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MODULE -5

SOLIDIFICATION& NON
FERROUS FOUNDRY PRACTICE
SOLIDIFICATION
DEFINITION
It may be defined in simple terms as the conversion of liquid metal at a higher temperature to solid metal at
a lower temperature. Solidification involves the mass of atoms and their growth. In general it is a process of
nucleation and growth process in the conversion of liquid to solid.
THEORY OF SOLIDIFICATION
Solidification process takes place by nucleation of tiny particles followed by the growth of these particles.
During cooling process of the liquid metal, a number of centers of nuclei are formed. The growth of these
nuclei is mainly dependent upon the nature of the thermal condition and crystallography. The tiny particles
when reaches a particular size will survive and are referred to as crystals. As the cooling process continues
growth of these crystals proceed at all places in predetermined directions. As the heat removal takes place
these crystals continue to grow opposite to the heat extraction direction and resemble a skeletal network
resembling a tree like structure with a number of branches and these are referred to as dendrites. These
dendrites grow in size and become thicker and thicker by consuming the liquid metal .the volume of the
liquid metal gets continuously depleted. Finally when all the liquid metal has been consumed the size of the
dendrite reaches its maximum value as a result of this process the completely grown dendrites will inhibit
the growth of the neighboring dendrites. When two such neighboring fully grown dendrites meet a
boundary is created around each of the dendrite. This boundary is referred to as grain boundary. The surface
within this boundary is referred to as grain. the size of the grain is controlled by various parameters such as
mould material property, liquid metal property, casting size ,casting geometry, temperature levels of the
molten metal, external agencies etc.,It can be concluded that the solidification process is highly a complex
phenomenon.
Figure shows the details
NUCLEATION
A metal in molten condition possess high energy and atoms have
great mobility. As this metal cools it loses its energy so also decreases
the mobility of the atoms. The extraction of heat is more rapid near
the mould walls than at any other portion. The first submicroscopic
crystallites called nuclei are formed. Nucleation is the beginning of
phase transformation. Nucleation may involve the following:
The assembly of right kind of atoms by diffusion
Formation of critical sized particles
Structural changes into one or more unstable intermediate structure.
GROWTH
Minute nuclei or the crystallites formed during the process grow by atoms
adding on to the nuclei. This growth proceeds with the release of high
energy at the crystal melt interface as they possess high thermal energy.
With further decrease in temperature the nuclei grow rapidly along certain
crystallographic direction, the growth of these takes place along
crystallographic planes in preferential direction to form crystal structure
characteristics of the material.
These crystals grow and they tend to form structure resembling a tree. This
structure is often termed as dendrite as shown in below figure.
Dendrite in 3D view
STEPS IN THE FORMATION OF A GRAIN
Submicroscopic crystallite nuclei try to form around submicroscopic
impurities
Dendrites begin to form around these submicroscopic impurities
Dendrites grow in all directions and also dendrite arms grow
When the molten metal solidifies completely only the grain boundary
is visible.

TYPES OF NUCLEATION
Basically two types of nucleation processes have been identified they are:
1. Homogenous nucleation
2. Heterogeneous nucleation

HOMOGENOUS NUCLEATION
This type of nucleation is observed when solids are formed within its own
melt without the help of any foreign particles. Homogeneous nucleation
occurs in perfectly homogenous materials as in pure metals. As the molten
metal starts cooling below liquids temperature atoms tends to collects and
forms embryos. When these particles reaches a critical size, nuclei are
formed which will grow further. Particles having size greater than critical
size will sustain and help nucleation process.
Energy needed to create interface=Energy released by volume of condensing phase.
G=4r2+4/3r3Gv where r= critical radius, = surface free energy, Gv=volume free energy
Figure shows homogenous nucleation
HETEROGENEOUS NUCLEATION
Generally foreign particles will be present in the melt which alter the
liquid solid interface energy sufficient to assist in nucleation; thereby
reducing the amount of super cooling required to effect nucleation.
