Explain the two major governing factors of nucleation of super cooled grains.

(1) Free energy available from the solidification process

(2) The energy required to form a liquid solid interface

Explain the effect of inoculation in casting with example.

Modification (development of nodular type graphite structure) of the structure and properties by
the addition of small amount of another metal to the alloy before pouring.

Eg: Addition of sodium to Al -12%, Si alloys. In this case the addition acts to delay and alter
precipitation of the solid from the liquid.

List the controlling factors of the size and characteristic of the grains in solidification. Mesion the
major points to be considered when a casting solidifies.

(1) Composition of the alloy

(2) Cooling rate

What is the purpose of splash core placed in the bottom of the poring basin

To prevent erosion of the gating system when a large of metal to be poured.

Explain the cane developed equation for steel which expresses the relative freezing time of riser and
casting in terms of the relative volume of the riser and casting.

Casting developing equation.

X ={ 0.10 / (y -0.03)} + 1, Where x = relating freezing time or freezing ratio., y = riser volume / casting
volume.

Volume ratio = (volume of riser as poured / volume of casting)

Freezing ratio = {(surface area of casting / volume of casting) / (Surface area of rising / Volume of
riser)}
Write short notes on padding

Padding is the excess metal added to the casting to develop temperature gradients for directional
solidification. Padding applied to patterns is one of the foundry man’s mean’s (method) of
compacting centreline shrinkage and of promoting directional solidification. Padding on patterns
may be removed by machining it before casting is accepted.

MODULE 4

Assignment

1. How underwater welding is performed.

2. List the equipments needed in foundry also sketch the layout of a mechanised foundry for
medium size.
3. What sand reclamation. How is pollution controlled in foundry achieved?
4. What are the new development in the following areas: Materials, Processes and inspection
method in metal casting.
5. Write notes on computer application in metal casting
6. Write notes on Automation of welding in aerospace and surface transport vehicle.