Yashasvi Sharma 17BME0011

Digital Assignment 2

1.Classify various continuous casting process with the help of simple

sketches.
Continuous casting is a method that was invented to enhance the
production of metals. The continuity of the casting helps to lower the
cost of the casted metal. Carefully controlled process also reduces
errors leading to better quality metal. They increase the productivity
and produce better yields. It is used to cast long ingots square billets
and complex sectioned components.
Major types of continues casting processes are:
1.Vertical Continuous Casting
a) Vertical Downward Continuous Casting

The solidified billet or the solidified bar will travel towards the bottom.
Below the tundish there is a graphite mould. Now the molten metal
from the ladle is poured into the tundish and from the tundish the
molten metal will be flowing through the graphite mould, as it is
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flowing there is a cooling system and a crystallizer because of that it

solidifies as it is going out of the graphite mould. It will be further
cooled in secondary cooling. There are roll supports so it will be
rotating because of that the solidified bar will be coming down. After
it is completely solidified, there is a saw which cuts periodically.
Used for manufacture of copper brass and bronze bars tubes and
sections.
b) Vertical Upward Continuous Casting

In the case of the vertical upward continuous casting, the solidified bar
goes upwards in the opposite direction. The molten metal from the
ladle is poured into the tundish. After solidification it will be pushed
to pass through the graphite mould it will be come upwards. There is
a crystallizer and also a cooling system because of that the solidified
bar will be moving upwards. Rollers will be rotating and there will
further push the solidified upwards and then the saw cuts the
solidified bar periodically or at the desired location.
Vertical Upward Continuous Casting is used for casting of bronze
copper and also nickel alloys.
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2.Curved Continuous Casting

The curved continuous casting is similar to the vertical downwards

casting, but there is a difference. In the case of the vertical downwards
casting the bar only comes downwards, but it does not but here when
the molten metal from tundish comes downwards to some extent it
curves and then becomes horizontal. The ladle accommodates the
molten steel. As the molten metal passes through the mould it
undergoing solidification. In spray cooling system cooling will take
place by means of a spray. The rollers will be rotating; the solidified
bar will be taking a curve and slowly it takes a horizontal direction and
is totally solidified, It will be cut using some torch or a saw.
it is used for making steel billets sections bars
3.Horizontal Continuous Casting
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From the ladle molten metal will be flowing into the tundish. There is
a graphite mould and the graphite mould will have possess a circular
or a square or a hexagonal depending on the requirement and then
there is a crystallizer which cools down the metal it enables
formations of the crystallization. Once it passes through the secondary
cooling, it is totally solidified and here there are roller supports which
will be pulling the solidified bar away from the mould and then there
is a saw which will be cutting the solidified bar at the equal intervals
or at the desired location.
Horizontal Continuous Casting used for making of thin wires, making
of rods, making of tubes, making of strips and custom sections and
commonly used to cast non-ferrous alloys like copper alloys.

4.Strip Continuous Casting

The molten metal is taken in a reservoir and supplied through a

rectangular spout to the rectangular gap provided by two steel band.
The lower and upper bands are driven by rollers. A slight downward
slope is given to the exit end. To stop the lateral flow of liquid metal,
two flexible side moulds in the form of thick belts are moved along
with the steel bands. The molten copper coming out of the spout flows
to the flat steel band and begins to solidify forming the outer skin. The
cooling is obtained by spray of water on both sides. As the belt moves
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forward cooling and freezing progress and the solid strip comes out at
the exit end along with the belt.
Aluminium alloys and copper strips are produced with thickness up to
12.5mm and width can be 1.5m to 2m.

2.What is meant by slush casting? Explain the process with the help of
line sketches.
Slush casting is a variation of permanent mold casting that is used to
produce hollow parts. In this method neither the strength of the part
nor its internal geometry can be controlled accurately. This metal
casting process is used primarily to manufacture toys and parts that
are ornamental in nature, such as lamp bases and statues.
When producing a cast part using the slush casting method, a
permanent mould is employed and set up. See basic permanent
mould casting. The mould is clamped together and prepared for
pouring.

After pouring the mould will set, as solidification begins to take place.
The main principle of this casting process relies on the fact that when
a metal casting hardens in a mould, it will solidify from the mould wall
towards the inside of the casting.
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In slush mould casting, during the solidification of the material, when

the solid-liquid boundary has reached a certain point, the mold is
turned over and the remaining liquid metal from the casting is poured
out. This will leave only the solidified skin with the exterior geometry
of the metal cast part and a hollow interior. The longer the metal
casting was allowed to solidify before pouring out the excess metal,
the greater the casting's wall thickness will be.
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3. Give advantages, limitations and application of electro-slag casting.

It is based on the principle of electro slag welding process. It dispenses

completely with the risering and gating system and also with the need
for a separate melting unit, pouring ladle and transportation
arrangements.