This type of nucleation is observed when a solid is formed within a melt
with the help of a foreign particle.
SOLIDIFICATION VARIABLES
During solidification of metal or alloy the following variables influence the
solidification process
Solidification time (f)
Solidification rate (R)
Temperature gradient (G)
Cooling rate (CR)

Solidification time (f)


It is the time taken by the molten metal for its transformation to solid state. Smaller
the solidification time, lower will be the soft zone, better will be the properties.
Shrinkage will be reduced. Sand moulds show higher solidification time as
compared to a metal mould. Solidification time is expressed in
secondsSolidification time has a pronounced effect on the casting properties. There
exists a relationship between solidification time, UTS, Yield strength and
percentage elongation. As f increases UTS & YS decreases. Figure shows this.
Solidification rate (R)
Solidification rate indicates the rate at which the solidification is
progressing from one point to another.
1&2 are the two adjacent points in the casting
X= thickness of metal solidified
Refering to figure consider two adjacent points 1 & 2 as shown in figure. Let
the distance between them be x x represents the thickness solidified
between 1 & 2 .If solidification time between 1 & 2 is t then we can write
X=Kt where K is a constant depending on the nature of metal
Differentiating the above we get dx / dt = K / 2t
R= dx / dt is referred as solidification rate. Smaller the solidification time
larger the solidification rate and faster is the solidification process and vise
versa. Solidification rate is expressed as cm/sec. Higher the value of R better
is the properties of casting.
Temperature gradient (G)
Temperature gradient for time t1, G1=dT1/dx for time t2, G2=dT2/dx
At any interval of time interval there will be temperature difference between
two points which can be represented as in figure at any given time interval
dT be the temperature difference between points 1 and 2 Higher the value
of G better will be the casting soundness and higher will be the properties.
There exists a linear relationship between ultimate tensile strength and
temperature gradient. Temperature gradient is expressed as oC/cm. All these
factors influence the structure and properties of the casting.
dx= distance between two adjacent points
dT= difference in temperature between 1 & 2 at any given time.
Cooling rate (CR)
Cooling rate represents the rate at which the liquid metal is converted
to solid metal or represents how fast or how slow the liquid metal is
cooling in the mould. It is normally represented as (dx/dt) with units
cm/s.Smaller the solidification time larger the cooling rate and vice-
versa. Higher cooling rate yield better properties in the casting.
DIRECTIONAL SOLIDIFICATION
Solidification pattern which is made to occur directional i.e., in a
particular direction is called directional solidification .Here the
solidification process is made to proceed from the thinnest section
towards the heavier sections i.e., section distant from the liquid metal
starts solidifying first and then the solidifying metal is successively fed
with the molten metal until the heaviest section solidifies. These risers
heads are so placed at right locations that they continuously supply hot
liquid metal to the shrinkage castings until it is completely solidified.
NEED FOR DIRECTIONAL SOLIDIFICATION
For easy control of shrinkage it is preferable that solidification starts from one end and progress
towards the other. Normally the solidification should progress towards the riser end. This will
help efficient feeding of the casting by the riser thereby structure and properties can be
controlled. Even the segregation and other phenomenon can easily be taken care of.
METHODS OF ACHIEVING DIRECTIONAL SOLIDIFICATION
Insulate Risers:
Since the riser is the reservoir of molten material for the casting, it should be last to solidify.
Insulating the top as mentioned earlier, shown in figure will greatly reduce cooling in the risers
from the steep temperature gradient between the liquid metal of the casting, and the room
temperature air.
1. Consider V/Ratios:

In casting manufacture, V/A ratio stands for volume to surface area or mathematically
(volume/surface area). When solidification of a casting begins a thin skin of solid metal is first
formed on the surface between the casting and the mould wall. As solidification continues the
thickness of this skin increases towards the center of the liquid mass. Sections in the casting with
low volume to surface area will solidify faster than sections with higher volume to surface area.
When manufacturing a part by metal casting consideration of the V/A ratios is critical in avoiding
premature solidification of the casting and the formation of vacancies.
