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2012
Solidification Processes
Starting work material is either a liquid or is in a highly plastic condition, and a part is created through solidification of the material Solidification processes can be classified according to engineering material processed: Metals Ceramics, specifically glasses Polymers and polymer matrix composites (PMCs)
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Casting Process
Process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity. Once the mold and cavity inside the mold is prepared, the metal is melted, poured into the mold and let solified (freezed) inside the mold.
The term casting also applies to the part made in the process.
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Takes shrinkage into account Single-use or permanent mold Provides molten material at the proper temperature Molten metal is poured into the mold at a proper rate to ensure that erosion and or defects are minimized
2. Melting process
5. Casting removal
The casting is removed from the mold
Single-use molds are broken away from the casting Permanent molds must be designed so that removal of the casting does not damage the mold and itself. How? Mold should be opened during the removal of the casting and closed during the filling of the cavity with the molten metal.
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Disadvantages of Casting
Different disadvantages for different casting processes: Limitations on mechanical properties Poor dimensional accuracy and surface finish for some processes; e.g., sand casting Safety hazards to workers due to hot molten metals Environmental problems
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Casting Terminology
Pattern- approximate duplicate of the part to be cast Molding material- material that is packed around the pattern to provide the mold cavity Flask- rigid frame that holds the molding aggregate Cope- top half of the mold Drag- bottom half of the mold Core- sand or metal shape that is inserted into the mold to create internal features
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Casting Terminology
Mold cavity- combination of the mold material and cores Riser-additional void in the mold that provides additional metal to compensate for shrinkage Gating system- network of channels that delivers the molten metal to the mold Pouring cup- portion of the gating system that controls the delivery of the metal Sprue- vertical portion of the gating system Runners- horizontal channels Gates- controlled entrances
Gating System
Typical gating system for a horizontal parting plane mold, showing key components involved in controlling the flow of metal into the mold cavity.
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Casting Terminology
Parting line- separates the cope and drag Draft- angle or taper on a pattern that allows for easy removal of the pattern from the mold Casting- describes both the process and the product when molten metal is poured and solidified
Cross section of a typical two-part sand mold, indicating various mold components and terminology.
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(a) open mold, simply a container in the shape of the desired part; (b) closed mold, in which the mold geometry is more complex and requires a gating system (passageway) leading into the cavity.
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WHAT HAPPENS WHEN THE MOLTEN METAL IS POURED INTO THE MOLD?
The molten metal goes through the passageway into the mold cavit. It is also known as the gating system (yolluk sistemi). The passageway is usually made up of a pouring cup (basin) (dkme az) which is used to minimize splash and turbulence as the metal flows into a vertical passage known as a downsprue (dikey yolluk) through which metal enters a runner leading to the main cavity, and a gate (yatay yolluk) through which the metal flows from the sprue base to the mold cavity. In large castings a runner may be used which takes the metal from the sprue base and distributes it to several gate passageways around the cavity.
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Directional Solidification
To minimize damaging effects of shrinkage, it is desirable for regions of the casting most distant from the liquid metal supply to freeze first and for solidification to progress from these remote regions toward the riser(s) Thus, molten metal is continually available from risers to prevent shrinkage voids The term directional solidification describes this aspect of freezing and methods by which it is controlled
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Schematic of a sand casting mold, showing a) an open-type top riser and b) a blind-type side riser. The side riser is a live riser, receiving the last hot metal to enter the mold. The top riser is a dead riser, receiving metal that has flowed through the mold cavity.
Riser is a reservoir in the mold which is a source of liquid metal to compensate for shrinkage of the part during solidification The riser must be designed to freeze after the main casting in order to satisfy its function. Riser must be separated from the casting upon completion so the connection area must be as small as possible.
Riser Design
Riser is waste metal that is separated from the casting after solidifacation and remelted to make more castings To minimize waste in the unit operation, it is desirable for the volume of metal in the riser to be a minimum Since the geometry of the riser is normally selected to maximize the V/A ratio, this allows riser volume to be reduced to the minimum possible value
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Oppositely, exothermic chemical compounds may be packed next to a part of the casting so that heat is retained in that area slowing down the solidification .
External Chills
(a) External chill to encourage rapid freezing of the molten metal in a thin section of the casting; and (b) the likely result if the external chill were not used.
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Solidification of Metals
Transformation of molten metal back into solid state Solidification differs depending on whether the metal is A pure element or An alloy
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Characteristic grain structure in a casting of a pure metal, showing randomly oriented grains of small size near the mold wall, and large columnar grains oriented toward the center of the casting.
Solidification of Alloys
Most alloys freeze over a temperature range rather than at a single temperature
(a) Phase diagram for a copper-nickel alloy system and (b) associated cooling curve for a 50%Ni-50%Cu composition during casting.
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Solidification of Alloys
Characteristic grain structure in an alloy casting, showing segregation of alloying components in center of casting.
Solidification Time
Solidification takes time Total solidification time TTS = time required for casting to solidify after pouring TTS depends on size and shape of casting by relationship known as Chvorinov's Rule
V A where TST = total solidification time; V = volume of the casting; A = surface area of casting; n = exponent with typical value = 2; and Cm is mold constant. TST Cm
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Shrinkage of a cylindrical casting during solidification and cooling: (0) starting level of molten metal immediately after pouring; (1) reduction in level caused by liquid contraction during cooling (dimensional reductions are exaggerated for clarity).
(2) reduction in height and formation of shrinkage cavity caused by solidification shrinkage; (3) further reduction in height and diameter due to thermal contraction during cooling of solid metal (dimensional reductions are exaggerated for clarity). DO NOT FORGET THAT SHRINKAGE CAVITIES IN CASTINGS (SHOWN IN (3)) SHOULD BE PREVENTED BY USING DIRECTIONAL SOLIDIFICATION.
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Solidification Shrinkage
Occurs in nearly all metals because the solid phase has a higher density than the liquid phase Thus, solidification causes a reduction in volume per unit weight of metal Exception: cast iron with high C content Graphitization during final stages of freezing causes expansion that counteracts volumetric decrease associated with phase change
Shrinkage Allowance
Patternmakers account for solidification shrinkage and thermal contraction by making mold cavity oversized Amount by which mold is made larger relative to final casting size is called pattern
shrinkage
allowance
Casting dimensions are expressed linearly, so allowances are applied accordingly
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