Академический Документы
Профессиональный Документы
Культура Документы
Contents
Foundry furnaces.
Solidification fundamentals.
Casting design
Foundry Furnaces
Steel shell
Refractory bricks
Induction furnace
(copper)
Joule
Solidification Fundamentals
Pure Metal
Cooling curve
Pouring
Temperature
a
L
T
Melting
Point
Solidification
Nucleation and Growth
Grain boundary
Lattice mismatch
Full of defects
Small grains Y, UTS
Single crystal
creep strength
Turbine blades
Lattice:
Simple cubic
BCC
FCC
HCP
Nucleation
Formation of tiny stable solid particles from
liquid (200 atoms of ~ 10 nm dia.).
Surface energy required to create SLI
(solid-liquid interface).
Undercooling provides energy for creation
of SLI.
Larger the extent of undercooling, greater
will be the number of nuclei formed.
Homogeneous
Nuclei form on their own.
Occurs automatically in water below -36 C.
Greater undercooling.
Growth
Nuclei grow and then aggregate
Occurs as heat of fusion is extracted from
liquid
Direction and rate of growth can be
controlled by the manner of heat removal
Directional solidification
Movement of S/L interface opposite to the direction
of heat flow.
Higher strength in the direction of growth.
Directional solidification
molten metal
solid
Heat flow
Alloys
A
B
C
t
A = Pouring Temperature; B = Liquidus temperature (T L)
C = Solidus Temperature (TS)
BC = Both solid and liquid are present (Mushy zone)
Phase diagram
Cu Ni alloy
Metal Solidification
Alloy Solidification
L
S
L
Heat
Heat
~ m
L
S
L
Dendrite
Cast Structure
Chilled zone
Narrow band of fine, small, randomly
oriented crystals on mold/casting interface
Rapid nucleation because of fast initial
cooling rate. Crystals grow randomly
Columnar zone
Crystals tend to grow in all directions
Preferred growth direction is opposite to
the direction of heat flow
Crystals grow faster in the preferred
direction. Shut off crystal growth in other
directions.
Highly directional property
Equiaxed zone
Cooling rate decreases significantly
towards the centre
No preferred direction of growth
Leads to randomly oriented spherical
crystals
Inner zone of equiaxed grains can be
extended throughout the casting by
adding nucleating agents such as Na, Mg,
Bi
FFT
Equiaxed grains favourable in metal or
sand mold?
Is directional solidification desirable for
riser design for eliminating shrinkage
voids?
FFT
Compare structure and strength of similar
castings made in metal and sand molds
Compare structure and strength of similar
castings made in sand molds with varying
moisture content
See Fig. 11.20 in Kalpakjian
Shrinkage
Three principal stages
Shrinkage of the liquid (not a problem)
Solidification shrinkage (LS)
Solid metal contraction
Material
% in volume
Al
6.6
Cu
4.9
Low C steel
2.5 3.0
High C steel
4.0
-1.9
Fluidity, turbulence.
Tapered sprue, inclusions, ceramic pouring cups
Equalizing flow through gates?
Fluidity
Opposite of viscosity: with T.
Sprue Design
Cylindrical Vs. Tapered geometry
Cylindrical sprue: Vortex formation, sucks gas
Sprue well
Dissipates kinetic energy of falling stream
Directional Solidification
Solidification that occurs from farthest end of the casting
and works its way towards the sprue. Importance
Chorinovs rule
Chorinovs Rule
Predicts time for solidification of casting
V
t S B
A
n = 1.5 2.0
V = Casting volume ( total heat content)
A = Surface area of casting ( rate of heat
loss)
FFT
Devise an experiment to determine B, n for
a particular casting geometry or a series of
casting
Riser design
Riser material should solidify in the end
Size of riser
Riser placement
Shrinkage cavity
because of slow
cooling rate
Remedies
Vacuum degassing
Flushing with inert gas
Inclusions
Molten metal reacts with dissolved gases
such as oxygen to form fine particles (in
the m range)
If dissolved gas content is high, inclusions will
aggregate.
Float on top and form a dross or slag layer.
Should be skimmed off to prevent entrapment
in casting