Castings in the wind

A glance into
Ductile Iron properties, technology
and casting design
(CAD_Designers and FEA Designers)
 Subjects to discuss
n Introduction
n Metallurgy
n Chemical composition and elements impact
n Microstructure
n Defects - issues causing the trouble
n Control and remedies which applies
n Design guidelines

2
 Who I am?
n Per Magne Refstie
n Fund et Fort
n Kristiansand in Norway

n 40 years experience in
foundry technology at
Kristiansands Jernstperi A/S

n e-mail; kjern-a@online.no

3
Introduction
n The casting prosess has been used for more than
5000 years to produce both objects of art and
utilitarian items.

n To day designers use its freedom of form and its

replication of details to meet the basic goal of
industrial design the macthing of form to function
to optimize component performance.

n The design flexibility offered by the casting prosess

far exeeds that of any other prosess used for the
production of engineering components.
4
Introduction
n Castings offer cost advantages over fabrication and
forgings over a vide range of production rates,
component size and design complexity.

n As shown in the next figure, as component size and

complexity increace, the cost per unit of weight of
fabricated components can rise rapidly, while those
of castings can actually decreace due to the
improved castability and higher yield of larger
castings.

5
 Fabrication

Increasing:

Production
Cost / ton

Casting

Increasing: Section thickness

Shape complexity
Stiffening

6
 Materials advantages
n The deformation process used to manufacture forgings
and plate for fabrications produce laminations which
can result in a significant reduction in properties
transverse to the lamination.

n In fabricated components, design complexity is

normally achieved by the welding of plate or other
wrought shapes.

n This method of construction can reduce component

perforemence in two ways.

7
 Materials advantages
n First, material shape limitations often produce sharp
corners which increase stress concentrations.

n And second, the point of shape change and stress

consentration is often a weld, with related possibilities
for material weakness and stress-raising defects.

n The next figure shows the result of an acrylic joint

model in which the stress consentration factor for the
weld is substantially higher than for a casting, profiled
to minimaize stress concentration
8
Acrylic model stress
analyses for a
welded fabrication
and a casting

9
 Grey Cast Iron
n In grey cast iron the graphite
flakes acts as stress raisers and
under stress help crack
propagation.
n As a result, grey cast irons are
weak, with ultimate tensile
strenght of 150-400 Mpa. And
with practically no elongation.

n The size of graphite flakes varies

with production conditions and
section thickness. Normally flake
lengths are from 0.1 to 1.0 mm
Micrograph of Gray Iron with cracks
 Cast Iron with Spheriodal Graphite
(i.e. Ductile Iron)

n Became an industrial reality in

1948.
n A suitable treatment of the
molten iron causes the
graphite to precipitate as
spheroids rather then flakes.

n The nearely spherical shape of

the graphite removes the
crack effect, in fact, the
graphite spheroids act as
crack-arresters as shown
impressively in the illustration.
Micrograph of Ductile iron with cracks
Cast iron: The natural composite

n The term cast iron refers not to a single material,

but to a family of materials whose major constituent
is iron, with important amounts of carbon and
silicon, as shown in the next figure.

n Cast irons are natural composite materials whose

properties are determined by their microstructures
the stable and metastable phases formed during
solidification or subsequent heat treatment.

12
 Ductile iron

Approximate
ranges of carbon
and silicon for
steel and various
cast irons

13
 Annual world production of DI

n 40 years of
continual growth
worldwide.
n Success caused
by versatility,
and higher
performance at
lower cost.
14
Microstructure in DI
n Graphite.
The stable form of pure carbon in cast iron. Its
important physical properties are low density, low
hardness and high thermal conductivety and lubricity.

Graphite shape, which range from flake to spherical,

plays a significant role in determining the mechanical
properties of cast iron.

15
Microstructure in DI
n Carbide
Carbide , or cementite, is extremely hard, brittle
compound of carbon with either iron or strong
carbide formation elements, such as chromium,
vanadium or molybdenum. Massive carbides increase
the wear resistence of cast iron, but make it brittle
and very difficult to machine. Dispersed carbides in
either lamelar or spherical forms play an important
role in providing strength and wear resistance in as-
cast and heat-treated irons.

