2012:03

THANKS

Thank you for your business!!

 AGENDA

Fisher Controls TekSession Outline

April 4, 2012

1. Welcome and Introductions

2. MetalTek Overview
3. Metalworking Process Overview
4. Engineering of Cast Products
5. Material Selection

We would appreciate questions during the

presentation and at any break. We are here for you.
 AGENDA

Fisher Controls TekSession Outline

April 4, 2012

1. Welcome and Introductions

2. MetalTek Overview
3. Metalworking Process Overview
4. Engineering of Cast Products
5. Material Selection

We would appreciate questions during the

presentation and at any break. We are here for you.
AGENDA

Fisher Controls Introductions

Going around the room from Southeast to Northwest…we

know it’s early…
• Your name
• Department and role
• How metal products impact your job
• Have you been to a casting facility before – what kind
CORPORATE OVERVIEW

What We Do
• We work with manufacturers who use metal
castings, forgings, or fabrications that are
subjected to high temperature, corrosion, or wear
in their processes or in products that they make.

• We bring broad metallurgical expertise to help

customers analyze their needs to select alloys that
would perform best in their applications.

• We offer a range of casting capability that is not

available elsewhere, including Centrifugal, Sand,
and Investment casting, and help customers
choose the method of component manufacture that
delivers the performance that they need.

• Customers choose us because we provide delivery,

quality, certifications, and a commitment to
Customer Service Excellence at a price that
represents value to them.
CORPORATE OVERVIEW

Mission Statement
• MetalTek International, Inc. is a customer
service driven corporation supplying
superior quality engineered metal products for
corrosion, heat, or wear resistant applications.

• As a technological leader, we offer solutions to

challenges which provide additional
outstanding value as defined by our customers
throughout the world.

• We will meet or exceed stakeholders’

expectations through continuous
improvement.
PLANT LOCATIONS

Glenrothes, Scotland

Waukesha, WI Stoke on Trent, UK

Watertown, WI

Sandusky, OH
Pevely, MO
Rock Hill, SC
Chattanooga, TN
SALES

All MetalTek Sales By Market - 2011

Metalworking Environmental
3% 2%
Nuclear
3%

Pulp/Paper
9% Petrochem
24%

Defense
11%

Process Turbine
Equipment Engine
14% 18%
Mining /
Power Trans
17%
METALWORKING PROCESSES

• WROUGHT
• Forging
• Rolling
• Drawing
• Extrusion
• OTHER METALWORKING
• Fabrication
• Powder Metallurgy (Sinter or HIP)
• Spinning
• Flow-forming
• Hydro-forming
• CASTING
• Sand
• Investment
• Centrifugal
• Die
• Continuous
METALWORKING PROCESSES

Melt

Refine

Mold Pour Post-Cast NDE

ALMOST ALL METALS START AS CAST STRUCTURES

• Mold provides shaping and safe containment of molten metal.
• Refining process may be optional depending on specification.
• Casting is usually AOD (Argon Oxygen Decarburization) or VAR (Vacuum Arc
Remelt) or VIM (Vacuum Induction Melt).
• Wrought may include ESR (Electroslag remelting) or VAR.
METALWORKING PROCESSES

Reheat

Mechanical Heat
Cleaning Machining
Reduction Treatment

WROUGHT PROCESSES INVOLVE DEFORMATION OF THE

CAST STRUCTURE
• Work above re-crystallization temperature is hot-work.
• Work below re-crystallization temperature is cold-work.
• Depending on the amount of deformation, intermediate reheating may be
required.
METALWORKING PROCESSES

Forging Process
• Usually a Hot Working Process.
• Various Strain Rates – from press
to hammer.
• Types of Forging Operations.
• Open Die.
• Closed Die.
• Semi-Closed Die.
• Ring Rolling.
• Can Be Hollowed – but limited in shape.
• Pierced and Forged Over Mandrel.
• Trepanned After Forging.
• Typical Reduction in Section >4:1
METALWORKING PROCESSES
RING ROLLING PROCESS

Upsetting Billet Piercing

 METALWORKING PROCESSES

What is Happening in Hot

Working?
• Coarser cast grain structure broken up
• Re-crystallization

• Internal voids (shrink and gas) healed

• Chemical uniformity improved
• Improved uniformity of properties and heat
treatment response

• Mechanical properties increased in

longitudinal direction

Alloy 718 ESR ingot pre

and post forging
METALWORKING PROCESSES

Isotropic vs. Anisotropic

Primary Working Direction (Longitudinal)

Cast materials designed to be
isotropic (similar properties).
• Deformation after casting creates
directionality (anisotropy) in
metals due to grain alignment.
• Forgings may be either isotropic
or anisotropic.
METALWORKING PROCESSES

Forging
• When to use
• Open die for simpler shapes. closed for
more complex.
• Limited inside shaping.
• Standard metallurgical grades.
• Larger parts.
• Heavier sections.
• Higher mechanical properties.
• High internal soundness.
• Fatigue-limited applications.
• When to avoid
• Thin parts.
• Intricate inside shaping.
• Less common materials.
• Complex external shape with low quantities.
METALWORKING PROCESSES

Fabrication Process
• Generally uses wrought materials for
raw stock.
• Can use casting, forging, or other material.

