Application of Concept of Modulus in Non-Ferrous Foundries

G. M. Rajendra Prasad A/14, K. H. B. Colony Puttenahalli, Bengaluru - 560 064 Email : gmrpsbc@gmail.com

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1. Modulus = Volume / Surface Area

Volume indirectly indicates the amount of heat present in the molten metal, and Surface Area refers to the area through which that heat can be removed for solidificaion to take place. On page 149 of the book Directional Solidification of Steel Castings by Wlodawer, you find the following equation for solidification time of a steel casting poured in a green sand mould : Solidification Time = 2.1 (Modulus)2

If one calculates geometrically, he would get solidification time of 5.8 minutes. This difference (between 5.0 and 5.8 minutes in solidification time) is because of radiation heat loss at 1640 C (pouring temperature of steel). The top surface is no longer merely the geometrical area, but something more than that. This is called Apparent Surface Area (ASA). This ASA can be increased (by chilling in the casting), or decreased (by insulating the feeders). This alters the modulus, and it is called Modulus Extention Factor (MEF). To produce a sound casting we need to know: (i) % of shrinkage to be fed by the Feeder, (ii) % of contraction required for Pattern making, (iii) Size of Feeder, and (iv) Number of Feeders required.

where, solidification time is in minutes, and casting modulus is in centimeters. In case of 100 mm dia x 100 mm height casting (Fig. 1), poured in a sand mould, total cooling surface area can be divided into 3 groups : (i) Surface Area in contact with sand mould at the bottom (heat loss by conduction), (ii) Surface Area in contact with sand mould on the side (heat loss by conduction + heat loss by convection), (iii) Surface Area in contact with atmosphere at the top (heat loss by radiation). For molten steel, with no cover on top, one gets solidification time of 5.0 minutes (Fig. 1). (a)
Sand Mould

2. Shrinkages
V L-L = Loss of super heat in molten metal for solidification to begin. V L-S = Loss of latent heat during solidification. V S-S = Contraction in solid state from solidification point to room temperature.

(b)
Top Insulation

(c)
Insulation Sleeve Insulation Sleeve

(d)
Top Insulation

100 mm dia x 100 mm H

100 mm dia x 100 mm H

100 mm dia x 100 mm H

Molten Metal under solidification

Molten Metal under solidification

Molten Metal under solidification

Metal Steel Copper Aluminium 5.0 minutes 8.2 minutes 12.3 minutes

Solidification Time (in minutes) 13.4 minutes 14.0 minutes 14.3 minutes 7.5 minutes 15.1 minutes 31.1 minutes 43.0 minutes 45.0 minutes 45.6 minutes

Fig. 1 : Solidification Time for Various Metals (under different insulation conditions)

FOUNDRY

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100 mm dia x 100 mm H

Molten Metal under solidification

Feeder Plate Casting

Feeder Plate Casting

Feeder

Centerline Shrinkage

Feeder

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End Effect

Feeder Effect

End Effect

Feeder Effect

Fig. 2 : Unsound Casting (left), and Sound Casting (right)

Metal Steel Copper Aluminium

V L-L + V L-S 6% 6.7% 8.3%

V S-S 8% 5.7% 8%

Bar shape : In case of a Bar shape (1:1), Feeding Distance is lower, i.e. shorter (see Wlodawer).

4. Calculation of Feeder Modulus

In case of Steel casting : Mfeeder = 1.2 Mcasting This helps to calculate the feeder size. Similar equation for Copper and Aluminium will have to be established. Now you know the following to get a sound casting : (i) Size of Feeder(s) (ii) Number of Feeder(s) (iii) Contraction Allowance on Pattern As regards to MEF, one can get it from figures.

V S-S is 8% in Steel on volumetric basis. On linear scale, it becomes 2%. This indicates the contraction allowance to be provided while making the Pattern.

3. Feeding Distance (or Feeding Range)

Feeding Distance is directly proportional to the density of the alloy and its specific heat, and inversly proportional to the thermal conductivity of the solidifying alloy.
Feeding Distance = X (Alloy Density x Specific Heat) Alloy Thermal Conductivity

where, X depends on the metal/alloy of the casting. As X increases, feeding distance increases (but the actual data for different metals is not available). To evaluate its value in case of copper / aluminium, one has to pour a plate in copper or in aluminium, to ascertain the value of X, and to examine shrinkage-free length by radiographic testing (Fig. 2). In case of plate shape Steel Casting (width : thickness in the ratio of 5:1), Feeding Distance is 4.5 T For Stainless Steel Feeding Distance is almost 12 T where, T indicates the thickness of the plate shape. Total Feeding Distance is the sum of End Effect + Feeder Effect. In plain carbon steel casting, total feeding distance of 4.5 T consists of 2.5 T (end effect) + 2.0 T (feeder effect). Feeding Distance for Different Alloys (plate shape) Cast Alloy Steel (plate shape) Aluminium (plate shape) Copper (plate shape) FOUNDRY Feeding Distance 4.5 T 11 T 8T

Wlodawers Directional Solidification of Steel Castings has a wealth of information for Steel Castings. * But no such book is available for copper or aluminium alloys. It will have to be established for these alloys, so that sound copper/aluminium castings can also be made without trials. (As of now, it is not possible, as no data is available.) For S. G. Iron foundrymen, the books on Gating & Feeding can be obtained from <www.sorelmetal.com>. (This is because gating & feeding of steel castings is different from that of S. G. Iron.)

Reference
1. Wlodawer Directional Solidification of Steel Castings. 2. Beeley, Foundry Technology 3. Feeding Range, Cast Metals Research Journal (AFS), June 1975, Volume 11, No. 2
* This book is out of print now. Interested readers may please contact G. M. Rajendra Prasad (the author) by email <gmrpsbc@gmail.com> or by Mobile : 094805 04635.

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