16
Microstructure in DI
n Ferrite
This is the purest iron phase in cast iron. Ductile iron
ferrite produces lower strength and hardness, but
high ductillity and toughness. In Austempered Ductile
iron (ADI), extremely fine-grained accicular ferrite
provides an exceptional combination of high strength,
good ductility and toughness.

17
Microstructure in DI
n Pearlite
Pearlite, produced by the eutectoid reaction, is an
intimate mixture of lamellar cementite in a matrix of
ferrite.
Pearlite provides a combination of higher strength
with a corresponding reduction in ductility.

18
 General
relationship
between tensile
properties and
hardness

19
Relative damping
behaviours of
steel, Ductile-,
Malleable- and
Grey iron

20
Impact of deficiences on costs at GE*
le

* G. K. Bouse et Al
21
Production flow example
Production flow and quality plan for Bonus 1MW Hub. item ; 512563

Start Vibrate mould

and core Assemble cores Slag ladle, pour Knock out at max.
moulding
boxes. and coin for chem. 450C .
acc. to
Apply standard boxes. Apply air analysis Clean and fettle.
article
curing time and suction for Pour mould box as
specification
coating min. 2h from required Inspect acc. to
for item no.
practice mold cavity at 1350 to 1390C KI13753 ECN4904
512563

Analyse acc. to
Treat melt at KJ32 alloy
Run
Compose 1480C with Test mech.
preconditioning
charge MgFeSi alloy to properties at
procedure with
makeup to achieve t>=60-200mm acc.
0.2-0.3%
comply with 0.040.005 % Mg to KI13753
Desulco 9012.
KJ32F alloy Add 35g Sb and ECN4904. Prepare
Analyse TEU
1kg Disp. certificate as
pro ton required.

KJ 101-X.X rev:00 12.08.99 pmr

 Moulding process
Vents

Running system Pattern

Sand filling

Moulding box

23
 Moulding process

Separation of mould
from pattern

24
 Moulding process
Assembled mould ready for pouring
vents

Running system

Core print

Core

25
 Furane sand,
acid catalysed moulding media

n These binders, firtstly introdused in foundries in 1958,

are commenly used for moulding and coremaking of
medium and large sized parts, for small and medium
batch production, and for all alloy types.

n The prosess allows good flexibility in application and

properties. Furfuryl alcohol (FA) has the disadvantage of
being a (strategic) basic product, which leaves it open
to marked price variations.

26
 Furane, acid catalysed moulding sand..

n The addition of an acid catalyst to a furane resin causes

an exothermic polycondensation, which hardens the
binder.
n Furane binders are available with different formulations,
all of which are based on furfuryl alcohol:

- furane resin FA
- urea - formaldehyde -furfuryl alcohol UF-FA
- phenol - formaldehyde - furfuryl alcohol PF-FA
- urea - formaldehyde - phenol - furfuryl alcohol UF-PF-FA

27
 Furane, acid catalysed moulding sand..

n A silane is nearly always added to enchange the resin-

sand bond.

n The catalysts are strong sulphonic acids, such as

paratuluene, xylene, or bezene-sulphonic, sometimes
with an addition of sulphuric or phosphoric acid, usually
used in a diluted form.

28
Spartan III sand mixer machine

Capasity: 100 ton/h

29
Cope and drag moulding box

30
 Filling sand into moulding flask

n Ready prosessed
furane silica-sand
from mixser.

n Proper packing and

compaction

31
 Treating the mould right

n Obtains a well packed

Vibrate mould mould able to withstand
and core solidification pressure.
boxes. n Allow ample cureing period
Apply standard to achieve a firm and ridgid
mould.
cureing time
and coating n Apply both sulfur-stop and
high qualiy zircon based
practice coating.

32
 Cope and drag assembling

n Assemble according to
established workmanship.
Assemble cores
and n As furane cureing is in
boxes. Apply air prosess, vapour/gases will
be reaction products.
suction for
min. 2h from
n Alcohol/water-based coating
mould cavity liberate gaseous substance.