• Various welding processes used based

on specific component (material,
specification, inspections, etc.).

• Can be almost unlimited in size.

• May require machining after welding.

METALWORKING PROCESSES
WELDING
Fabrication
• Engineering
• Nesting and material utilization
• Directionality of properties
• Weld process / filler metal
• Material selection
SMAW SAW • Manufacturing
• Pre-forming
• Weld positioning
• Inspections
• Weld quality factor
GMAW GTAW • Fixturing
• Post-fabrication machining
METALWORKING PROCESSES

Fabrication
• When to use
• Large parts
• Thin sections
• Standard materials
• Available filler metal with mechanical /
corrosion properties
• Possible to machine in detail

• When to avoid
• Very heavy sections
• Difficult to machine internals
• Non-standard materials
METALWORKING PROCESSES

Miscellaneous Processes
• Spinning
• Cold plastic deformation of metal in lathe.
• Widely used for spherical sections
• Good properties.
• Can work to very thin sections with iterative
heat treatments if required.

• Flow-forming
• Cold plastic deformation of metal in flow-form
machine.
• Improved properties, dimensional tolerances.
• Can vary wall thickness.
METALWORKING PROCESSES

Container Miscellaneous Processes

liner
• Powder metals
• Alloyed or blended metal powders
• Bonded into pre-form or “canned”
• Sinter vs. HIP
• Excellent dimensional integrity
• Density varies depending on process

• Extrusion
• Uses billet as starting stock
• Widely used for shape cross-sections,
especially in light metals
• Can be performed hot or cold
• Pilger Mill
Extrusion
• Excellent dimensional control
Product
SAND CASTING

Sand Casting
SAND CASTING

Sand / Static Casting Process

PATTERNS MELT

MOLD REFINE

CAST FINISH
CORE

HEAT TREAT NDE

COREBOX
SAND CASTING

Sand Mold Schematic

• Cope – top half of mold.
• Drag – bottom half of mold.
• Core – molded shape inserted to put
internal shaping or other unmoldable
features.
• Sprue – vertical path for metal to
enter mold.
• Gating system – can be complex or
simple, engineered for proper filling.
• Riser – molten reservoir for metal
used during solidification.
SAND CASTING

Sand Casting
• Pattern Engineering
• Shrink rule
• Rigging / methods scheme
• Life expectancy
• Tolerances

• Core making
• Process selection varies by size and
tolerance
• Various materials (silica, zircon, etc.)
• Ceramics and Cerabeads®
• Various binder systems used
• No-bake (2 and 3-part)
• Oil sand
SAND CASTING

Sand Casting
• Molding processes
• Green sand
• No-bake processes
• Furan and phenolic urethane
systems (typically <1% binder)
• Patternless molding
• Resin shell
• Unbonded systems
• Replicast® CS and FM
• Vacuum process
• Critical mold parameters
• Compaction / surface integrity
• Gas permeability
• Fusion temperature
• Mechanical strength
SAND CASTING

Sand Casting
• Finishing
• Mechanical and thermal processes used.
• Weld procedure and control critical.
• Heat treatment
• Mechanical properties
• Corrosion resistance
• Inspection processes
• Visual.
• Non-destructive.
• Radiography.
• Liquid Penetrant.
• Ultrasonic (limited on alloy range).
• Magnetic Particle.
SAND CASTING

Sand Casting
• Tolerances
• Agreed to up front with foundry.
• ISO CT grades 11-14 typical.
• Fractional tolerance
• Approximately + 1% linear.
• Extra allowance for core sets and
across parting lines.
• Surface finish (as-cast)
• Typically 500rms for no-bake sands
• Influenced by :
• Pouring temperature of metal and
metal composition.
• Sand type and fineness.
• Mold compaction.
SAND CASTING

Sand Casting
• When to use
• Need shaping
• Air-melted materials
• Larger parts
• Any production quantity
• Have tolerance flexibility or can
machine
• Internal details

• When to avoid
• Vacuum melt materials
• Intricate internal details
• Tight tolerances on difficult to machine
or expensive alloys
SAND CASTING
INVESTMENT CASTING

Investment Casting
INVESTMENT CASTING

Investment Casting Process

WAX

SHELL MELT

AUTOCLAVE CAST FINISH

HEAT TREAT NDE

INVESTMENT CASTING

Investment Casting Process

A = Wax pattern of desired finished part
created.
B = Wax pattern injected and added to a
“tree” with metal delivery system.
C = Wax tree repeatedly dipped (invested)
in ceramic slurry and sand stucco to
build up ceramic shell.
D = Wax pattern removed using an
autoclave. Shell is fired at high
temperature.
E = Molten metal poured into shell cavity.
F = Shell broken away, leaving casting.
Gating system removed leaving part.
INVESTMENT CASTING

Investment Casting Tree

Assemblies
• Common to have multiple casting per tree.
• Number of castings depends on:
• Size
• Geometry
• Feeder contact requirements
• Ability to handle
• Economics generally favor maximizing the
number of castings per tree, as long as
quality is not compromised.
INVESTMENT CASTING

Investment Casting
• Die/pattern engineering
• Shrink Rule
• Wax shrink rate + metal rate
• Heat transfer across shell
• Wax pattern is invested