Heat Masses:
Avoid large heat masses in locations distant to risers. Instead, locating
sections of the casting with low V/A ratios further away from the
risers will insure a smooth solidification of the casting
Sections of the Casting:
The flow of material is very important to the manufacturing process. Do not feed a heavy
section through a lighter one.
Be Careful With Consideration To L,T,V,Y and + junctions:
Due to the nature of the geometry of these sections it is likely that they
will contain an area where the metal casting's solidification is slower
than the rest of the junction. These hot spots are circled in red Figure.
They are located such that the material around them, which will
undergo solidification first, will cut off the hot spots from the flow of
molten metal. The flow of casting material must be carefully considered
when manufacturing such junctions. If there is some flexibility in the
design of the metal casting and it is possible you may want to think
about redesigning the junction. Some possible design alternatives are
shown in Figure. These should reduce the likelihood of the formation of
hot spots
Prevent Planes of Weakness:
When metal castings solidify, columnar grain structures tend to develop,
in the material, pointing towards the center. Due to this nature, sharp
corners in the casting may develop a plane of weakness. By rounding the
edges of sharp corners this can be prevented.
Connection between Riser and Casting Must Stay Open:
Riser design is very important in metal casting manufacture. If the
passage linking the riser to the metal casting solidifies before the
casting, the flow of molten metal to the casting will be blocked and the
riser will cease to serve its function. If the connection has a larger cross
sectional area it will decrease its time to freeze. Good manufacturing
design, however, dictates that that we minimize this cross section as
much as possible to reduce the waste of material in the casting
process. By making the passageway short we can keep the metal in its
liquid state longer since it will be receiving more heat transfer from
both the riser and the casting
Use of Chills:
To achieve directional solidification within the metal casting, it is important to
control the flow of fluid material and the solidification rate of the different areas
of the metal casting. With respect to the solidification of the metal casting's
different sections, regulation of thermal gradients is the key.
Sometimes we may have an area of the metal casting that will need to solidify at
a faster rate in order to ensure that directional solidification occurs properly.
Manufacture planning and design of flow and section locations within the mould
may not be sufficient. To accelerate the solidification of a section like this in our
casting, we may employ the use of chills. Chills act as heat sinks, increasing the
cooling rate in the vicinity where they are placed.Chills are solid geometric shapes
of material, manufactured for this purpose. They are placed inside the mould
cavity before pouring. Chills are of two basic types. Internal chills are located
inside the mould cavity and are usually made of the same material as the casting.
When the metal solidifies the internal chills are fused into the metal casting itself.
External chills are located just outside of the casting. External chills are made of a
material that can remove heat from the metal casting faster than the surrounding
mould material. Possible materials for external chills include iron, copper, and
graphite. Figure demonstrates the use of the two types of chills to solve the hot
spot problem in a + and T junction.
DEGASIFICATION IN LIQUID METAL
SOURCES OF GASES
The main sources of gases in molten metal are listed below
Furnace charge
Metal flux scrap etc may contain moisture, oil, grease; rust etc.Furnace charge may contain moisture grease etc., during storage which will
result in the release of gases while carrying out melting operation.
Furnace refractories
If the refractories used for the furnace are not preheated properly they may contain residual moisture. During the constructions of the
furnace moisture is invariably used while shaping the furnace hearth along with refractory bricks. During melting operation the moisture in
the lining and bricks gets evaporated and dissociate into elemental gas. These gases get entrapped in the metal inspite of proper treatment
with different agents. Also even the lining of the ladles or pouring vessels may contain moisture which will cause dissolution of gases.
Hence crucibles, ladles, furnaces lining and other accessories are to be preheated well before receiving the molten metal.

Furnace atmosphere
The atmospheric condition surrounding the furnace where melting is being carried out influence the melt quality. Atmosphere may contain
moisture,H2,CO2,O,N etc.In addition the fuel used for combustion will result in SO2, CO2, etc.Both elemental and combined form of gases
are thus present. The combined gases are split into elemental gases. Elemental gases diffuses into molten metal.
Gases derived from flux residue
Flux contain salts such as MgCl2 or hygroscopic salts such as NaCl and residues of these fluxes trapped on the surface of the metal may
cause gas absorption, during remelting.Further flux residues may adhere to the used crucibles and even penetrate their walls.
Gases introduced during pouring
Gas bubbles may be introduced in the molten metal during pouring from a height. The atmosphere gas gets into the melt as entrapped
gases. Hence molten metal has to be poured into the mould with at least amount of disturbance and at a rapid pace to prevent too much
exposure of the molten metal with atmosphere.
DEGASSING METHODS
Degassing by fluxes
Fluxes composed of chlorine and fluorine containing salts are used for degassing molten aluminium alloys.
Degassing fluxes are commonly shaped in form of tablets.
Degassing operation starts when a flux tablet is plunged by a clean preheated perforated bell to the furnace
bottom. The flux components react with aluminium forming gaseous compounds (aluminium chloride,
aluminium fluoride). The gas is bubbling and rising through the melt. Partial pressure of hydrogen in the
formed bubbles is very low therefore it diffuses from the molten aluminium into the bubbles. The bubbles
escape from the melt and the gas is then removed by the exhausting system.
The process continues until bubbling ceases.

Rotary degasser
In the rotary degassing method an inert or chemically inactive gas (Argon, Nitrogen) is purged through a
rotating shaft and rotor. Energy of the rotating shaft causes formation of a large number of fine bubbles
providing very high surface area-to volume ratio. Large surface area promotes fast and effective diffusion of
hydrogen into the gas bubbles resulting in equalizing activity of hydrogen
Rotary degasser allows achieve more complete hydrogen removal as compared to the flux degassing.
Additionally rotary degasser does not use harmful chlorine and fluorine containing salts.
Rotary degasser may also combine the functions of degassing and flux introduction.
In this case the inert gas serves as carrier for granulated flux. The method is called flux injection.
FETTLING OPERATIONS
Knocking of dry sand core
Knocking out of dry sand cores. Dry sand cores may be removed by knocking with iron bar. For quick knocking pneumatic or hydraulic
devices are employed, this method is used for small, medium work. For large castings the hydro blast process is mostly employed
Removal of gate and riser
With chipping hammer
By using cutting saw
Flame cutting
With abrasive cut off machine
Removal of fins, rough spots and unwanted projections
The casting surface after removal of the gates may still contain some rough surfaces left at the time of removal of gates. Like. Sand
that is fused with surface. Some fins and other projections on the surface near the parting line. They are needed to be cleaned
thoroughly before the casting is put to use. The fins and other small projections may easily be chipped off with the help of either
hand tools or pneumatic tools. But for smoothing the rough cut gate edges either the pedestal or swing frame grinder is used
depends upon the size of castings.
Cleaning of Castings
After the solidification of the casting, the mould is knocked out and solidified casting is taken out of the moulding sand. At this
juncture the cast product is attached with risers, and gates. many times the moulding sand also get adhered to the casting as some of
the sand gets fused with the molten metal. The cleaning of castings refers to the removal of gates, risers and sand. Also, cleaning may
involve machining or abrasive finishing of the cast product. The cleaning operations usually performed on a casting are given below:
1. Removal of gates, in-gates, riser, feeder etc.
2. Surface cleaning
3. Trimming
4. Finishing
Removal of gates, in-gates, riser, feeder etc.
There are various methods of removal of unwanted metallic parts from the solidified cast product. in case of
brittle material, the gates, risers, and feeder can be removed by impact force. this is usually done in shakeout
or knock out devices. Other processes that may be used to cut off the metallic parts include, band saws,
grinding machine, shearing machine, cutting torches, etc.