33
Cores assembly in drag

34
 Core assembling
core

Mould
finished with
ceramic
coating

35
Sand testing

36
 Sand testing

n Sand gain distribution

n Sintering temperature
n Compression strenght
n Permeability
n Sulfur level

37
 Prepare for melting
Doc

Compose charge
n Pick raw material of high
makeup to
quality for melt charge
comply with
makeup to satisfy
specification.
KJXXF alloy

38
 Charge/melt makeup

OB pig iron:
30-35 %
Sorel and Tinfoss; 50/50

High quality steel sheets 35-45 %

Returns;
Running system
Feeders
20-30 %
Flashes
Internal and external scrap
Chippings
39
 Melt ready for further processing

nTapping from a
coreless induction
furnace

40
 Desulfurization
n If the iron is to be treated with Mg (as desribed later) to
produce nodular cast iron, then sulfur levels >0.015%
should be neutralised to prevent later dross formation.

n In the porous plug method, nitrogen or argon gas is used

to agitate metal and added CaC2 powder.
n Upon contact with the liquid metal CaS is formed and
removed as slag.

n The treated metal then flows to a holding ladle or

furnace, from which it is subjected for further treatment.
41
 Sulfur control of iron melt

n Porous plug ladle for

reduction and control
of sulfur level.

42
 Preconditioning of the melt

n Prepare the melt for the

subsequent Mg-treatment.
Run
n Makes starting point in the
preconditioning
melt (nucleation centers)
procedure with to promote a proper
0.2-0.3% solidification.
Desulco 9012. n Best achieved by addition
Analyse TEU of high quality crystalline
graphite.

43
Magnesium treatment methods

The addition of spheroidizing agents to molten iron is

probably the most important singel step in the
production of ductile iron!!
Magnesium is used exclusively as the spheroidizing
element in commercial practices.
Frequently its added with cerium and other rare earth-
containing materials.
Magnesium and its alloys have low vaporization
temperatures and, consequently their addition to
molten iron must be done with extreme care.
44
Magnesium treatment methods

n Open-ladle, Pour-over n Flowtret method

process.

n Sandwich method n Plunging method

n Tundish cover ladle n Cored wire treatment

n In-mold treatment n GF converter process

45
 Magnesium ferro-silicon nodulalizer

Typical analysis %

Si Mg Ce TRE* Ca Al Size

43-48 5-6.5 0.30-0.45 0.5-0.75 0.8-1.3 1.2 max 6-30 mm

*)Total rare earth

46
 Mg-treatment

n The Tundish Cover: This is an improved sandwich

technique, whereby the ladle is covered by a lid after
the MgFeSi alloy has been placed at the bottom of
the ladle.

n The metal is poured in a concave lid and flows

through a hole in the ladle, where the reaction takes
place.

47
 Mg-treatment of ductile iron

n Tundish covered
ladle for Mg-
treatment of iron
melts.

48
Postinoculation
n Suitable inoculation provides sufficient
nucleation centers for solidification to take
place in the stable graphite-plus austenite
system.

n The greather the degree of nucleation, the

greather the number, and the smaller and
more uniform in size and shape will be the
graphite spheroids.

49
 Postinoculation

n The term late inoculation includes any

method of adding inoculants to the metal
stream as the casting is poured, or within the
mould cavity itself.

n It is possible to produce greather levels of

inoculation by these methods with much less
inoculant then is required with ladle
inoculation.

50
 Inoculation in pouring basin

n Inoculation
blocks placed
in the pouring
basin

51
 Mould inoculation

n Poor inoculated
ferritic, heavy
section ductile
iron casting.

Nital 70X

52
 Mould inoculation

n Properly inoculated
ferritic, heavy
section ductile iron
casting.

Nital 70X
53
 The moment of treatment

Treat melt at n Keep treatment ladle

1480C with clean and preheated.
MgFeSi alloy to
achieve
n Keep Tundish full
0.040.005 % Mg
during the treatment
Add 35g Sb and
process.
1kg Disp.
pro ton

54
Pouring

Slag ladle, pour

coin for chem. n Keep pouring
analysis basin full during
Pour mold box as the whole period
required of pouring.
at 1350 to 1390C

55
 Ductile iron- ferritic matrix- section modulus,
M>10

Chemical analysis spesification

ppm
%C % Si % Mn % P % S % Mg % Ti % Al % Cu % Sn % Ni % Cr %V spor

3.70 2.05 0.27 max .010 .040 max max max max 0.1 max max
70
0.1 0.1 .03 0.03 .002 .005 0.04 0.03 0.1 0.01 .03 0.06 0.06
F&F32 pmr_12