• Core making
• Collapsible pattern
• Some internal details can be molded into wax
• Limited by shelling
• Core types
• Soluble wax cores
• Fused ceramic cores
• Quartz cores
INVESTMENT CASTING

Investment Casting
• Shelling processes
• Robotic
• Manual
• Critical shell parameters
• Strength
• Permeability
• Slurry properties
• Specific gravity
• Viscosity
• Wetting / surface tension
• Prime coat material
• Fusion point / specific heat
• Permeability
• Chemistry
• Backing coats / stucco
• Strength
• Permeability
INVESTMENT CASTING

Investment Casting
• Finishing
• Mechanical processing typical
• Fine detail control critical
• Weld procedure control critical
• Heat treatment
• Properties
• Corrosion resistance
• Inspection processes
• Visual
• Non-destructive
• Radiography
• Liquid penetrant
• Fluorescent particle
• Ultrasonic (material dependent)
• Eddy current
INVESTMENT CASTING

Investment Casting
• Tolerances
• Agreed to up front
• Linear dimensions typically +0.5%
• Surface finish (as-cast)
• Typically 125rms or better
• Prime coat determines much of surface
finish
• Grain refiners may be added to
prime coat
• Can degrade surface with poor
finishing operations
INVESTMENT CASTING

Investment Casting
• When to best use
• Most alloys
• Part sizes usually limited by shelling
operations
• Any production quantity
• Internal details
• Tight tolerances, reduced machining
• Eliminate fabrication

• When to avoid
• Extremely large parts (>>1m)
• Very heavy parts
INVESTMENT CASTING
CENTRIFUGAL CASTING

Centrifugal Casting
CENTRIFUGAL CASTING

Centrifugal Casting Process

MELT

REFINE

DIES POURING HEAT TREAT

MACHINE NDE
CENTRIFUGAL CASTING

Horizontal Centrifugal
• G-forces up to 170g.
• Tubular with limited OD shaping.
• Straight walled ID.
• Dies are typically steel alloys.
• Up to 1300mm+ (48”) OD / 8000mm+ (210”)
length.

Vertical Centrifugal
• G-forces up 60g, can be variable.
• Can have complex OD shaping, some minor ID
shape control.
• Typically steel dies, can include graphite, sand
and ceramic molds for shaping.
• Up to 4600mm diameter, up to 1800mm tall;
depending on aspect ratio.
PROCESSES

Centrifugal Casting Process Animation

 CENTRIFUGAL CASTING

Centrifugal Casting Process

1. Directional 2. Oxides and impurities

are forced inward;
3. Impurities are
concentrated in the
4. Impurities are
removed by
solidification of
metal is forced bore; the centrifugal machining, resulting
sound metal
centrifugally to is completely in a defect- and
progresses
the outside. solidified. shrink-free structure.
from outside
toward the bore.
 CENTRIFUGAL CASTING

Secondary Refining and Stokes’s Law

Small low density particles (inclusions) Behavior of small spherical
behave according to Stokes’ Law. particle in viscous fluids
CENTRIFUGAL CASTING

Centrifugal Casting
• Die Engineering
• Permanent mold
• Die safety
• Material and heat transfer
• Shaping technologies
• Shaping
• Primarily used on vertical process
• Various consumable materials used
• Metal
• Graphite
• Sands
• Ceramics
CENTRIFUGAL CASTING

Centrifugal Casting
• Critical mold parameters
• Die safety
• G-forces
• Mold coating
• Heat transfer and thermal profile of
mold
• Die mass and dimensions
• Metal hydraulics on shaping
• Erosion
• Fracture
• End effect
CENTRIFUGAL CASTING

Centrifugal Casting
• Post-Cast Processing
• Machining of ID (boring)
• OD machining typical (exc furnace tubes, etc.)
• Very little requirement for weld upgrade
• Heat Treatment
• Properties
• Corrosion resistance
• Inspection Processes
• Visual
• Non-destructive
- Radiography
- Liquid penetrant
- Magnetic particle
- Eddy current
- Limited ultrasonic (material dependent)
CENTRIFUGAL CASTING

Centrifugal Casting
• Tolerances
• Usually delivered rough machined at
+0.5mm (+1/32”).
• As-cast tolerance usually.
+ 1.5-3.0mm ON O.D. (1/16 – 1/8”).
• Surface Finish (As-Cast)
• Typically 500rms or rougher on as-cast
surface.
• Material soundness can allow
achievement of any level of finish,
including food grade with proper
machining and polishing
CENTRIFUGAL CASTING
CENTRIFUGAL CASTING

Centrifugal Casting
• When To Use
• Severe service
• Part can be developed with axis of
rotation
• Limited internal shaping
• Wrought and cast conversions
• Vacuum grades to 1.25m (48”) OD,
340kg (750lb.) pour
• Shield-cast alloys
• When to Avoid
• Intricate internal shaping
• Parts where symmetry / balance cannot
be achieved
 PROCESS COMPARISONS
Attribute Forging Fabrication Spinning Flow- Powder Extrusion Sand Investme Centrifugal
forming Metals Cast nt Cast Cast
Mechanical High High, weld High High High when High Medium Medium Medium- High,
Properties factor applies HIP, Lower incl. LCF
for Sinter