Surface cleaning
As the temperature of molten metal is usually high, sand particles near the surface of the casting gets fused
and adheres to the surface of the casting. the cleaning of the surfaces both interior and exterior thus becomes
necessary. There exist several methods to remove the adhered sand from the castings. Some of the most
common methods of removal of sand are tumbling, and sand or metallic shot blasting. Tumbling is done in a
barrel like machine called as tumbling mill which helps to remove the sand by rubbing action of the cast parts
with each other. Whereas, in blasting, abrasive particles are thrown on the surface of the casting in a carrying
medium. Air is the most common medium used in this process. Sometimes, metallic shots are thrown on the
surface of the castings to remove the unwanted material. Blasting processes include air blasting, centrifugal
blasting, hydro-blasting etc. Other methods to clean the cast surface include wire brushing, and buffing.
Trimming
Trimming operations involves the removal of fins, gates and risers appendages, metallic chaplets, etc. These
unwanted material is removed by using hammer and chisel called as chipping process, or by pneumatic
chipping hammers or by the use of grinders.
Finishing
The finishing at this stage refers to the final cleaning. The castings after the removal of gates, risers, fins,
chaplets, adhered sand is washed and then depending upon the requirements of the end product final finish is
provided by machining, polishing, buffing, chemical treatment etc.
TYPES OF CASTING DEFECTS
The proper designing and molding can give a defect free cast but due to
some control limitation and human interference, defects are generally
occurring. By the proper assistance on work we can minimize the
casting defects. Generally a proper casting product also has some
defects so a research is going in foundry industry to minimize these
defects. These casting defects can be found out by the non destructive
testing methods which includes ultrasonic testing, radiography testing,
magnetic particle testing, die penetration testing etc
1. Blow Hole: It is a gas hole or gas cavity which is occurs at the surface
or the internal part of casting. It is due to gas interrupted into the
casting due to poor ventilation. Mostly it is occur at surface which
makes a circular of oval shape gas hole. These defects can be seen after
machining of surface. These defect cause due to improper venting
system, excessive gas or moisture contain and due to low permeability
of sand and high temperature of sand. It is also due to low pouring
temperature of metal.
2. Scar: Scar is generally occurring at flat surface and it is due to
improper venting or permeability of sand. The blow is covered by the
thin layer of metal.
3. Scab: This is also known as slag inclusion of sand inclusion. This is
look like as slag inside the cast and very difficult to remedy because
generally it does not occur at single point. This defect generally occurs
due to defective mould or core, low binding strength of moulding
material or sand. It is also due to low permeability of sand.
4. Penetration: This defect occurs when fluidity of molten metal is high.
When mould is porous and does not enough stronger to resist molten
metal, this defect occur. The liquid metal penetrates the mould and mix
with sand. This gives uneven casting surface.
5. Cold shut: It is the basic defect which generally occurs. It is occur
when the molten metal flow through two different paths. When the
two stream of molten metal comes in contact and solidify before they
mix completely, some bubbles form between them. This phenomenon
is known as cold shut. It is also known as cold lap.
6. Mismatch: It is defect due to mismatch of cope and drag. It is also
known as shift. When the cope shift relative to drag known as mould
shift and when drag shift known as cope shift. It is due to the bouncy of
the molten metal, loose box pins etc.
7. Misruns: Misruns is a phenomenon when the cast materials solidify
before the proper filling of mould. This result presence of incomplete
cavity filling. It is due to too thin wall thickness, improper gating
system, slow pouring, damaged pattern and poor fluidity of molten
metal.
8. Hot tear: A hot tear or crack is generally not visible because the
casting has not separated into fragments. This is occurring due to
uneven cooling and improper position of chills. This is generally occur
where abrupt section change. This is occurring during solidification of
casting when the solid portion has not sufficient strength to resist
tensile force.
9. Shrinkage: This defect generally arises during volume contraction
during solidification. It is occurwhen the liquid metal does not
sufficient to compensate the volume shrinkage. This is due to
insufficient size of riser, improper direction solidification of casting,
improper location of chills or in gates.
10. Buckle: The formation of uneven line on the cast surface is known as
buckle. It generate due failure of sand surface or expansion of sand surface
due to heat of molten metal.

11. Pin hole: Pin holes are similarly to blow holes but smaller into size. These
are generally present at surface or sub surface and in large numbers. This is
due to improper ventilation for gas and low permeability of moulding
material.
12. Warpage:It is the defect or deformation in a casting that occur during or
after solidification due to different rates of solidification of different sections
of casting, so stresses are set up in adjoining walls resulting in war page
these area.
NONFERROUS FOUNDRY PRACTICE
ALUMINUM CASTINGS - ADVANTAGES, LIMITATIONS
ADVANTAGES
Many aluminium casting alloys display excellent fluidity for casting thin sections and fine detail.
Aluminium casting alloys melt at relatively low temperatures.
Aluminium casting processes can be highly automated.
In many cases, multi component welded or joined assemblies can be replaced with a single cast part.
Machining requirements are reduced.
Aluminium castings display controlled variations in as-cast finish.
Contrasts between as-cast and machined finishes can be highlighted to create pleasing cosmetic effects.
Capital requirements are typically less than for wrought products.
Tooling can range from simple patterns to complex tool steel dies depending on product requirements and
production volume.
Metallurgic ally or mechanically bonded bimetal parts can be routinely cast.
Aluminium parts are routinely cast by every known process, offering a broad range of volume, productivity,
quality, mechanization, and specialized capabilities.
Most aluminium casting alloys display solidification characteristics compatible with foundry requirements for
the production of quality parts.
LIMITATIONS
Very thin sections may not be cast able.
There are practical limitations in size for specific casting processes. The
solidification behaviour of some alloys precludes casting in difficult
engineered configurations or in specific casting processes.
The casting process is simpler and less capital intense than processes
for producing forgings, extrusions, and rolled products. However,
solidification in complex geometrical shapes, as with other fabrication
options, can result in surface discontinuities and internal
microstructure features with varying degrees of quality that affect
properties and performance.
MELTING OF ALUMINUM USING LIFT-OUT TYPE CRUCIBLE FURNACE
Crucible furnaces are one of the oldest and simplest types of melting unit used in
the foundry. The furnaces use a refractory crucible which contains the metal
charge. The charge is heated via conduction of heat through the walls of the
crucible. The heating fuel is typically coke, oil, gas or electricity as shown in figure.
Crucible melting is commonly used where small batches of low melting point
metals are required like aluminium. The capital outlay of these furnaces makes
them attractive to small non-ferrous foundries. Lift-out furnace, in which the
crucible and molten metal are removed from the furnace body for direct pouring
into the mould. The melting point of pure aluminum is 658 C. The most common
manufacturing processes in the production of aluminum castings are die casting.
The melting may take place by means of a fuel fired Lift-out furnace. The raw
materials for the production of re-melted aluminum consists of various types of
scrap, and cutting, punching, milling and turnings obtained during manufacture of
virgin aluminum objects, and worn aluminum parts such as recycled cans, old car
parts and appliances.In modern re-melting plants the aluminium scrap is pre-
treated by different methods and then melted in Lift-out furnace. The melt is
normally treated with large quantities of flux and sometimes chlorine gas. This
result in a high quality product. Most of the re-melted metal is used in foundries
and is then alloyed with copper and/or silicon. Delivery is in the form of ingots or
liquid metal in well insulated ladles.
HARDENERS USED
Aluminum's mechanical and physical properties are enhanced with the use of alloying
elements. These alloying elements are commonly referred to as hardeners. Aluminum-
based master alloys which contain the hardener elements in high concentrations, provide a
convenient and economical way to add them to aluminum to achieve desired properties.
These master alloys readily go into solution at lower liquid aluminum temperatures, thus
minimizing dross formation and solubility of hydrogen. Lower furnace temperatures also
mean reduced energy consumption and longer furnace life. Hardeners are available in a
number of alloys including Ca, Co, Cu, Cr, Mn, Mg, Ni, Si, Ti, V, Zr, Zr-V, and more. AMG
Aluminums hardeners are available in a variety of concentrations depending on the alloy.