* ppm spor= Pb + Bi + Ti/10

56
Mandatory types of testing

l Chemical analysis
l Mechanical testing
l Metallographic analysis
l Visual inspection (VT)
l Ultrasonic inspection (UT)
l Magnetic particle inspection (MPI)
l Dimensional measurements (DT)
57
 EN1563

Cast-on samples:

Mechanical t Rm Re A5d KV
Material symbol
properties mm MPa MPa % J/-20C

example <30 400 240 18 12

EN-GJS-400-18U-LT 30-60 390 230 15 12

60-200 370 220 12 10

Separately cast sample:

Rm Re A5d KV
Material symbol
MPa MPa % J/-20C

EN-GJS-400-18S-LT 400 240 18 12

pmr_05
 Issues causing the trouble

n Instable pattern and core box equipment

n Mould assembly of huge copes and drags
n Graphite flotation (dendrites with high carbon)
n Metal penetration
n Graphite structure anomalies
n Lack of datum planes and pick up points

59
 Frame section drag pattern
Core print

Running system

60
Core box assembly

61
Part of corebox Core stripping

62
 Filters and
inoculation
Mould assembly inserts

63
 Topics to be controlled
n Chemical composition close to the eutectic point

n Controlled level of miner and trace elements

n Simulation of the filling sequence

n Simulation of the solidification pattern

n Heavy compaction of moulding media

64
 Further issues

n Preconditioning of the melt

n Close control of thermo-analytical parameters

and pouring temperatur

n Inmould inoculation

n Avoidance of reactions in the mould surface

65

Controlled cooling cycle

 Design of the running system

n Controlled filling

n Surface turbulence

n Melt velocity

n Uniform flow pattern

66
 Surface turbulance

n Bulk turbulence n Surface turbulence

Reynolds number Webers number

Re = Vrd/h We = V2rr/g
V= linear velocity V=linear velocity
h = viscosity g = surface tension
r = density r = density
d = geometry of flow path r = radius of surface curvature

67
General types of running
systems

Type 1

Type 2

Type 3
68
Flow-3D filling simulation

X.Jung and Flow-3D X.Jung and Flow-3D

Histogram of UTS distributions

Type 1 Type 2 Type 3

70
*)
Weibull plot of
ultimate tensile
strength from
type 1, 2 and 3
filling systems

*)
71
Simulation and filling
sequence

72
Solidification pattern

73
 F&F

Filling of the mould at a

required speed < 50 cm/s

Whats achieved at the

end of the exercise
The delivery of only liquid
metal
into the mould cavity

Freezeing off within

a certain time

Ease of removal

pmr_05
 F&F
C a rb o n S h rin ka g e
F lo ta tio n of g ra p h ite

Criterias to control S ilico n P rom o te s gra p hite

M a trix
stre n g th /b rittle n e ss
within limits close
M a trix stre n g th
M an g a n es e
P e a rlite a n d c arb id e s