Material Varies, Std grade and Varies, Varies, Varies, can Standard Wide Almost all Almost all,
Availability standard weld standard Standard be materials range, air vacuum size ltd.
grades OK electrode grades OK grades OK customized typical melted

Part Size To Very Almost To 3-4m Machine Sinter or Machine To Very To 1m+ To 4,5m /15’ OD
Large Unlimited typical Limited HIP Limited Limited Large (48”), 350kg to 5,3m
(15ft.) (larger ltd) /210”length

Shaping Varies by Can be Limited or Can vary Complex Can be To Complex OD to Complex,
process, complex, N/A diameters, usually 2D complex, Complex, ID Limited
internal ltd. machining? sections limited 2D only Machining

Internal Limited Can be Limited or Can vary Sinter Ltd, None or Yes Yes Limited
Details Complex N/A diameters, None on HIP very limited
sections

Tolerances Varies by Varies if Machining Machining Sinter near Close Open Close Close, Typically
process, fixtured, open tolerances tolerances machining, machined
material unless H/T unless H/T HIP open tolerances.

Inspections Visual, RT, Visual, RT, Visual, Visual, UT, Visual, Visual, FPI, Visual, RT, Visual, RT, Visual, LPI, FPI,
(Typical, LPI, MPI, LPI, UT UT, LPI, MPI, LPI, Limited on LPI, UT LPI, MPI, LPI, FPI, MPI, Limited UT
consult on UT, Other FPI, RT, FPI, Other Sinter, All on Limited UT MPI, Limited
others) Other HIP UT
SOLIDIFICATION + MODELING

Understanding the Science

of Castings
• Thermal Dynamics
• Fluid Dynamics
• Physical Properties
• Mechanical Properties
PROCESSES AND ENGINEERING

Evolving from Art to Science

Castings have for a long time been
considered a pseudo-science, even a
“black art.” But to succeed, you must:
• Control the Processes.
• Control the Inputs.
• Understand the Capabilities.
• Predict the Outcome.
AIM

Standard
Optimum
SOLIDIFICATION + MODELING

Control of Shrinkage
• Casting geometry
- Design for feeding
- Avoid isolated heavy sections
- Increase fillets where possible
• Feeder design
- Placement
- Size
- Quantity
• Gating system
- Ingate locations
- Rate of fill
- Metal temperature distribution
• Pouring parameters
- Metal temperature
- Mold temperature
• Material selection
- Mold material
- Mold coating
- Chills
SOLIDIFICATION + MODELING

Control of Turbulence –
Critical to Casting Quality
• Effects of Turbulence
• Oxidation of metal during filling
(re-oxidation)
• Entrainment of mold gasses
• Mold erosion
• Control of Turbulence
• Gating design for laminar flow
• Mold orientation
• Use of metal filtration
• Casting design modifications where
Water Model Showing Initial possible
Transient Flow
SOLIDIFICATION + MODELING

Solidification
• Metals solidify away from a heat sink in a
predictable manner. Control of solidification
is critical.
• Nucleation – The relatively cold mold
surface acts as a low free energy site, where
solidification initiates through crystal
nucleation.
• Growth - Crystals usually grow with a
dendritic structure along preferred atomic
lattice planes.
• Orientation – Lattice planes that are aligned
with the temperature gradient grow
preferentially to those that are not.
Solidification Directional solidification will occur as long
as the temperature gradient is maintained.
SOLIDIFICATION + MODELING

Dentritic Solidification
(Examples shown are both Fe-0.11 wt %C)

Solidus velocity of 10 mm/s,

Temperature gradient 100 K/mm

Solidus velocity of 10 mm/s,

Temperature gradient 300 K/mm

(Computer simulations using “cellular automata”

combined with finite difference methods, created by
ISF-Welding Institute of Aachen University.)
CASTING QUALITY

Different types of contraction

3 distinct
contribute to dimensional control
and certain defects.
1. Liquid contraction: Liquid metal contracts as it
stages of gives up superheat and cools to the solidification
temperature.
volume 2. Solidification contraction: The metal freezes,
changing from a liquid to a higher density solid.
contraction For pure metals, contraction occurs at a single
temperature. For alloys it will take place over a
during temperature range.
• This is the concern of gating design.
solidification • Shrinkage cavity is due largely to this factor.
3. Solid contraction: The solid casting cools from its
solidification temperature to room temperature.
• This is the concern of tooling.
• Dimensional control is tied closely to this
factor.
SOLIDIFICATION + MODELING

Shrinkage
• Most metals contract as they cool,
particularly during the phase change
from liquid to solid.
• Shrinkage porosity occurs when molten
metal solidifies in areas that are isolated
from feed metal.
Micro-shrinkage • Micro-shrinkage - Typically inter-
dendritic voids as a result of the inability
of molten metal to feed through the
tortuous path of the dendrite arms.
• Macro-shrinkage – Centerline or heavy
section shrinkage resulting from
isolation of the solidifying front from
feeder metal.