Advantages:
• Cooling rate is very low so there is no problem of cold cracking.
• There is no problem of slag inclusion or porosity in electroslag
casting.
• The process is semi-automatic and faster.
• Heavier section can be casted.
• High productivity can be achieved.
• Low cost.
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Limitation:
• Too high heat input to base.
• High temperature of casting needs cooling arrangement.
• Slow rate of cooling gives columnar grain in casting.
Application:
It is used in heavy industries to produce casting of complex shapes and
composite forms. The typical items cast by this process are
crankshafts, connecting rods, nozzles, valve bodies and high pressure
vessels

4.What is single crystal casting? Explain it briefly.

Single crystal casting can be explained wit the help of an example

Single-crystal blades:
The mould has a constriction in the shape of a corkscrew, the cross-
section of which allows only one crystal through. A single crystal
grows upward through the constriction and begins to grow in the
mould. Strict control of the rate of movement is necessary. The
solidified mass in the mould is a single-crystal blade. Although more
expensive than other blades, the lack of grain boundaries makes
these blades resistant to creep and thermal shock. Thus, they have a
longer and more reliable service life. Single-crystal growing has
become a major activity in the manufacture of microelectronic
devices. There are several methods of crystal growing that are used
world-wide, e.g:
a) Seed crystal growing (Crystal-pulling] process)
b) Floating-zone method
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c) Hydrothermal synthesis (also termed: Hydrothermal

growth/method).

In the crystal pulling method, (Czochralski Crystal Growth Process) a

seed crystal is dipped into the liquid and then pulled out slowly, at a
rate of about 10 – 20 mm/s, while being rotated at about 1 rev/s.
The liquid material begins to solidify on the seed, and the crystal
structure of the seed is continued throughout. Dopants (alloying
elements) may be added to the liquid, to impart special electrical
properties. This process grows single crystals of silicon, germanium,
and various other chemical elements. Single-crystal ingots typically
50-150 mm in diameter and over 1 m in length have been produced
by this technique. A semi-metal, such as silicon is melted in a crucible
in an inert gas. A seed crystal of the desired orientation is lowered
into the liquid and the temperature is reduced slightly until the liquid
begins to crystallize onto the seed. The seed crystal is then drawn up
slowly, until a long, thin crystal (the "neck") has formed on the end.
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Once the neck has been grown at a sufficient rate and diameter to
ensure that it is free of dislocations, the temperature is reduced
further and the growth rate is reduced to allow the crystal
to become larger in diameter. As the diameter of the crystal
approaches the desired dimension, the growth rate is again
increased. The crystal diameter is controlled during body growth by
varying the lift rate of the seed and the temperature of the melt.
During this period the crucible is also raised at the rate required to
maintain the position of the liquid surface in relation to the heated
area of the chamber. Both the seed and crucible are rotated in
opposite directions and at various rates to control the properties of
the crystal. The growth rate is dependent on crystal type, diameter,
hot zone configuration and various other factors. For silicon, typical
body diameters now range from 100 to 300 mm and typical growth
rates vary from 40 to 85 mm/hr.
The single-crystal growing floating-zone method is also widely used
in the manufacture of micro-electronic devices. Starting with a rod of
polycrystalline silicon resting on a single crystal, an induction coil
heats these two pieces while moving slowly upward. The single
crystal grows upward while maintaining its orientation. Thin wafers
are then cut from the rod, cleaned, and polished.
Hydrothermal synthesis includes the various techniques of
crystallizing substances from high temperature aqueous solutions at
high vapour pressures (the term "hydrothermal" originated from
geochemical and mineralogical studies of hydrothermal phase
equilibria). This method of synthesis of single crystals depends on the
solubility of minerals in hot water under high pressure. The crystal
growth is performed in autoclaves (steel pressure vessels) in which a
nutrient is supplied along with water. A gradient of temperature is
maintained at the opposite ends of the growth chamber so that the
hotter end dissolves the nutrient and the cooler end causes seeds to
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take additional growth. Possible advantages of the hydrothermal

method over other types of crystal growth include the ability to
create crystalline phases which are not stable at the melting point.
Also, materials which have a high vapour pressure near their melting
points can also be grown by this method. The method is also
particularly suitable for the growth of large good-quality crystals
while maintaining good control over their composition.
Disadvantages include the need for expensive autoclaves, good
quality seeds of a fair size and the impossibility of observing the
crystal as it grows.
Single crystal products include, filters, windows and sensors (e.g. for
security systems and satellite equipment), antennas, laser
components, scanners for brain- and heart-examination,
telecommunication filters, resonators and oscillators, optical
components etc. The range of industrially produced crystals includes
Oxides, Tungstates, Titanates, Gallate, Aluminates, Molybdate,
Zirconate, Metals and Salts.