to analytical
S u lp hu r In ocu la tio n

capability D ro ss g e ne ra tion

M a g ne siu m N o du le fo rm a tion
D ro ss a n d sh rin ka g e

C e rium B a la n ce in g P b , S b e tc.
S hu n ky g ra p h ite

S h rink ag e a nd n od u le
T ita n iu m
form a tio n

T h e rm a l C on trol o f g ra p h ite
a n alysis stru ctu re
S hrin ka g e

pm r_05
Minimize chunky graphite

Control trace elements at low levels

Apply the formula

Sb/(Re+Ca) > 0.7

76
 Haig diagram
showing anomalous
structure influence on
fatigue endurance *)

*)
Fraunhofer Nr FB-214(1998)
 F&F

6
Strain amplitude for N > 2*10 cycles

Fatigue endurance Surface

effected by anomalous Classification machined as cast

structure and other R= -1 R= 0 R= -1 R= 0

types og defects *)
DI without defects 1.00 1.00 1.00 1.00

Dross 0.54 0.46 0.50 0.43

Cut through CC1

0.73 0.65 - -
shrinkage
Cut through CC5
0.50 0.42 - -
shrinkage

Chunky graphite 0.75 0.65 - -

*) Structure with
0.83 0.72 0.85 0.72
anomalies
Fraunhofer Nr FB-214(1998)
pmr_05
Physics
of
fatigue
 Crack initiation at grain boundaries
n The diagram shows how
the shear stresses result in
local plastic deformation
along slip planes.
n As the loading is cycled
sinusoidally, the slip planes
move back and forth like a
pack of cards, resulting in
small extrusions and
intrusions on the crystal
surface.
n These surface disturbances
are approximately 1 to 10
microns in height and
constitute embryonic
cracks.
 Stress intensity factor

n Crack showing stress

concentration at the
tip.

( K=Q )
Q = size and material
konstant
n Crack path
propagation in ferritic
dutile iron under
tensile stress.

n Occurance of voids

n Deformation of
nodules
Fatiuge crack growth showing 3 stages

I II III
Log crack
growth rate Unstable crack growth

[da/dN]
Crack propagation

Crack formation

Log stress intensity

 Crack growth Paris law

n Paris equation:
m
da/dN = C*K
where:
da/dN = crack rate increment
C and m = material constants
K = stress intensity range
84
 Growth rates of cracks

Fatigue crack
growth rates
for
GJS-400-18U,
compared with
steel
 Iron-carbon phase diagram

DI

Eutecktic
composition
is the choice
Carbon equivalent

The formula:

CE = C + 1/4 Si +1/2 P

87
Carbon equivalent

n A value of CE=4.3 is chosen.

n Yielding an eutectic composition.
n Favour optimum fluidity.
n Produce highest expansion of graphite.
n Resulting in a most sound casting.

88
 Carbon and silicon influence

n Typical carbon and

silicon ranges for
ductile iron as limited
by processing factors.
*)
Target

* H. Hendersen

89
 Carbon and silicon influense on
the mechanical properties

n The effect on the nodule count of ductile iron.

n The effect on the pearlitic hardenability of ductile iron.
(the formation of ferrite and/or pearlite in the as-cast,
annealed or normalized condition.)
n The effect of these elements of ferrite present in the
matrix structure.

n The effect on the formation of martensite and/or bainite

during quench and temper heat treatments

90
 Element influence on solidification

Effect on the stable

and metastable
solidification mode of
ductile iron.

91
Siliciumeinflu auf die Festigkeit

92
Influence of silicon on charpy-V

93
Charpy V as function of carbon

94
Effect of matrix on impact properties

95
Nodularity and charpy V

96
Nodule number and Charpy V

97
 Influence of
Mg and Pb on
nodularity

98
 Effect of nikkel
Tensile strenght in "as cast" ferritic DI as function of nikkel content
450
Rm = 71.65Ni + 356.38
Sampling type: D2 EN1563
R2 = 0.7789
400

350 Re
Rm
Rm [MPa]
Liner (Re)
300 Liner (Rm)

250
Re = 72.506Ni + 231.44
R2 = 0.7705
200
0 0.1 0.2 0.3 0.4 0.5 0.6
pmr_06
Ni [%]

99
 Pearlite promoting elements

Formula for I-factor

I = 4.9 Cu + 0.37 (Ni+Cr) + 7.9 Mo + 4.4 Ti + 39 Sn + 0.44 Mn + 5.6 P

pmr 11_06

100
 Subversive elements
Influence of subversive elements are expressed
in the formula below:

Sb= 4.4Ti + 2.0As + 2.3Sn + 5.0Sb + 290Pb + 370Bi + 1.6Al

The trace number Sb should be <1

101
Cleanliness of the melt

n Fatigue strength is reduced by the

presence of inclucions, dross, and other
non-metallic surface defects which act
as crack initiation sites.

102
 Influence of
non-metallic
inclusions on
rotory bending
fatigue.

103
Effect of inclusions on fatigue

104
 J-integral in ferritic DI

J-integral as a
function of proof
stress (Rp0.2),
elongation(A5d and
mean distance ()
between graphite
particles.
Ferritic ductile iron

Metallographic
structure in a 2MW
Hub
(cast on sample, D)

Nodules size 4-7 in ferrite

nital 100x
 Classification of graphite based on size.

