BY: ANJALI SAHU ARCHANA BEHERA ARUNI SAHU NEHA JAIN

Copper melting and casting is known to have occurred as early as 3000 B.C. Pure copper shows low mechanical and casting properties and thus finds limited application for cast parts. In more common use are alloy based copper. Copper makes no. of alloys with elements such as Sn, Zn, Be, Cr, Mn, Pb, Al, Ni, Si, etc Some of the commonly used copper base alloys are: 1.Tin Bronze 6.Leaded tin bronze 2. Aluminium bronze 7.Leaded nickel bronze 3. Red Brass 4.Silicon brass 5.yellow brass

Alloys of Cu readily oxidizes in the liquid state,hence to avoid oxidation of Cu alloys during pouring gating system must secure quite filling of the mould cavity. A skim bob is provided in the cope. For the purpose of controlling the rate of filling the

casting , a gating arrangement with choke in the

ingate is provided.

A choke is a restriction controlling the rate of liquid

metal flow into the mold.

GATING SYSTEM FOR COPPER ALLOYS

As many Copper alloys: Posses high solidification contraction Have long freezing range Freeze dendritically This freezing makes the transfer of molten metal from risers to casting difficult. Because of dendritic solidification Cu castings posses many shrinkage cavities Risers of sufficient amount and size eliminates the above problem.

Pouring basin in the gating system is preferred to permit the molten metal to be poured straight down the sprue.

SPRUE:

CSA of the sprue should not be larger than the required. A sprue should have a sump or well at the base to

reduce the velocity of the vertical flow of metal.

RUNNER:

It provides uniform flow into the casting cavity.

Runners should be rectangular and the CSA can

should be 4-6 times that of sprue exit.

Copper alloys melt at temperature higher than Al, Mg, Zn

& Pb alloys.

Tapping temperatures for Cu alloys are often as high as 13150c. Molten Cu alloys get contaminated from refractories as well as the atmosphere. Cu casting alloys are subject to fuming from vapourization of zinc which is a major alloying element.

Metal charge employed for melting consists of foundry

scrap and ingot of desired analysis.

Gates , risers, casting rejects should be properly cleaned of molding sand and other contaminants.

There is melting loss of the charge due to burning out,

oxide formation and interaction between the alloy and lining of the melting furnace.

The melting loss varies in quantity with the kind of charge,

type of melting furnace, melting procedure etc.

Furnaces used for melting Cu based alloys:

Crucible furnace
Reverberatory furnace Induction furnace Indirect arc furnace Selection of a furnace depends on the quantity of

metal to be melted, the degree of purity required and

the variety of alloys to be melted.

Charge must be weighed accurately. Furnace being charged must be cleaned of slag and be empty. Furnace temperature at the time of charging must be controlled. Melting is done under oxidizing or reducing conditions, gas absorption is kept at a minimum, as the absorbed gas must be removed prior to pouring. When Cu alloys having Zn content are melted oxidizing atmosphere is used to prevent the loss of Zn by vapourization. Speed is required to minimize contamination from the atmosphere & vapourization of volatile alloying elements.

The pouring temperatures for a number of copper alloys are given below:
Alloy
Leaded tin bronze Leaded red brass Manganese bronze Aluminum bronze Silicon brass

Pouring temperature, 0C
1070-1260 1070-1290 970-1120 1095-1205 980-1150

Copper alloys such as aluminium bronze & manganese bronze form tight, adherent, non fluid slags or oxides. Molten aluminium bronze & manganese bronze: I. Should not be stirred or agitated to minimise oxide entrapment. II. Pouring should be smooth and even to avoid splashing and separated metal streams. Fluxing and Flushing is carried out I. To separate molten metal & dross. II. To remove dissolved gases & dross.

Lithium is a very effective deoxidizer and removes

hydrogen by forming lithium hydride.

Another effective deoxidizer is zinc alloyed with 2% sodium. High leaded tin bronze and leaded red brass form fluid slags or oxides .

Bronze pour

Natural sand is used for most molds for the casting of copper alloys. Foundry producing bronze tablets and statues - fine sand Plumbing goods industries - coarse sand Synthetic sand is employed to overcome the deficiencies of natural sand. Bonding clays western bentonite, southern bentonite and fire clay. Synthetic sand includes additives such as cereals, wood flou and carbanaceous materials like sea coal. The moisture of green sand should be kept at a minimum and permiability at a maximum. Any of the available types of cores used for metal casting can be used in the casting of copper alloys

Best suited to the casting of tin, silicon, aluminium, and manganese bronze and yellow brasses. Molds are made of gray iron having Ni, Cr, or Mo in small quantities to improve its high temperature properties. The mold temperature for the casting of copper alloys ranges from 120 to 3700C. The permanent cores which project into the metal stream should be cooled to increase their life. In order to prevent the metal from shrinking and clinging to mold components , it is necessary to pull the cores , open the mold , and eject the casting as rapidly as possible.

Best suited for yellow brass. Close dimensional control, good surface finish & high rate of production can be achieved but die life is short. Gas fired stationary crucible furnace is used for melting and holding the Cu alloys. Cold chamber die casting machines are used for this process. Ram pressure 215 to 715 kg/cm2 Speed of injection plunger 25 to 625 cm/sec Water/oil is circulated through cores and dies to control their temperatures.

Very little lubricant is applied to dies because it burn

into the casting, resulting in defects. Mixture of oil &

graphite is sprayed on the plunger & sprues where release is a problem.

Defects encountered are cracks, misruns, cold shuts,

porosity etc. caused due to improper pouring temperature, die temperature, gating, vent, die design.

It ensures close dimensional control , smooth surface

finish, and low cost in high volume production.

Since pouring temperature is lower than those of ferrous metals, silica sand is entirely satisfactory for making the shell molds and cores.

Good Castability In-built Corrosion Protection Low Frictional Properties and Good Resistance to Wear Non-Sparking Characteristics High Electrical and Thermal Conductivity Good Mechanical Properties at Ambient and High Temperatures Enhanced Low Temperature Properties Machinability Recycling Cost-Effectiveness

Electrodes of resistance welding machines

Turbine runners
Water-meter housings Bearings

Gears and corrosion resistant pumps

Marine equipment Plumbing goods

Valves and fittings

Steam pipe fittings