiaxed dendrites
CET
56
Source: Elmquist et al, 2008
Shrinkageandthemacrostructure
Similarities
Shrinkageporosity
Surfacedefects
Penetratingnetwork
Contactwithatmosphere
Lennart Elmquist
Tammerfors 2012-11-08
57
Source: Elmquist, Diszegi, 2008
Shrinkageandthemacrostructure
DAAS(DirectAustempering
AfterSolidification
Macrostructure
Equiaxeddendrites
Columnardendrites
CET
Lennart Elmquist
Tammerfors 2012-11-08
Columnarzone
Abnormalcolumnarzone
SimilarCET
58
Source: Elmquist, Diszegi, 2008
Shrinkageandthemacrostructure
Porositybetweenprimarycrystals
Lennart Elmquist
Tammerfors 2012-11-08
59
Source: Elmquist, Diszegi, 2008
Shrinkageandthemacrostructure
Formationofshrinkage
porosity
Hotspot
Migration
Lastareaofsolidification
Weakcolumnarzone
Atmosphericgas
Shrinkageporosity
Surfacedefect
Lennart Elmquist
Tammerfors 2012-11-08
60
Source: Elmquist, Diszegi, 2008
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
61
Penetration Introduction
Metalpenetrationisacastingconditionresulting
fromreactionsatthemouldmetalinterface
Physical
Mechanical
Thermochemical
Lennart Elmquist
Tammerfors 2012-11-08
Metalpenetrationisdefinedastheconditioninwhichcast
metalhasenteredintotheporespacesofthemoldandcore
beyondthemidpointofthesurfacelayerofsandgrains.
(Draper and Gaindhar, 1977)
62
Penetration Introduction
Fourbasicmechanisms:
Mechanical(liquidstate)
Chemical
Vaporstate
Explosionpenetration
Theliquidmetalexerts:
Staticpressure
Dynamicpressure
Pressurebecauseofexpansion
Lennart Elmquist
Tammerfors 2012-11-08
Source: Stefanescu, 2008
Source: Draper and Gaindhar, 1977
63
Penetration Introduction
Generallyoccursatlocationswherethesandisthehottest
(cores,concavesections)andisoflowestdensity
Lowsurfacetension
HighP,Si,orMncontent
Elevatedstaticordynamicmetalpressure
Highmetalandsandtemperature
Sandtoocoarse,orinsufficientlyrammed
Thermalconductivityofsandtoolow
Poorqualitymoldwashorblacking
Lennart Elmquist
Tammerfors 2012-11-08
(AFS International atlas of casting defects)
64
Penetration Introduction
Onlyremovedbyextensivechippingandgrinding
Oftensoseverethatcastingsarebeyondthepointof
economicalreworkandmustbescrapped
Toolwear
Lennart Elmquist
Tammerfors 2012-11-08
(Source: Levelink and J ulien, 1973)
65
Penetration Introduction
Lennart Elmquist
Tammerfors 2012-11-08
Source: Diszegi and Dugic, 2007
66
MetalExpansionPenetration
CASEStudy Cylinderheads
Shrinkage noPenetration
Noshrinkage Penetration
Lennart Elmquist
Tammerfors 2012-11-08
ShrinkagePorosityvs.Penetration
Migrating hotspot isrelated also topenetrationproblems
67
Source: Elmquist et al, 2008
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
68
MetalExpansionPenetration
Lennart Elmquist
Tammerfors 2012-11-08
Geometry generating metalpenetration
69
Source: Elmquist, Diszegi, 2008
MetalExpansionPenetration
Lennart Elmquist
Tammerfors 2012-11-08
Columnar zone
Equiaxed zone
TestCasting
Source: Diszegi and Dugic, 2007
70
MetalExpansionPenetration
Lennart Elmquist
Tammerfors 2012-11-08
Thevolumetric changes causeeither asurplusora
deficitofmelt
Hotspot atcasting/mold interface theweakest part
Source: Diszegi and Dugic, 2007
71
MetalExpansionPenetration
Lennart Elmquist
Tammerfors 2012-11-08
Sand grains.
Equiaxed
austenite grains.
Columnar
austenite grains.
Liquid metal.
Eutectic cells.
Eutectic strip.
Penetrated
eutectic phase.
Source: Diszegi and Dugic, 2007
72
MetalExpansionPenetration
Lennart Elmquist
Tammerfors 2012-11-08
Sand grains
Equiaxed
austenite grains.
Columnar
austenite grains.
Columnar to
equiaxed
transition.
Eutectic cells.
Penetrated
anomalous
phase containing
late nucleated
austenite
dendrites.
Source: Diszegi and Dugic, 2007
73
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
74
OtherProblems
Residualstresses
Priorhistoryofthematerial
Segregation
Degeneratedgraphite
Lennart Elmquist
Tammerfors 2012-11-08
75
Source: Soivio, Elmquist, 2011
Source: Elmquist
WhatAboutFuture?
Inspection/detection
Mostoftheproblemsneverreachthecustomer
Research
Processcontrol/thermalanalysis
Castingsimulation
Optimization
Manyoftheproblemscanbesolvedorminimizedwitha
combinationofprocesscontrolandoptimaldesignof
componentaswellasgatingsystem
Lennart Elmquist
Tammerfors 2012-11-08
76
Future
Sustainability
Lifecycleanalysis
Theinfluenceofdefects
Nearnetshape
Minimizetheneedformachining
Highperformingcastironmaterials
Increasedstrength
Lessvariationsinproperties
Lennart Elmquist
Tammerfors 2012-11-08
77
Outline
Gasdefects
Gasabsorption
Gasevolution
Inclusions
Shrinkageporosity
Defectcharacterization
Migratinghotspot
Primaryaustenite
Metalexpansionpenetration
Primaryaustenite
Otherqualityproblems
Whataboutthefuture?
Summary
Lennart Elmquist
Tammerfors 2012-11-08
78
Summary
Casting
Mouldcavity
Meltingprocess
Pouring
Solidification
Mouldremoval
Cleaningandfinishing
Advantages
Complexshapes
Holesandinnercavities
Widerangeofalloys
Melttreatment
Economical
Lennart Elmquist
Tammerfors 2012-11-08
79
Summary
Why?
Whocares?
Lennart Elmquist
Tammerfors 2012-11-08
80
Thankyouforyour
attention!
Lennart Elmquist
Tammerfors 2012-11-08
81