What is the size ASTM 247-67

Size Max. dimension
class [mm] x100
of a graphite 128
1
nodule? 64
2

3 32

4 16

5 8

6 4

7 2

8 1
Bulls eye structure

n Graphite nodules in
ferrite and mainly
pearlitic matrix.

Nital 200X
108
 Segregation defect

n Graphite flotation

109
 Effect of low magnesium level

n Inproper treatment with

MgFeSi resulting in
reduced content of Mg.

n Consequently graphite
nodule structure suffers
and yields only ca. 30%.

110
 Subvercieve elements

n Spiky graphite
caused by
lead (Pb)
contamination

300X

111
 Intermetalic carbides

n Carbides formed
by segregated
Mo, V, Cr, Mn
and other minor
elements.

112
 Volumetric defects

n Porosity due to
shrinkage.

113
Shrinkage defect CC 2 (ASTM)

114
 Volumetric defects

n Porosity caused
by gas.

115
 Darkened surface

n Darkened area on
large ductile iron
component, 200 mm
wide.

n The darkening was

below the riser.

Ref: Bouse et al.

116
 Futher excample of darkened surface

n Extreme excample of
darkened surface on
a ductile iron casting
showing cellular
structure.

n The groove goes into

the core center of
the casting wall.

Ref: Bouse at al
117
 Chunky graphite

Structure showing
extensive volume
of chunky graphite

118
 Kodak GrayScale

A tool for the determination of anomalous

structure?

119
 Dross inclusions
ariseing from
inadequate running
and filling systems.
 Surface structure degeneration

n Surface structure
anomalous from
sulfur-containing
moulding sand.

n Are you buying

grey iron instead
of ductile??

121
 Sulphur contamination of
the gating system
n Pouring big volumes
1.6 % S
n High metal velocity

n Extended pouring 2.0 % S

time ()3m

n Incomplete filling
2.2 % S
n Sulphur potential in
moulding sand
Pmr_05

122
 Sulphur content in downsprue

Charge 22201-158 pos. 3

085097
1.5

%S

y = 0.5141x -1.2127
R2 = 0.8815

0.5 Sprue center

0
0 5 10 15 20 25 30 35 40 45

Position [mm]

123
 Thermal analysis

Extraction of values
from the cooling curve
give rise for carbon
equvialent (CE) to be
calculated.
This is by far the most
precise method for the
determination of
carbon.

124
 Accurate carbon
determination
n Use of thermal analyses

n Apply data from white solidification mode

n Combine with results from OES* instrument

n Calibrate against volumetric method

*) Optical Emission Spectrometer Pmr_05

125
Some math
Temperature liquidus:
Tl = f (C,Si,P)
which is the most recognised equation for the determination
of temperature liquidus (Tl), in carbon rich iron alloys

and transformed..
CTl = 13.459 - 0.008065Tl - 0.22Si - 0.54P

Pmr_05

126
 Jet type filling mode

J. Campbell

127
Surface entrainment event

Gas phase

Liquid DI
alloy
Dobble film
J. Campbell
128
 Oxide flow tube defect from a fall

Dobble film
entrainment
caused by fall

J. Campbell

129
 Advancing front.
Film trapped and
held against mould
wall by friction.

Film entrainment
from retreating
front.
J. Campbell
Profile of melts of
aluminium and
cast iron
emerging from
ingate at various
speeds.

Runyoro et al 1992
 Reliabilities and ingate speeds

J. Campbell
 Exfoliated dross

n Dross defect cope

produced by
copious gas from
core blow prior to Core blow
liquid
any solidification

core

J. Campbell

133
 Rising bubbles

(a) Schematic
illustration of
rising bubbles and
associated trails.

(b) Cross-section
illustrating the
progressive
collapse of the
bubble trail. (a) (b)
J. Campbell
134
 Datums

A datum is simply a plane

defining the zero from
which all dimensions are
measured.
In (a) a badly dimensioned
sump, resulting in a casting
that can only be produced
with difficulty.
 Datums

In (b) the casting

dimensioning is
datumed on the
most critical
casting feature,
leading to an easy
and effective
manufacturing.

136
Location/tooling points

137
 Tooling points
n Whereas the casting datums are invsible planes,
defining the consept of a zero in the dimensional space
in and around the casting, the tooling points are real bits
on the casting. The datums are the software, whereas
the the tooling points are the hardware of the
dimesioning system.
n For the greatest accuracy, all six points are moulded in
one mould half, usually the drag. For castings whose
critical features are all internal, all six tooling point are
to be moulded in the internal core. The separation of
points between mould halves, or having some defined
from the mould and some from cores, will compromise
accuracy.
138
 Tooling points

n Infact, the six points are used in a 3,2,1

arrangement. Basicly point 1, 2 and 3 locate plane A;
point 4 and 5 define plane B; and point 6 defines
plane C.

n Clearely, to maximize accuracy, point 1, 2 and 3 need

to define a widely based triangle, and point 4 and 5
similary need to be as widely spaced as possible.

139
 Solidification
n

t= solidification time
B= mould constant
V= casting volume
A= cooling surface
n= 2
1940

140
 Casting modulus

The term in Chvorinovs formula is the fundation

for all calculations done regarding the rating of feeders
and directional solidification in casting metod design.

is denoted casting modulus

141
Exercise

1) What is the modulus for a cube (casting)

with length = a ?

2) What is the modulus for a infinite plate with

thickness = t ?

142
 Draft

Not possible Possible Good

143
Draft angle

144
a) Simple cake core and
drag assembly

b) Cope and drag with side

cores, all located in the
drag.

c) An apparently lower-cost
alternative to b), but
resulting in possible loss
of dimensional control
 Heat extraction from mould
An improved
design of square
or rectangular
corners would
involve rounding
off corners to
promote more
equal heat
extraction through
the mould wall.
146
 Design for soundness
n Design so that all Riser
members of the parts
increase in dimension
progressively to more
suitable locations Shrink
where feeder heads defect

can be placed to offset

liquid shrinkage. INCORRECT
Heavy section
CORRECT

cannot be fed

147
Design for soundness

148
 Avoid hot spots

Avoid stress
concentration
and hotspot

Incorrect Correct

149
Internal hot spot corner

Avoid internal hot spot corner resulting in poor

cooling rate and release of core gases.

150
V and Y-formed sections
In case of V or Y sections and other angular
forms, always design so as to allow a generous
radius to avoid localization of heat

Hot
spot

POOR IMPROVED

151
 Arm and leg influence in a T-junction

50
Slope 2 Slope 1

40

30 "Hot spot"
T/mm Avoid this area

20

Slope 1/2
10

0
0 10 20 30 40 50
t/mm

152
 A cross joinment

To reduce
solidification
time for the
design in fig.A,
fig.E version
has to be
chosen.

153
Fillet radius

Apply a minimum
fillet radius of at
least 25mm.
Generally adopt fillet
radius equel to wall
thickness T.

154
 Dobbel leg design
n In design a) the
distance A ought
to be 8-10 times A to
solve solidification
problems.

nA better solution
would be the design
under b).

155
 Design advice
Bad design Good design
 Design advice
Bad design Good design
 Design advice
Bad design Good design
Design like nature grows
Design like nature grows
Design like nature grows
SKO und CAO!! Sprechen Sie deutsch?
 SKO and CAO approach

SKO = Slow kill option

CAO = Computer aided optimalisation

163
 Design advice

Obtain uniformety
in section wall
thickness.

164
 Design guidelines
n Consult Foundryman - communicate requirements,
service functions and where it fits into total assembly.
n Design sections as uniform in thickness as possible.
Avoid abrupt section changes. Make transitions
gradual, blending heavier sections into light once.
n Design so that all members of the parts increase
progressivly in thickness to convenient locations where
risers can be placed.
n Reduce bosses, lugs and pads and other projections to
a minimum.
165
Design guidelines
n Bring the minimum number of sections together.
Three is inviting trouble; four is bad. Shrink and
porosity troubles most often occur at member
junctions. Stagger if possible.
n Avoid multiple cores.
n In designing adjoining sections, replace corners with
radii, and avoid heat and stress concentration.
n Apply datums at a casting feature.

n Introduce a 6-point location/tooling system.

166
l Casting design
basic rules. (ZGV)
End of lesson

Thanks for listening.

168