Macro-shrinkage
CASTING QUALITY

General Types of Casting Defects

• Porosity/Cavities: shrinkage porosity, gas porosity, blowholes, or
pinholes
• Discontinuities: cracks, cold or hot tearing, cold shuts (usually from metal
constrained from shrinking)
• Inclusions: form during melting, solidification, and molding.
• Defective surface: folds, laps, scars, shell cracks, or adhering sand/mold
material
• Metallic projections: flashes, fins, or projections
• Incorrect dimension or shape: improper shrinkage allowance, irregular
contraction, core/wax issue, or pattern mounting error
CASTING QUALITY

Casting Defects: Porosity

1. Shrinkage Porosity
• Caused by solidification about thick
section/thin section regions.
• Thin sections solidifies first and may
starve thick section of molten metal during
last portion of solidification results in
shrinkage porosity
Shrinkage Porosity • Appears rough and angular

2. Gaseous Porosity
• The result of higher solubility of gases in
liquid metal versus solid metal results in
gaseous porosity on solidification.
• Sources include ambient moisture in
feedstock and mold/core materials, poor
venting, other??
• Appears smoother, like Swiss cheese.
Gaseous Porosity
CASTING QUALITY

Casting Defects: Porosity

Effects
• Reduces strength, ductility, fatigue,
surface finish, weldability & corrosion
resistance.
• Inter-connected porosity affects casting
pressure tightness

Prevention
• Use of internal or external chills in sand
casting to increase solidification rate in
critical locations. Dissolved gasses may be
removed from the molten metal by purging
with an inert gas, de-oxidation additions or
vacuum melting.
• Reduce turbulence during pouring
• Proper preparation of melt stock and mold
materials to reduce moisture
• Insure proper gating, risers, vents.
• HIP after the fact to close internal porosity
CASTING QUALITY

Casting Defects: Hot Tear / Crack

Types
• Hot tears: Occur between dendrites
• Hot cracks: Occur between/across dendrites
• Hot spots

Hot crack: occurs between or across Effects

dendrites
• Lack of soundness
• Detrimental effect on most properties

Prevention
• Design: Avoid rapid thin to thick transitions
and allow generous fillet radii to help
minimize the potential of hot tear/crack
• Alloy Selection and Process Control: Hot
tear/crack prone alloys require careful
Hot tear: occurrs between dendrites control of the casting processes, including
mold/gating design and cooling rate.
CASTING QUALITY

Casting Defects: Misruns / Cold

Shuts
Types
• Misrun - Unfilled portion of the mold
• Cold shuts - Two fronts of flowing metal
Misrun solidify before fusing together
Effects
• Lack of soundness
• Detrimental effect on most properties
Prevention
• Increase fluidity metal through additional
superheat (but not too much) or
compositional adjustments.
• Proper venting to reduce back pressure
• Casting design and modeling to understand
min section thickness vs. length that can be
cast, etc.
CASTING QUALITY

Casting Defects: Inclusions

1. Non-metallic (such as oxides, nitrides,
carbides, calcides, or sulfides, silicates)
• Refractory from furnace/ladle, dross or slag
• Mold erosion
• Can be caused by reaction of oxygen (metal
re-oxidation) or other element with metal to
form oxides, sulfides, etc. Not always
detrimental.
2. Metallic
• May be contamination of melt stock with high
melting point metals that are not fully melted.
Metallic (V) inclusion in Ti-alloy
casting • Reaction to form undesirable phase
• Insufficient hold times at temperature to
completely melt all feedstock
CASTING QUALITY

Casting Defects: Inclusions

Effects
• Reduces corrosion resistance, can lead to
localized or overall mechanical property
debits, reduced fatigue, weldability.
• Insufficient alloying element distribution
within all areas of part.

Prevention
1. Insure proper furnace and ladle practices,
compatibility with alloy
2. Utilize inert gas or vacuum during melting
Radiograph showing sand inclusion and pouring.
in steel casting
3. Control feed stock composition and
cleanliness, use master alloys if possible
4. Consistent melt practices
CASTING QUALITY

Residual Stresses
Residual stress can result from:
• Mold restrictions during solidification (the mold is in compression and the metal
in tension)
• Differential heating and cooling due to section changes
• Especially on higher temperature / faster cooling cycles
• Solution anneal
• Excessive weld upgrade without post-weld heat treat
Prevention and Elimination
• Any methods to minimize differential cooling rates will help mitigate problem.
• stress relief heat treatment may be necessary to avoid distortion or propensity to
crack
SOLIDIFICATION + MODELING

Evaluation of Non-Metallic
Flotation in Centrifugal
Casting
• Computer simulation of particle
flotation is used to evaluate
probability of entrapped low
density inclusions, and to predict
the placement of low or high
density metal matrix composites
within the molten alloy.
• This model was run to establish
whether the composite particle
component would spin to the bore
ahead of the solidification front.
SOLIDIFICATION + MODELING

Engineering and Modeling

• Recognition of the need to control
solidification and turbulence in the
casting process has led to a vast
increase in the use of computer
simulations to model thermal and
fluid dynamics during filling,
solidification, and cooling.
• More than any single tool, these have
impacted the foundry business in the
21stcentury. Many versions of
software are now commonly
available.
SOLIDIFICATION + MODELING

Available Software Includes:

• AutoCAST Advanced Reasoning
Technologies P. Ltd., Mumbai
• CAP/WRAFTS EKK, Inc., Walled Lake,
Michigan, USA
• CastCAE CT-Castech Inc. Oy, Espoo, Finland
• Castflow, Castherm Walkington Engineering,
Inc., Australia
• FLOW-3D, Flow Science Inc., Santa Fe, New
Mexico, USA
• JSCast Komatsu Soft Ltd., Osaka, Japan
• MAGMASoft MAGMA GmbH, Aachen,
Germany
• MAVIS Alphacast Software, Swansea, UK
• Nova-Solid/Flow Novacast AB, Ronneby,
Sweden
• PAM-CAST/ProCAST ESI Group, Paris, France
• RAPID/CAST Concurrent Technologies Corp.,
USA
• SIMTEC RWP GmbH, Roetgen, Germany
• SOLIDCast Finite Solutions, Inc., Illinois, USA
SOLIDIFICATION + MODELING

Computer Simulation Programs

at MetalTek.
• MagmaSoft®: Sand casting optimization, gating
and feeder design, solidification and stress
analysis. Strength is in detailed solidification
MagmaSoft analysis, data base, wide use in industry.
• Flow 3D®: Centrifugal casting optimization, as
Flow 3D well as detailed analysis of fluid dynamics of
sand and investment castings. Strength is in
fluid dynamics, turbulence mitigation and filling
temperature distribution.
• SolidCast®: Investment casting setups and quick
analysis of sand casting feeder design. Strength
is in flexibility, speed, cost and data base
support.
SolidCast
• ProCast®: Detailed investment casting
optimization, filling and solidification. Strength is
ProCast in finite element analysis, radiant heat, thin
sections, shell build.
SOLIDIFICATION
CASTING +DESIGN
MODELING

Solidification and Fluid Dynamics

• Development and design time is expensive,

and prototype costs are high.
• Optimizing tool design, pour parameters,
and temperature in the computer rather
than in the foundry saves time and cost.
• Proper simulation can greatly increase
casting quality and greatly reduce first
article lead times
• Customers come to the supplier with
product design challenges. Tools like
solidification modeling prevent problems
before they reach the shop floor.
SOLIDIFICATION + MODELING

Sand Casting Solidification

Soundness Prediction
• 2D views are also used to evaluate the
likelihood of micro-shrinkage as a
function of Niyama criteria and more
advanced porosity prediction methods
involving solidus velocity.
MODELING
CASTING
CENTRIFUGALS
DESIGN

Most People Think of

Centrifugal Castings as
Tubes or Rings
MODELINGINDUSTRIAL
CENTRIFUGALS
Centrifugals Can Have Complex
O.D. Shaping
• Net and Near Net Shaped Centrifugals
• Integrity of a centrifugal with the
surface finish and complexity of an
investment casting.
• Significant machining and processing
cost can be avoided by casting in
features.
• Tooling cost and lead times can be
reduced by use of rapid prototyping.
MODELING
CASTING
CENTRIFUGALS
DESIGN

Filling of a Moderately Shaped

Vertical Centrifugal
• Metal generally fills the
outermost areas of the
mold first, as it is
picked up by the
rotating mold surface.
• The center is always a
parabola whose slope
is dependent on the
G force applied.
MODELING
CASTING
CENTRIFUGALS
DESIGN

Solidification of a Moderately
Shaped Vertical Centrifugal
• As is typical with
centrifugals, whether
shaped or not,
directional
solidification
progresses from the
OD to the ID.
MODELING CENTRIFUGALS

Not All Centrifugals

Have Hollow Centers

• Complex shaped
centrifugal casting
poured with solid center.
• Material – Modified Alloy
N26625
• Cast Weight – 1400 lbs. /
636 kg
MODELING CENTRIFUGALS

Centrifugals Do Not Have to be

Symmetrical About the Center
• With proper die balancing, non-symmetric
castings such as this large housing can be
centrifugally cast.
• This engine casing was converted due to cost
overruns associated with sand castings and
fabrications.
CASTING QUALITY

Casting Design Considerations

1. Avoid sharp corners, angles and fillets
• Fillet radius should neither be too sharp (stress concentration) nor large
(excessive volume)
• Section changes should gradually blend into each other (avoid “large circle” hot
spot regions)
2. Flat areas.
• Large flat areas should be avoided, as they may warp from thermal gradients or
develop poor surface finish from uneven flow of molten metal during pouring.
• Improved by adding ribs with stiffness benefit.

3. Parting line in casting (line separating upper & lower halves of mold)
• Parting line be along a flat plane, rather than contoured.
• Parting line preferred at corners or edges of casting rather than flat surfaces in the
middle of the casting
 CASTING QUALITY

Casting Design Considerations

4. Work with manufacturer, foundry, or metallurgist up front in design process.
• Design has biggest impact on cost
• reduce problem areas specific to an alloy, process, or unique shape.
• improves the robustness of this difficult to predictable process

5. Machining allowance (included in pattern dimensions)

• Allowance depends on type of casting and increase with section thickness
• Usually range from 2-5 mm. In small castings to ~ 25 mm. In large castings

6. Consider residual stress.

• In some cases, stress relief heat treatment may be necessary to avoid distortion or
propensity to crack
NON-DESTRUCTIVE TESTING
Quality Factor Increases to 100%
Non-Destructive Examinations
• Hydro testing – usually requires pre-machining to seal
• RT – through component / all materials to 30+ cm thick
- ASME, MIL and customer standards
- Comparator plates – 1T and 2T sensitivity
- ASNT level II and III
- Orientation sensitive
• MPI – surface and near surface / magnetic materials
- ASME, MIL and customer standards
- Various techniques – can be orientation sensitive
- ASNT level II and III
- ASNT level II training
• LPI / FPI – surface only / all materials
- ASME, MIL and customer standards
- Various sensitivities
- ASNT level II and III
• Surface preparation to 250rms or better
• Visual inspection – surface only / all materials
- MSS SP55 and ASTM A802 standards
- Lighting critical
BREAK

Let’s Take a
10-Minute Break
MATERIALS

Enhancing Performance
with Material Selection
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
AVAILABILITY

Corrosion Resistant Alloys

• Aluminum and Nickel-Aluminum Bronzes.

