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AQ2
Question Sheet 2, Solidification Recommended reading Chapter 4, pp 185-243 in Porter D. A. and Easterling K. E, Phase Transformations in nd Metals and Alloys, 2 edition. Chapman & Hall, 1992. [Dept. library Ln30] Chapter 4, pp 189-248 in 3 edition, 2009. Chapter 14, pp 421-478 in Abbaschian R., Abbaschian L. and Reed-Hill R.E., th Physical Metallurgy Principles, 4 edition. PWS Publishing, (2010) [Dept. library A161]
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Web software and other resources www.matter.org.uk/solidification Matter software - see page 3 for site map.
Cambridge Engineering Selector CES on computers in Department or can download a copy for your own use (PC platform only) from www.msm.cam.ac.uk/teaching/ces.php Excellent summaries of many metallurgical processing approaches including solidification www.msm.cam.ac.uk/phase-trans/phase.field.models/movies2.html Solidification movies. www.msm.cam.ac.uk/phase-trans/dendrites.html Dendritic solidification.
www.msm.cam.ac.uk/Teaching/ces Individual casting processes described succinctly in Process Universe in Cambridge Engineering Selector (CES) software see page AH103 for details of how to access this. [CES software can be downloaded from the above web address for your own use only.] www.efunda.com/processes/metal_processing/sand_casting_intro.cfm www.diecasting.org/faq/ Sand casting.
See dynamic processes (e.g. hot chamber machines). Continuous casting & steel making. Investment casting. Fabrication of silicon wafers.
Questions 1. Distinguish between thermal dendrites and those induced by constitutional undercooling. Using the Al-Si phase diagram, determine the solid/liquid solute partition coefficient and the gradient of the liquidus curve for the solidification of aluminium-rich alloys. State any assumptions. Calculate the thermal gradient necessary to ensure a planar front at a solid-liquid interface in a melt of composition Al-0.3 Si wt.% when solidification occurs at a speed of 5 x 10 mm s . [The diffusivity of Si in liquid Al is 5 x 10 m s .] 2. Give examples of industrial applications for one-dimensional solidification. A bar of aluminium is contaminated with copper at a concentration four times the acceptable limit. It is to be purified by directional freezing, with a planar growth front. Use the Al-Cu phase diagram (Data Book) to estimate the fraction of the bar that will have an acceptable purity. [Assume the maximum solubility of copper in an aluminium solid solution is 5.7 wt.%.]
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rob.wallach@msm.cam.ac.uk
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Question Sheet 2
AQ2
3. Sketch free energy versus composition graphs at the three temperatures for the peritectic reaction shown below.
Liquid L+!
L+"
Question Sheet 2
AQ2
5d. Specimens M3, M4 (cast Al-Cu alloys) and also M6 (as this shows more clearly the eutectic seen in samples M3 and M4). Study of the Al-Cu phase diagram (see Data Book) reveals that the maximum solid solubility of copper in aluminium, ~5.7 wt.%, is above the copper content of both of these specimens. The cast microstructures, however, show significant levels of second phase, ! (CuAl2). Account for this, assuming that the amount of solid-state precipitation during cooling was negligible. Estimate the content of eutectic ("+!) seen in these specimens, and compare these values with those predicted using the Scheil equation. Comment on this comparison. 5e. Specimen M25 is a section from a casting of commercial purity aluminium. The grain structure is visible to the naked eye, although some features may usefully be inspected at low magnification in an optical microscope. Sketch the grain structure of the complete casting and account for the main features observed. Account for the presence of the pronounced shrinkage "pipe" in the upper central part of the casting. How would you expect this to be modified if the alloy had been, say, Al-5 wt.%Cu? Numerical answers to AQ2; full answers will be distributed later. 1. Thermal gradient = 104 K mm at a speed of 5 x 10 mm s . 2. Fraction solidified = 0.37. 4. Maximum thickness = 3.5 x 10 m, i.e. 35 m. Computer-based exercises Matter software on solidification on the web www.matter.org.uk/solidification Choose site map to show below and then select topics equivalent to sections in the lecture notes.
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rob.wallach@msm.cam.ac.uk
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