Forms include waffle, slab, and ingot profiles.

ALUMINUM DROSS
It is a mass of solid impurities floating on a molten metal. It appears usually on the melting
of low-melting-point metals or alloys or by oxidation of the metal. Aluminum dross is the
mixture of metallic aluminum and non metal part mostly Aluminum oxide. Dross is formed
on the surface of molten Aluminum or its alloys by oxidation. Dross is a valuable by product
of any Aluminum Smelter or Aluminum Foundry. Dross is recycled to recover the valuable
Aluminum.
FLUXES FOR MELTING ALUMINIUM
These are solid substances (commonly mixtures of chloride and fluoride salts) used in
aluminium foundries in order to reduce the melt oxidation, minimize penetration of the
atmospheric Hydrogen, absorb non-metallic inclusions suspended in the melt, keep the
furnace/ladle wall clean from the built up oxides, decrease the content of aluminium entrapped in
the dross, remove hydrogen dissolved in the melt, provide aluminium grain refining
during Solidification, modify silicon inclusions in silicon containing alloys, oxidize excessive
magnesium. Common practice of flux introduction is manual application. Most of the fluxes are
applied on the melt surface and stirred into the melt. Some of the fluxes (degassing, grain refining)
are plunged to the bottom by a clean preheated perforated bell. Fluxes may also be introduced into
the melt by injection in form of a powder in an inert gas (Argon or Nitrogen) stream. The simplest
flux injection technique is a lance immersed into the melt.
The most effective flux introduction method is injection by rotary degasser. Classification of fluxes
for melting aluminum
Drossing fluxes
Cleaning fluxes
Wall cleaning fluxes
Degassing fluxes
Grain refiners
Silicon modifiers
GRAIN REFINEMENT
It is a process used for grain boundary strengthening of casting material. Aluminum alloys with ultra fine grain
structure has received tremendous increase in research interest in various disciplines especially in automotive
and aerospace industries for properties like low density and good cast ability. Grain refinement of Al and its
alloys improve the mechanical properties of casting along with surface finish, soundness etc
Methods of grain refinements used in casting process are mainly classified into following three groups
Thermal method i.e. Cooling rate control
Chemical method i.e. Grain size refiners addition
Mechanical method i.e. agitation of melt during solidification
Benefit of Grain Refinement Process
Improved Feeding.
Improved Fluidity.
Improved Surface finish & Mach inability.
Better mechanical properties
STIR CASTING SETUP
Stir casting technique is currently the most common practiced commercial
method for processing Metal Matrix Composites. This approach involves
mechanical mixing of the reinforcement particulates/particles into a molten
metal bath. A simplified apparatus is shown in Figure and typically is
comprised of a heated crucible containing molten aluminum metal, with a
motor that drives a paddle, or mixing impeller, that is submerged into the
melt. The reinforcement is poured into the crucible above the melt surface
and at a controlled rate, to ensure a smooth and continuous feed. As the
impeller rotates at moderate speeds, it generates a vortex that draws the
reinforcement particles into the melt from the surface. The impeller is
designed to create a high level of shear, which helps strip adsorbed gases
from the surface of the particles. The high shear also surrounds the particles
in molten aluminum, which promotes wetting. Proper mixing techniques and
optimized impeller design are required to produce adequate melt circulation
and homogeneous distribution of the reinforcement.
(1)Stirrer spindle, (2) sliding mechanism with impeller position
control unit, (3) electric motor, (4) sprue, (5) crucible,
(6) electric furnace, (7) impeller, (8) argon gas inlet, and (9)
thermocouple
Advantages
High material yield
Low initial cost,
Simplicity and flexibility
Disadvantages
Possibilities of agglomeration of reinforcements sedimentation of the
reinforcements at the bottom of the as cast and high interfacial reactions.
Applications
In manufacturing of composites like Al and Mg alloys

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