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A Large Sand Casting Weighing 680 KG For An Air Compressor Frame
A Large Sand Casting Weighing 680 KG For An Air Compressor Frame
Pouring vessels
Molten metal is prevented from oxidation by covering the molten metal with
fluxes or by carrying out melting and pouring in vacuum
Ladles which pour the molten metal from beneath the surface are used
The two main consideration during pouring are the temperature and pouring
rate
Fluidity of molten metal is more at higher temperature but it results into
more amount of dissolved gases and high temperature also damage the
mould walls and results into poor surface quality of the casting
To control the amount of dissolved gases low, the temperature should not
be in superheated range
In ferrous metals, the dissolved hydrogen and nitrogen are removed by
passing CO. In non-ferrous metals, Cl, He, or Ar gases are used.
Therefore, fluidity and gas solubility are two conflicting requirements. The
optimum pouring temp. is therefore decided on the basis of fluidity
requirements.The temp. should be able to fill the whole cavity at the same
time it should enter inside the voids between the sand particles.
Cooling rate depends on casting material and configuration. It
also depends on volume and surface area of the casting also.
The pouring rate should be such that solidification does not start
and the cavity is completely filled without eroding mould surface
and undue turbulence.
On the basis of experience following empirical relations are
developed for pouring time
K: Fluidity factor
W: Weight In kg
Tp: Poring time in sec
The Gating System
1. Minimize turbulent flow so that absorption of
gases, oxidation of metal and erosion of mould
surfaces are less
2. Regulate the entry of molten metal into the
mould cavity
3. Ensure complete filling of mould cavity, and
4. Promote a temperature gradient within the
casting so that all sections irrespective of size
and shape could solidify properly
The Gating System
A: pouring basin
B: Weir
C: Sprue
D: Sprue well
E: Runner
F: Ingates
G: Runner break up
H: Blind
J: Riser
Use of chills
Cooling and Solidification
Pure metal
Alloy
Mechanism of Solidification
Pure metals solidifies at a constant temp. equal to its
freezing point, which same as its melting point.
The change form liquid to solid does not occur all at
once. The process of solidification starts with nucleation,
the formation of stable solid particles within the liquid
metal. Nuclei of solid phase, generally a few hundred
atom in size, start appearing at a temperature below the
freezing temperature. The temp. around this goes down
and is called supercooling or undercooling. In pure
metals supercooling is around 20% of the freezing temp.
A nuclease, more than a certain critical size grows, and
causes solidification.
By adding, certain foreign materials (nucleating agents) the
undercooling temp. is reduced which causes enhanced
nucleation.
In case of pure metals fine equi-axed grains are formed near
the wall of the mold and columnar grain growth takes place
upto the centre of the ingot.
In typical solid-solution alloy, the columnar grains do not
extend upto the center of casting but are interrupted by an
inner zone of equiaxed graines.
My adding typical nucleating agents like sodium, magnesium or
bismuth the inner zone of equiaxed grained can be extended in
whole casting.
Crystal structure in Castings
Dendrite formation
Graphite+oil
General Configuration of a Die Casting
Machine
In Die casting the molten metal is forced to flow
into a permanent metallic mold under moderate
to high pressures, and held under pressure
during solidification
This high pressure forces the metal into intricate
details, produces smooth surface and excellent
dimensional accuracy
High pressure causes turbulence and air
entrapment. In order to minimize this larger
ingates are used and in the beginning pressure is
kept low and is increased gradually
Cycle in Hot Chamber Casting
Cycle in Cold Chamber Casting
Centrifugal Casting