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Casting Processes A. Why are Castings used? 1. Complications of Shape-can form complex internal cavities 2. Product Si e !very small to very large ". #esulting Properties ! generally nondirectional $. Alloy Properties-can use alloys %hich may &e other%ise processed such as cast iron or refractory metals 'conomics ! generally lo% cost (. Classification System &y 1)*ype of +old 2)*ype of Production or Pattern C. *ypes of Sand used in ,oundries 1) Silica Sand-Si.2) -has free silica/ dust is carcinogen) 2) .livine Sand-+g. Si.2) ") Chromite Sand-Cr2." ,e2." Al2.") $) 0ircon-0r.2 Si.2)
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1. *heoretical Aspects 1. 2ucleation *heory ! 3omogeneous 4 3etergeneous 2. 5rain Si e ! '6uiaxed and Columnar ". Chvorinov7s Solidification #ule t 8 9+2 '. Casting 1esign Concerns 1. +etal ,luidity ! a&ility of metal to fill mold: reciprocal of viscosity-high fluidity fills mold easily is similar to lo% viscosity) +a;or factors are<a) superheat-phase diagram) &) single point free ing 2. 5ating 1esign a) Sprue<#unner<=ngate Area &) Cho>e ?elocity Control

". #iser 1esign a) #iser Si e &) #iser ,eeding 1istance $. 'conomics/ @ield/ 4 Scrap
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5ating 1esign-5et the metal into the mold as fast as possi&le %ithout excess superheat or tur&ulent flo%. *ur&ulent flo% can cause slagAdrossAinclusions in the metal from mold erosion and gas porosity.) 1. 5ating #atio +ethod *otal *otal *otal Sprue Area < #unner Area < 5ate Area $<2<1 8 pressuri ed system ?S B ?5 1<2<$ 8 non-pressuri ed ?S C ?5 DDD ?cho>e 8 2gh ?elocity Eimit-Camp&ell) -F inAsec ! heavy metals) -2G inAsec ! light metals)

2.

". #eynolds 2um&er #H 8 ?1e6 A -dynamic viscosity) '6uivalent 1iameter 8 $AAP $. ,lo% #ate I I 8 A1?1 8 A2?2 8 A"?" 8 ?olAt
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#iser 1esign 1) 1esign #e6uirements A.J 3eat *ransfer-solidification) *#C*C (.J ,eed +etal #e6uirements ?,C Shrin>age C.J ,eed Path #e6uirements 1. Kunction #e6uirements '. ,lo% Pressure #e6uirement! feed dendrites ,. Pressure #e6uirement - prevent &u&&les 2) Solidification *ime #e6uirement *# C *C implies +# C +C + 8 modulus 8 volumeAcooling surface area ,or cylindrical risers/ 1 8 F +c and 381 for side risers 381A2 for top risers

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") ,eed +etal Capacity ?feed 8 - - A2) ?riser 8 feed metal from riser 8 feed metal capacity-1F-FLM) 8 solidification shrin>age-2-1GM) Casting feed metal re6uirements 8 ?C Therefore ?riser 8 N A- - A2)O J?C ?riser 8 123A$ Solve for 1 Qse the maximum diameter from the solidification and feed metal calculations $. ,eeding 1istance-distance metal %ill flo% &efore free ing) Plates 1) +aximum 1istance E1-mm) 8 R2+1A2 ! 1$G 2) (et%een 1istance
5

8 1"A$-side riser) 8 1"AP-top riser)

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E2-mm) 8 $*-section thic>ness) L) Centerline ,eeding #esistance C,# 8 ,ree ing-solidification) time at centerline *otal free ing-solidification) time 3igh C,# implies a S+ushy AlloyT and poor solidification

Centerline ------------------------------------------1istance Start Surface 'nd DDDDDDDDDDDDDDDDDDDDDDDDDDDDDD

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+ass (alances ! +aterial (alances +etal Poured 8 Casting U #eturns-gates 4 risers) U +elt Eoss U -*WP) Casting Scrap U ,inishing Scrap @ield-@) 8 NCasting WeightO A NCastingU5atesU#iser8+old Wt) +elt Eoss-+E) 8 Eoss due to slag/ dross/ dust/ etc. Casting Scrap-CS#) 8 Castings #e;ected &y Casting 1efects ,inishing Scrap-,S#) 8 Castings #e;ected-.ther ,inishing .pr. #eturn Weight 8 Weight of #unners 4 5ates #eturned for *WP 8 CW J -1A@) J N1A -1-+E)O J N1A -1-CS#)O J N1A-1-,S#)O #W 8 CW J N-1-@)A@O J N1A-1-CS#)O J N1A-1-,S#)O +EW 8 CW J N+EA-1-+E)O J N1A@O J N1A-1-CS#)O J N1A-1-,S#)O CSW 8 CW J NCS#A-1-CS#)O J N1A-1-,S#)O ,SW 8 CW J N,S#A-1-,S#)O

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=f one has a casting %eight of 21 l&s/ and the follo%ing parameters of 3ot +etal Cost-$ VAl&)/ #eturns 4 Scrap- 1VAl&) and 'nvironmental Costs-1L VAl&) and process parameters of< @ield 8 FLM-typically "G-PGM) +elt Eoss 8 "M-typically 2-1GM) Casting Scrap 8 1GM-typically 2-"GM) ,inishing Scrap 8 $M-typically G-1GM) *hus Casting Weight 8 21.GG l&s #eturns-5ates 4 #isers) 8 1".GW l&s +elt Eoss 8 1.1F l&s Casting Scrap 8 2.$" l&s ,inishing Scrap 8 G.PP l&s *otal Weight Poured 8 "P.LF l&s 3ot +etal Cost 8 "P.LF x $VAl& 8 V 1L$.2$ 'nvironmental Cost 8 1.1F x 1LVAl& 8 1R.$G Credits ! #eturns 1".GW x 1VAl& 8 - 1".GW Scrap-2.$" U G.PP) x 1VAl& 8 - "."1 *otal Cost 8 V 1LL.2$ -not $x218P$)
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Casting 1efects Classification of Casting 1efects-A,S Classification System) 1. +etallic Pro;ections ! fins/ flash/ etc. 2. Cavities ! shrin> holes/ gas holes/ etc. ". 1iscontinuities ! crac>s/ tears/ etc. $. Surface =rregularities ! seams/ &urn-on/ etc. L. +issing Portion of Casting ! misrun/ pour-out/ etc. F. =ncorrect 1imensionsAShape ! pattern errors/ incorrect shrin>age allo%ances R. =nclusions ! metallic inclusions-not fused/ from splash)/ slag in casting/ moldAcore materials from erosion

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*ype of +old Permanent +old *ype of Production Continuous Production 1iscrete Production Continuous Casting Permanent +old -5ravity Casting) Consuma&le +old *ype of Pattern Permanent Pattern Consuma&le Pattern (onded Sand Casting 5reen Sand Chemical (onding Sodium Silicate Shell-*hermoset) .rganic 2o-(a>es ,uran =socyanate ?acuum Casting -?-Process) -Qn&onded Sand) PlasterACeramic +old Centrifugal Casting -Sand +olds) =nvestment Casting

1ie Casting -3igh Pressure) #heocasting -Ei6uidUSolid) Eo% Pressure 1ie Casting -B1 atmosphere)

Styrofoam Casting -,ull +old) -'vaporative Casting) #apid Prototyping -Stereolithography)

Centrifugal Casting -+etal +olds ! Pipe Castings)

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