UNIT II CASTING

METALLURGY

Solidification
In a casting process, the material is first

heated to completely melt and then poured

into a cavity of the mould.
As soon as the molten metal is in the mould, it
begins to cool.
When the temperature drops below the
freezing point (melting point) of the material,
solidification starts.
Solidification involves a change of phase of
the material and differs depending on whether
the material is a pure element or an alloy.

pure metal solidifies at a constant

temperature, which is its melting point
(freezing point).
For alloys, the solidification occurs over a
temperature range depending upon the
composition.
As temperature drops, solidification begins at
a temperature indicated by liquidus and is
completed when the solidus is reached.

Nucleation and Growth of

Crystals
At the solidification temperature, atoms from the

liquid, such as molten metal, begin to bond

together and start to form crystals.
The moment a crystal begins to grow is know as
nucleus and the point where it occurs is the
nucleation point.
When a metal begins to solidify, multiple crystals
begin to grow in the liquid.
The final sizes of the individual crystals depend on
the number of nucleation points.
The crystals increase in size by the progressive
addition of atoms and grow until they impinge
upon adjacent growing crystal.

a)Nucleation of crystals, b) crystal growth, c)

irregular grains form as crystals grow
together, d) grain boundaries as seen in a
microscope.

Nucleation and Growth

Transformation
Nucleation

The physical process by

which a new phase is produced in a
material. In the case of solidification, this
refers to the formation of tiny stable solid
particles in the liquid.

Growth - The physical process by which a

new phase increases in size. In the case of

solidification, this refers to the formation of
a stable solid particle as the liquid freezes.

The Nucleation and Growth Transformation

may be of two types
1. Homogeneous Nucleation
2. Heterogeneous Nucleation

Homogeneous Nucleation
Homogeneous Nucleation Formation of

a critically sized solid from the liquid by

clustering together of a large number of
atoms at a high undercooling (without
an external interface).
heterogeneous nucleation occurs in
a liquid on the surface of its container,
insoluble impurities and other structural
materials that lower the critical free
energy required to form a stable nucleus

Mostmetalsandalloysshrinkas

the
material
changes from a liquid state to a solid state.
Therefore, if liquid material is not available to
compensate for this shrinkage ashrinkage
defectforms. When progressive solidification
dominates over directional solidification a
shrinkage defect will form.
progressive
solidification, the cooling and
solidifying process begins at the walls of the
casting and works its way inward. With directional
solidification, the process of solidification begins
at the bottom of the casting and works its way to
the top.

Degasification

Degasificationis the removal of dissolvedgases

frommolten metal.
If they can not escape they may form vacancies in the
material, causing porosity in the metal casting.
Prevention Of Gas Defects When Manufacturing A
Part By Casting
Gases being expelled by the material during solidification
can be eliminated by a proper venting system in the mold.
This can be planned out during the manufacturing design
phase of the metal casting process.
Removal of slag will help eliminate gases and other
impurities in the casting.
Gases may be removed by flushing a metal melt with inert
gas.
Elimination of gases may also be accomplished by pouring
the metal casting in a vacuum.

Castability
Castabilityis the ease of forming acasting.
Castability (Fluidity) is the ability of the molten metal to

flow easily without premature solidification is a major

factor in determining the proper filling of the mould
cavity.
The higher the castability of a molten metal, the easier it

is for that molten metal to fill thin grooves in the mold

and exactly reproduce shape of mold cavity, there by
successfully producing the castings with thinner sections.
Poor

castability leads to casting defects such as

incomplete filling or misruns especially in thinner sections
of a casting.

Castability is dependent mainly upon the

viscosity of molten metal, it is clear that higher

temperature improves castability of molten
metal and alloys.
A very castable part design is easily developed,

incurs minimal tooling costs, requires minimal

energy, and has few rejections.
castability is the capability of molten metal to
fill mould cavities.
This consists of two basic factors.
1. Characteristic of molten metal
2. Casting properties

1. Characteristic of molten metal

a) Viscosity:)As the viscosity increases the fluidity decreases
since the resistance to flow for the molten metal
increases and the molten metal cannot pass
through the mould cavity successfully.
b) Surface Tension:)High surface tension of the liquid metal reduces
the castability. Some times oxide films
developed on the surface of the molten metal
have adverse effects on the castability since
they also increases surface tension.

c) Freezing zone:Freezing zone is the range of temperature where

solidification of molten metal starts and
temperature where it ends. Castability is
inversely proportional to the freezing zone.
Pure metals and eutectics have shorter freezing
zones and high
castability.
Solid-solution alloys have long freezing zones
and castability is low.
2. Casting properties:
a) Mold Design:Design and dimensions of the components such
as sprue, runners and risers influence the
castability.

b) Degree of Superheat:Superheating
is
the
improvement
of
temperature above the melt point of the alloy.
Superheat improves the fluidity by delaying
solidification.
c) Mould material and its surface
characters:Mould material should have low thermal
conductivity and fine surface. Higher the
thermal conductivity of mould and rougher the
surface the lower will be the castability.
Example: Dry sand mould has high castability
than green sand mould.

d) Rate of pouring:Slower rate of pouring lower the castability

because of high rate of cooling.
e)Heat Transfer:- It directly affects the
viscosity of liquid metal.
f) Pouring temperature of moulds are to be
a little above the melting temperatures of alloys
along with a sufficient superheat to account for
cooling of molten metal from time it is tapped
from furnace till it is poured into mould.

The three major factors that influence

castability are explained in detailed as follows:

1. Material Selection.
2. Geometry Planning.
3. Quality.
1.Material Selection:
)The metals used for casting are characterized
by their following casting properties:
A. Solidification capacity.
B. Slag formation.
C. Pouring temperature.

2.Geometry Planning:
Designing the geometry of the product is quite
cost effective & it depends upon the
complexity of the process. It also depends on
the tools used.
3. Quality:
Quality of the casting product means free of

defect or less defect. The casted product

should have a desired surface quality, a proper
dimension and internal reliability. Radiography
and pressure testing are some of the methods
by which the quality of a casted product can be
tested.

Castability of different metals:

Ferrous casting alloys:

Grey cast iron:- It is the most fluid of all

ferrous alloys and it has the high castability of

all other ferrous metals.
Cast steels:- Because of high temperature

required to melt cast steels up to about

16500c (30000 ) are difficult to cast. Selection
of molding material is a different task.
Stainless steels:- these have long freezing

Non-ferrous castings alloys:-

Alluminium based alloys:- castability

depends on oxides & alloying elemnets in the

metal. These have good thermal conductivity.
Magnesium-based alloys:-same as the

alluminium alloys.
Zinc-based alloys:- These have good

castability & commonly used in die casting.