• Austenitic and Super-austenitic Stainless.

– MetalTek Alloy 31®.
• Duplex and Super-duplex Stainless.
– Ferralium® .
• Nickel-based (A494, A991).
– Alloy B, C, N, 600, Others .
• Precipitation Hardened Alloys.
– 17- 4PH, 15-5PH® .
• 400-Series Martensitic Stainless.
– CA6NM, CA15, CA40.
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
MATERIALS

Material Specifications
• International Specification
Agencies
• Government Regulations
• Customer Specifications
• Proprietary Alloys
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
MATERIALS

AUSTENITIC STAINLESS STEEL ALLOWABLE STRESS* Austenitic Stainless Steel

ASME B 31.3 Table A-1 Allowable Stress in Tension
160 Allowable Stress
140

•
CF8

120
CF8C
CF8M ASME B31.3 allowable stress values for
three cast austenitic stainless steels
Stress, MPa

100

80
• Allowable stress values differ between
60
specification agencies.
40

20
• Allowable stress values dependent
0 upon the method of manufacture and
0 200 400 600 800 1000

Temperature, C
o non-destructive examination.
DUPLEX, ALLOWABLE STRESS
Duplex and Super Duplex Allowable Stress Values
280
2205 - ASME V111
Duplex Alloys - Allowable Stress
Zeron 100 - ASME V111
260 2507 - ASME V111
Zeron 100 - B31.1
2507 - B31.3
240

220
• Allowable stress values increase with
Stress, MPa

200
alloy content.
180

160 • Alloy 2205 has the lowest allowable of

140 the duplex and super duplex families.
120
0 50 100 150 200 250
o
300 350 400 • Allowable stress values may differ
Temperature, C
based on the method of manufacture
(i.e. wrought, rolled and welded, cast).
MATERIALS

Copper Base Alloy Allowable Stress in Tension* Copper Alloys Allowable Stress
* ASME B31.3 - 2008 Table A-1

300

•
250
ASME B31.3 allowable stress values for
200
aluminum bronze, nickel aluminum
Stress, MPa

C952
C954
C955
150 C963
bronze, and manganese bronze alloys.
100
• Aluminum bronze alloy C95200 has
50
highest maximum service temperature
0
0 200 400 600 800 1000
due to lower aluminum content.
o
Temperature, C

• Manganese bronze alloy C963 has

highest allowable stress at room
temperature but rapidly falls off above
100C.

Alloy 95800
Micrograph
 MATERIALS

Alloy Steels And Martensitic Stainless Steel

Allowable Stress Values
LOW ALLOY and ALLOY STEEL ALLOWABLE STRESS* MARTENSITIC STAINLESS ALLOWABLE STRESS*
* ASME B31.3 - 2008 Table A-1 Allowable Stress in Tension * ASME B31.3 Table A-1 Allowable Stress in Tension
200 300

250 CA15
CA6NM
150
200
Stress, MPa

Stress, MPa
100 150

100
50 WC-1(C-1/2Mo castings)
WP-1 (C-1/2Mo Forgings) 50
WC6 (1 1/2Cr - 1/2Mo castings)
WP11 (1 1/2Cr - 1/2 Mo forgings)

0 0
0 100 200 300 400 500 600 700 0 200 400 600 800 1000
o o
Temperature, C Temperature, C
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
CORROSION

Types of Corrosion
• Uniform corrosion
• Pitting
• Crevice
• Intergranular
• Galvanic
• Stress corrosion cracking
• Microbial induced corrosion
• Selective leaching
• Flow accelerated corrosion
CORROSION

Pitting Corrosion
FIND IT – Submerged pipes, pumps
• Corrosion is localized and aggressive
• Corroded area relatively small v total
surface
• Once initiated, very difficult /
impossible to eliminate
Mechanism
• Oxidizing aqueous environment, esp.
with chlorides
• Localized impurity, scratch in metal, or
holiday in coating, etc.
• Pit environment concentrates
electrolytes
• Higher temperatures increases rate
CORROSION

Pitting Corrosion
One Of The Most Destructive Forms Of
Industrial Corrosion

Reduce chances by
• Treating water for chlorides and pH
• Material Selection (PREN Number)
• Good metal finish on static components
(smooth welds, etc.)
• Remove suspended materials from water
• Avoid stagnant water conditions – have
some flow
• Cathodic protection sometimes works
CORROSION

PREN Calculation
Duplex and Super Duplex SS Alloys:
PREN= Cr + 3.3Mo + 16N
or
PREN= Cr + 3.3(Mo + 0.5W) + 16N
Ferritic SS Alloys:
PREN= Cr + 3.3Mo
Super Austenitic SS Alloys:
PREN= Cr + 3.3Mo + 30N
CN3MN Weld Nickel Base Alloys:
PREN= Cr + 1.5(Mo + W + Nb) + 30N
CORROSION

Crevice Corrosion
FIND IT – Bolted joints, deep recesses in
metal surfaces, under gaskets, at the base
of threads
Mechanism
• Generally occurs in a chloride-containing
environment
• Recessed area creates localized
difference in chemical environment
• Electrolyte concentration increases
Failure
• Failure generally occurs due to Pitting or
Stress Corrosion Cracking (SCC)
CORROSION

Crevice Corrosion

Reduce chances by
• Design system to minimize overlap joints
• Select welded over bolted or riveted
joints
• Use impervious gasket materials and
avoid wet packing
• Remove deposits as they form (PM)
• Appropriate / allowed sealants
CORROSION

Intergranular Corrosion
FIND IT – Adjacent to welds, especially in
stainless steels, heavy section components
Mechanism
• Localized segregates at grain
boundaries due to material solidification
or processing
• Chromium depletion adjacent to grain
boundaries in welded stainless steels
CORROSION

Intergranular Corrosion
Reduce Chances By
• Order stainless steels in solution
annealed condition
• Material selection – e.g. low carbon
(ELC) or stabilized stainless steels
• Solution anneal fabrications or use low
heat input welding practices
• Cast austenitic SS alloys contain 20%
delta ferrite which reduces susceptibility
to IGA
CORROSION

Galvanic Corrosion
FIND IT – Components with dissimilar
metals in contact with each other
• Requires two electrochemically
different alloys which are in contact
Steel clamp on with each other
copper pipe • One metal is attacked, the other not
Mechanism
• Metals have large difference in
electrochemical potential and/or large
difference in exposed surface area ratio
• Submerged in electrolyte solution
either continuously or intermittently
CORROSION

Galvanic Corrosion
Reduce Chances By
• Electrical insulation of materials
from each other
• Surface area ratio – avoid small
anode and large cathodes, especially
• Coatings – apply coatings correctly –
if you can only coat one material,
coat the cathode
 CORROSION

Galvanic Series Indicates Relative Potential

Steels

Stainless Steels
Typical Stainless Steels
with Passivation

Bronze Alloys
Nickel-based Alloys
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
MATERIALS

Galling and Wear

Resistance

• Recognize potential problems

• Select compatible materials

MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
MATERIALS

Factors Influencing
Weldability
• Chemical Composition
• Grain Structure
• Heat Treatment
• Casting Process
MATERIALS

Material Selection is a
Compromise
• Availability
• Material specifications and Code
requirements
• Mechanical properties
• Corrosion resistance
• Wear and galling characteristics
• Weldability
• Cost
 MATERIAL SELECTION

Alloy Cost Relative to CF8 Stainless

Material Costs
0 1 2 3 4 5 6 7

Super Austenitic

Alloy 718
• Material cost may account for
Alloy 625 approximately 30% of the cost of a part
•
Super Duplex

2205 Alloy costs include raw materials and

17-4PH

CF8M
processing (melting restrictions, heat
CF8 treat requirements, etc.)
•
CA15/CA6NM

Alloy Steel Thus, simple cost comparisons

0 1 2 3 4

Cost Factor
5 6 7
between different materials are
possible using the relative alloy cost
chart
RESEARCH AND DEVELOPMENT

Research and Development

MATERIAL IMPROVEMENT

Alloy Improvement Possible

Using Modern Phase Prediction
And Identification Tools
• Electron Back Scanning Diffraction (EBSD)
analysis helps to identify and quantify micro-
constituents.
Thermo- • Thermo-Calc predicts phase distribution, liquidus-
Calc solidus, and other valuable information over a wide
Analysis range of temperatures.
• Thermo Process Modeling is used to predict the
influence of heat treatment temperatures on a
material.

Thermo Process Modeling

RESEARCH AND DEVELOPMENT

Heat Treatment Optimization Results

Super Austenitic Stainless
25

Development Activity
20

• SFSA Sponsored heat treatment studies at several

Weight Loss, %

15

leading universities
10

• Goal: To optimize heat treatment, welding

5
and corrosion resistance
0 • Compared wrought AL6XN and 254 SMO
AL6XN

CN3MN - 1205 C - 1 hr

CN3MN - 1205 C - 4 hrs

CN3MN - 1150 C - 1hr

CN3MN - 1150 C - 2 hrs

CN3MN - 1150 C - 4 hrs

CN3MN - 1205 C - 2 hrs

CN3MN - As Cast

with cast equivalents CN3MN and

o

o
o

CK3MCuN alloys
• Results indicate that heat treatment
temperatures and soak times have a
critical impact on corrosion resistance
• Welding study suggests that dilution and
filler metal type significantly influence
CN3MN Weld corrosion resistance
MATERIAL SELECTION

Questions And Discussion

CLOSING

THE INFORMED DECISION –

SAFELY HOME.

METALTEK INTERNATIONAL

CARONDELET SANDUSKY
CORPORATION INTERNATIONAL

MACKSON SOUTHERN
INCORPORATED CENTRIFUGAL
MEIGHS WISCONSIN
CASTINGS LTD CENTRIFUGAL
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