Professional Documents
Culture Documents
DMME
AKMBRashid
Professor,DepartmentofMME
BUET,Dhaka
5/31/2010
TodaysTopics
NineClassesofProcess
Raw Materials
CASTING
METHODS
Gravity, pressure,
die casting
PRESSURE
MOULDING
Polymer moulding,
glass moulding
DEFORMATION
PROCESSING
Roll, forge,
draw, press
POWDER
METHODS
MACHINING
HEAT TREAT
Anneal, normalise,
quench, temper
FINISH
SPECIAL
METHODS
Layup, CVD,
electroform
JOINING
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MetalFormingProcess
atomise
LIQUID METAL
casting
Metal Powder
continuous casting
Ingots
Intermediate Shapes
Slabs, Billets, Bars, Rods, Sections
moulding
and casting
pressing and
sintering
FORGINGS
CASTINGS
MISCELLANEOUS
WROUGHT FORMS
SINTERED
COMPACTS
machining
joining
Machined Shapes
Fabrications
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TheCastingTechnology
Stepsinvolvedinmakingacasting
Pattern Making
Moulding and Core making
Melting and Pouring
Fettling and Finishing operations
Inspection and Quality Control
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TheCastingTechnology
Elementsofamould
Feeder
Mould
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TheCastingTechnology
Advantages of casting process
1.
2.
3.
4.
Versatile
Dimensional accuracy
One stepp pprocess
Low cost
Directional properties
Grain size
Density
Design advantages of castings
1.
2.
3.
4.
5.
6.
Size
Complexity
Weight saving
Production of prototypes
Wide range of properties
Versatility in casting alloys
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TheCastingTechnology
Disadvantagesofcastingprocess
1.
2.
3.
4.
5.
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TheCastingTechnology
TheFoundryEstablishment
Classes based on type and capacity of production
1. Jobbing foundries
2. Production foundries
3. Captive foundries
Classes according
g to the type
yp of materials melted
1. Ferrous foundries
(a)
(b)
(c)
(d)
Steel foundries
Grey iron foundries
Malleable iron foundries
Ductile iron foundries
2. Non-ferrous foundries
(a) Light metal foundries (for Al and Mg)
(b) Copper, brass and bronze foundries
(c) Lead, tin and zinc-base foundries
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TheCastingTechnology
Influenceofcastingtootherindustrialsectors
F
Foundry
d is
i ab
basic
i iindustry.
d t
Its product, castings, enters into every field in which metals serve man.
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TheCastingProcesses
Sand system
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TheCastingProcesses
Non-sand system
Metal (or permanent) mould processes
Gravity die casting
Low-pressure die casting
High-pressure die casting
Centrifugal casting
Vertical centrifugal casting
Horizontal centrifugal casting
Ceramic moulding
Plaster moulding
Graphite moulding
Hybrid processes
Squeeze casting
Semisolid metal casting (rheocasting)
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CastingFundamentals
Presently, casting is not an art.
Creating casting without major defects repeatedly
requires a good understanding on the following
scientific knowledge:
1 The melt dynamics and fluid flow
2 The principles
p p of heat transfer and kinetics solidification
Design of running system
Solidification of metals and alloys
Solidification shrinkage and design of feeding system
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DesignofRunningSystem
The series of funnels, pipes
andd channels
h
l to guide
id liliquid
id
metal from the ladle into the
mould is known as the
gating system or the running
system.
An accurate design of running
system is crucial for obtaining
defect free castings
repeatedly.
Pouring
system
Cope
Casting
Feeding
system
Parting
Line
Running system
Drag
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DesignofRunningSystem
Basic components
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DesignofRunningSystem
Essentialfunctionsofagoodrunningsystem
1 Economy of size to increase yield of casting and productivity.
1.
productivity
2. The filling of the mould under the critical speed:
Al-bronze
Al-base and Mg-base alloys
Cu-base and Fe-base alloys
: 75 mm/s
: 250 mm/s
: 500 mm/s
DesignofRunningSystem
Progressivesolidificationvs.directionalsolidification
Flow of
molten metal
Progressivesolidification
Directionalsolidification
Source of
molten metal
Combinationofprogressiveanddirectionalsolidifications
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DesignofRunningSystem
Streamliningtherunningsystem
DesignofRunningSystem
Toppouringvs.Bottompouring
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DesignofRunningSystem
Presurrised systemvs.Unpressurisedsystem
Pressurised system
Unpressurised system
DesignofRunningSystem
Controllingfactorsingatingsystem
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DesignofFeedingSystem
Molten metal occupies considerably more volume than the
solidified casting. Thus, liquid contracts on freezing because of
rearrangement of atoms from open randomly-packed structure
to a regular densely-packed structure.
