MIE 441 – FOUNDRY

TECHNOLOGY
Introduction to
casting
 Introduction
One of the oldest processes used to shape metals is the casting process (CP) which
basically involves:

1. Pouring molten metal into a mold cavity

2. Allowing it to solidify (cool), and
3. Removing the part from the mold.
Casting processes developed over the years can be classified
1. Expandable mold: sand, shell, expandable pattern, plaster, ceramic and
investment.
2. Permanent mold: slush, pressure, die, centrifugal, squeeze, and semisolid.
3. Single crystal growing: single crystals for microelectronics, single-crystal
turbine blades, and directional solidification.

Casting processes are most often selected over other manufacturing methods,
for the following reasons:
1. Casting can produce complex shapes with internal cavities or hollow
sections.
2. Very large parts can be produced in one piece.
3. It can utilize materials that are difficult or uneconomical to process by
other means.
4. Casting is competitive with other processes.

Almost all metals can be cast in the final shape desired net-shape-mfgoften
with only minor finishing operations required. Important considerations in
casting operations:
1. Flow of the molten metal into the mold cavity.
2. Solidification and cooling of the metal in the mold.
3. The influence of the type of mold material.

Solidification of Metals
• After pouring molten metal into a mold, a series of events takes
place during the solidification of the metal and cooling to room
temperature.
• These events greatly influence the size, shape uniformity, and
chemical composition of the grains formed throughout the casting,
which in turn influence its over all properties.
 Solidification of Pure Metals
• A pure metal solidifies at a constant temperature. It has a clearly
defined melting (or freezing) point
• After the temperature of the molten metal drops to its freezing
point, its temperature remains constant while the latent heat of fusion
is given off.
• The solidification front (solid-liquid interface) moves through the
molten metal, solidifying from the mold walls in toward the center.

SOLIDIFICATION TIME
Whether the casting is pure metal or alloy, solidification takes time. The total
solidification time is the time required for the casting to solidify after pouring. This
time is dependent on the size and shape of the casting by an empirical relationship
known as Chvorinov’s rule, which states:
(a)Temperature as a function of time for the solidification of pure
metals. (b) Density as a function of time
Characteristic grain structure in a casting of a pure
metal
oriented grains of small size near the mold wall, and large columnar
grains oriented toward the center of the casting.
Solidification of Alloys
Effects of cooling rates
Fluid Flow
Bernoulli’s theorem
 Chvorinov’s rule
Chvorinov’s rule indicates that a casting with a higher volume-to-surface area
ratio will cool and solidify more slowly than one with a lower ratio.
This principle is put to good use in designing the riser in a mold. To perform its
function of feeding molten metal to the main cavity, the metal in the riser must
remain in the liquid phase longer than the casting.

• n = 2, the units of Cm are min/cm2, and its value depends on the particular
conditions of the casting operation, including mold material (e.g., specific
heat, thermal conductivity), thermal properties of the cast metal (e.g., heat of
fusion, specific heat, thermal conductivity), and pouring temperature relative
to the melting point of the metal.
 Heating The Metal
• Heating furnaces of various kinds are used to heat the metal to a molten
temperature sufficient for casting. The heat energy required is the sum of (1)
the heat to raise the temperature to the melting point, (2) the heat of fusion to
convert it from solid to liquid, and (3) the heat to raise the molten metal to the
desired temperature for pouring. This can be expressed:
Example 1
 Characteristics of Molten Metal
Viscosity: As viscosity and its sensitivity to temperature
(viscosity index) increase, fluidity decreases.
Surface tension: A high surface tension of the liquid metal reduces fluidity.
Oxide films on the surface of the molten metal have a significant adverse
effect on fluidity.
Inclusions: As insoluble particles, inclusions can have a significant adverse
effect on fluidity. For example, liquid with sand in it has a higher viscosity and
hence lower fluidity than a liquid without sand.
Solidification pattern of the alloy: The manner in which solidification takes place
fluidity. Fluidity is inversely proportional to the freezing range. The shorter the
range (as in pure metals and eutectics), the higher the fluidity. Conversely, alloys
with long freezing ranges have lower fluidity.
 Casting Parameters
Mold design. The design and dimensions of sprue, runners and risers all
influence fluidity.
Mold material and its surface characteristics. The higher the thermal
conductivity of the mold and the rougher the surfaces, the lower the fluidity
of the molten metal. Although heating the mold improves fluidity, it slows
down solidification of the metal. Thus casting develops coarse grains and
hence lower strength.
Degree of superheat: Defined as the increment of temperature above the
melting point of an alloy, superheat improves fluidity by delaying
solidification. The pouring temperature often is specified instead of the
degree of superheat.
Rate of pouring. The slower the rate of pouring molten metal into the mold,
the lower the fluidity because of the higher rate of cooling when poured
slowly.
Heat transfer. This factor directly affects viscosity of the liquid metal .
 Test for fluidity
• In one such common test, the molten metal
is mode to flow along a channel that is at
room temperature; the distance the metal
flows before it solidifies and stops flowing is
a measure of its fluidity.
• The greater the length of the solidified
metal, the greater is its fluidity

Fluidity of Molten Metal

Fluidity is the capability of the molten metal to fill mold cavities. Fluidity is
influenced by(consists of) two basic factor: