CENTRIFUGAL CASTING

Introduction Centrifugal casting or rotcasting is a casting technique that is typically used to cast thin-walled cylinders. It is noted for the high quality of the results attainable, particularly for precise control of their metallurgy and crystal structure. Unlike most other casting techniques, centrifugal casting is chiefly used to manufacture stock materials in standard sizes for further machining, rather than shaped parts tailored to a particular end-use. The essential feature of centrifugal casting is the introduction of molten metal into a mold which is rotated during solidification of the casting. The centrifugal force is relied upon for shaping and feeding the molten metal with the utmost of detail as the liquid metal is thrown by the force of gravity into the designed crevices and detail of the mold. The concept of centrifugal casting is by no means a modern process. This technique which lends clarity to detail was used by Benevento Cellini and others in the founding arts during the 16th century. The mention of actual centrifugal casting machines is first recorded when a British inventor, A.G. Eckhardt, was issued a patent in the year 1807. His method utilized the placing of the molds in an upright position on pivots or revolving bases (sometimes referred to today as a "vertical" centrifugal casting machine). In 1857 a U.S. patent described wheel molds which presumably were used for the centrifugal casting of railroad car wheels.

Process

1. Molten metal is poured into the spinning mold cavity and the metal is held against the wall of the mold by centrifugal force. 2. The speed of rotation and metal pouring rate vary with the alloy and size and shape being cast. 3. The inner shape will remain cylindrical because the molten metal is uniformly distributed by centrifugal forces. 4. In true centrifugal casting, without a central core, the metal solidifies from the outside toward the center (axis) of rotation in most cases considering the length to diameter ratio. 5. The true centrifugal casting is spun about its own axis, has no central core, and the cooling takes place from the periphery toward the central axis. 6. In true centrifugal casting, the important consideration is that the cooling takes place inonly one direction, from the outside toward the center of rotation. 7. Essentially cylindrical in shape which is produced without a center core and in which the direction of solidification is from the outside of the casting towards the axis of rotation.

In centrifuge casting manufacture, molds employed to produce the desired castings are arranged around a central sprue. These molds contain all the necessary geometry for the cast part, as well as the gating system. Runners travel from the central sprue to the mold entrances. During the pouring phase of centrifuge casting manufacture, molten material is introduced into the central sprue. The entire system is rotated about an axis with the central sprue at the center of rotation. When an object is rotated, forces are produced that act directly away from the center of the axis of rotation. It would be known from the previous discussions concerning the other two branches of centrifugal casting, that the utilization of the forces of centripetal acceleration which act to push material away from the center of rotation is the trademark characteristic of all the manufacturing processes of centrifugal casting. Centripetal force is not only utilized to distribute molten material through a mold, but to help control the material properties of a cast part. In centrifuge casting manufacture, the molten material to produce the casting is poured into the central sprue. Centripetal forces from the rotating apparatus push this material outward from the center, through the runners and into the molds. When the correct amount of molten metal to manufacture the casting is poured and distributed completely into the molds, the apparatus will continue to rotate as solidification is occurring. After the castings have completely solidified, the apparatus will stop rotating and the parts can be removed.

Centrifuge Casting Manufacture There are many specific advantages in the quality of parts manufactured by centrifuge casting. Since the metal is forced into the mold, the mold cavity usually fills completely and cast parts with thin walled sections are possible. Also, great surfaces can be produced by centrifugal casting, which is another characteristic of castings manufactured by a process that uses large amounts of force to fill a mold. One of the most notable features, specific to the centrifugal casting processes and discussed in the preceding sections, is the effect of centripetal forces acting continuously on the material as the casting solidifies. Molten material that solidified under greater force will be denser than the same material that solidified under less force. This can be observed in a round cylinder manufactured using the true centrifugal casting process.

During the solidification of this part the mold was rotating. The forces acting on the material farther from the center were greater than the forces that were acting on the material closer to the center. Consequently, it can be seen in the manufactured part that the density is greatest in the outer regions and decreases towards the center. Another specific effect that the centripetal forces used in centrifugal casting methods have on the material of a cast part is that impurities, such as inclusions and trapped air, tend to collect and solidify in the less dense material closer to the center of the axis of rotation.

Features of centrifugal casting

Castings can be made in almost any length, thickness and diameter. Different wall thicknesses can be produced from the same size mold. Eliminates the need for cores. Resistant to atmospheric corrosion, a typical situation with pipes. Mechanical properties of centrifugal castings are excellent. Only cylindrical shapes can be produced with this process. Size limits are up to 3 m (10 feet) diameter and 15 m (50 feet) length. Wall thickness range from 2.5 mm to 125 mm (0.1 - 5.0 in). Tolerance limit: on the OD can be 2.5 mm (0.1 in) on the ID can be 3.8 mm (0.15 in). Surface finish ranges from 2.5 mm to 12.5 mm (0.1 - 0.5 in) rms.

Application 1. Can produce to be hollow cylindrical parts, such as pipes, tubes, bushings, and rings. 2. Outside shape of casting can be round, octagonal, hexagonal, etc , but inside shape is(theoretically) perfectly round, due to radially symmetric forces.

Advantages 1. The mould surface can be shaped so that pipes with various outer shapes can be made. 2. The mechanical properties are nearly equal in all directions.

Disadvantages 1. 1.Since no gates and risers are used, the yield or ratio of casting weight-toweight of metal is high. 2. The speed of rotation and metal pouring rate vary with the alloy and size and shape being cast.

Applications Typical parts made by this process are pipes, boilers, pressure vessels (see autofrettage), flywheels, cylinder liners and other parts that are axi-symmetric. It is notably used to cast cylinder liners and sleeve valves for piston engines, parts which could not be reliably manufactured otherwise.

References 1) Thornton, British Foundryman, 51, 559, 1958. 2) Cumberland J, Centrifugal casting techniques, British Foundryman, 3) Jones M C, Investigation of Centrifugal casting techniques, Foundry trade journal, June, 1970. 4) Samuels M L, Schuh A.E, Some recent developments in centrifugal casting, Foundry, pg. 84, 1951.