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MPP - 4 Casting Process - SRS - 2014
MPP - 4 Casting Process - SRS - 2014
• (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting. Note
that after 11 min. of cooling, dendrites reach each other, but the casting is still mushy
throughout. It takes about two hours for this casting to solidify completely.
• (b) Solidification of carbon steels in sand and chill (metal) molds. Note the difference in
solidification patterns as the carbon content increases.
Effects of Cooling Rates
• Slow cooling rates (on the order of 102 K/s) or long local
solidification times => coarse dendritic structures with
large spacing between dendrite arms
• Higher cooling rates (on the order of 104 K/s) or short local
solidification times => structure becomes finer with
smaller dendrite arm spacing
• Still higher cooling rates (on the order of from 106 to 108
K/s) => structures developed are amorphous
• Structures developed and the resulting grain size influence
the properties of the casting
• As grain size decreases
– strength and ductility of the cast alloy increase
– microporosity (interdendritic shrinkage voids) in the casting
decreases
– tendency for the casting to crack (hot tearing) during
solidification decreases
Fluid Flow
Typical riser-gated casting
Q = v1 A1 = v2 A2
– Q = volumetric flow rate, m3/s
– v = velocity, m/s
– A = Cross sectional area of the liquid, m2
A1/ A2 = √ (h2/h1)
Fundamentals of metal casting
Fluid Flow
If the liquid level has reached a height of x at the gate, then the
gate velocity is
v = c √ {2g (h-x)}
• The flow rate through the gate will be the product of this
velocity and the gate area according to Mass Continuity
equation
• The shape of the casting will determine the height as a
function of time
• Mold Filling Time = casting volume /mean flow rate = V/ Q
– V = Volume of mold cavity, m3
– Q = Volume flow rate, v x A, m3/s
Fundamentals of metal casting
Flow Characteristics (Reynolds number)
• presence of turbulence (as opposed to the laminar flow) in
fluid flow in gating systems
• Turbulence is flow that is highly chaotic => aspiration in
casting systems
• Reynolds number, Re, (ratio of the inertia to the viscous
forces) is used to quantify presence of turbulence
• v = velocity of the liquid
• D = diameter of the channel
• = density of the liquid
• = viscosity of the liquid
Re < 2000 = Laminar flow
2000<Re<20000 = Mixture of laminar and turbulent flow - Harmless
Re > 20000 = Turbulent flow – Air entrainment and formation of dross/slag (the
scum that forms on the surface of molten metal) from the reaction of the liquid
metal with air and other gases <= vacuum casting, using properly designed
pouring basins and runner systems, using filters (ceramics, mica, or fiberglass)
Fundamentals of metal casting
Solidification Time
• During the early stages of
solidification, thin skin
begins to form at the
relatively cool mold walls,
• as time passes, thickness
of the skin increases
• With flat mold walls, this
thickness is proportional
to square root of time
• Thus, doubling the time
will make skin √2 = 1.41
times or 41% thicker
Fundamentals of metal casting
Solidification Time
• The solidification time is a function of the volume of a casting and its
surface (Chvorinov’s rule)
• 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).
Measures to reduce porosity
hot isostatic pressing
Porosity caused by dissolved gas
• Because gases are more soluble in liquid metals than
solid metals,
– when metal begins to solidify, dissolved gases are expelled
from the solution
• Gases may result from reactions of molten metal
with mold materials
• Gases either accumulate in regions of existing
porosity (such as in interdendritic regions) or cause
microporosity in the casting, particularly in cast iron,
aluminum, and copper
• Dissolved gases may be removed from molten metal
– by flushing or purging with an inert gas or
– by melting and pouring the metal in vacuum
• If dissolved gas is O2, molten metal can be deoxidized
– Steel usually is deoxidized with aluminum, silicon,
– copper-based alloys with phosphorus, copper,
titanium, or zirconium bearing materials
Thank You