Liquid metals experience 3 different contractions during solidification.
1. Liquid contraction - not troublesome
2. Solidification contraction - causes feeding problem
3. Solid contraction - causes hot tearing/cracking
Shrinkage porosity is the
most common and most
important defect in castings.
Solidification shrinkage
Aluminium
Copper
Magnesium
Zinc
Iron
FCC
FCC
HCP
HCP
BCC
7.14 vol.%
5.30
4.10
4.08
3.16
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DesignofFeedingSystem
Feeding thesixrules
1.
2.
3.
4.
5
5.
6.
24
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DesignofFeedingSystem
Controllingfactorsinfeedingsystem
1.
2.
3.
4.
25
SolidificationofMetalsandAlloys
FREE ENERGY, G
Nucleationofsolid
The driving force,
GV = GS - GL = H TS
GV = L T / Tm
GV
GS
Undercooling, T
GL
TM
TEMPERATURE, T
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SolidificationofMetalsandAlloys
Nucleationofsolid
For r > r* :
Surface free energy
FREEENERGY,G
SL
G*
RADIUS, r
r*
GV
For r < r* :
free energy decreases
if the solid grows.
unstable nucleus.
r* = critical radius
free energy requirement
is the maximum.
27
SolidificationofMetalsandAlloys
Nucleationofsolid
G = ((4/3)r
) 3 . GV + 4r2 . SL
For a critical radius, r* :
d (G) / dr = 0
2SL
2SL TM
r* ==
GV
L
G* =
16 (SL)3
=
3 (GV)2
1
T
16 (SL)3 TM2
3 L2
1
(T)2
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SolidificationofMetalsandAlloys
Nucleationofsolid
Under suitable conditions, liquid nickel can be undercooled
to 250 K below TM (1453 C) and held there indefinitely
without any transformation occurring.
Normally undercooling as large as 250 K are not observed.
The nucleation of solid at undercooling of only ~ 1 K is
common.
In the refrigerator,
g
, however,, water freezes even ~ 1 K below zero.
In winter, we observe that water freezes ~ a few degrees below zero.
SolidificationofMetalsandAlloys
Heterogeneousnucleationofsolid
From the equation
G* =
16 (SL)3 TM2
1
2
(T)2
3L
30
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SolidificationofMetalsandAlloys
Heterogeneousnucleationofsolid
Heterogeneous
g
nucleation of
spherical cap on a flat mould wall
SolidificationofMetalsandAlloys
Heterogeneousnucleationofsolid
Inoculating agents
Inoculatingagents
Small interface energy
Similar crystal structure
Same physical properties
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SolidificationofMetalsandAlloys
Growthandmicrostructure
33
SolidificationofMetalsandAlloys
Growthandmicrostructure
Mould
Undercooling, T
Equilibrium freezing
Temperature, Te
Liquid
Solid
skin
Distance from
mould wall
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SolidificationofMetalsandAlloys
Growthandmicrostructure
Temperature
Compositional depression
Equilibrium freezing
temperature, Te
SolidificationofMetalsandAlloys
Growthandmicrostructure
Primary crystal
Dendrites
Secondary crystal
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SolidificationofMetalsandAlloys
Microstructureofingot
Outer equiaxed
q
chill zone
Massive nucleation due to intense cooling
(high T) at the interface.
Some re-melted, some flushed always to the
centre of the mould due to convection current.
Those having favourable nucleation sites, grow.
I t
Intermediate
di t columnar
l
zone
Favourably oriented chill crystals grow at the
expense of the others and form columnar zone.
The growth of columnar crystals are blocked by
the central equiaxed crystals.
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SolidificationofMetalsandAlloys
Microstructureofingot
Central equiaxed zone
As the temperature is decreased, the
broken dentritic crystals that are
flushed always to the centre of the
mould start growing.
Thus form the central equiaxed
crystal zone.
38
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SolidificationofMetalsandAlloys
Microstructureandpropertiesofingot
39
SolidificationofMetalsandAlloys
Defectsingrainstructures
Segregation
Gas porosity
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