#02 CastingTeory 2019 PDF

TI184308
Manufacturing Processes
(3 credits)
Fundamental of Metal Casting

Manufacturing System Laboratory
Dept of Industrial Engineering - ITS
2019
Jurusan Teknik Industri FTI - ITS
Casting since about 4000 BC…
Ancient Greece; bronze

statue casting circa 450BC Iron works in early Europe,
e.g. cast iron cannons from
England circa 1543
TI091302 - Manufacturing Process #02
Casting of Metals
Process in which molten metal flows by gravity or
other force into a mold where it solidifies in the
shape of the mold cavity
 The term casting also applies to the part made in
the process
 Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze

Casting Processes

Parts Made by Casting

 Big parts
 Engine blocks and heads for automotive
vehicles, wood burning stoves, machine
frames, railway wheels, pipes, church bells, big
statues, pump housings
 Small parts
 Dental crowns, jewelry, small statues, frying
pans
Capabilities and Advantages of Casting

 Can create complex part geometries
 Can create both external and internal shapes
 Some casting processes are net shape; others
are near net shape
 Can produce very large parts (more than 100
ton)
 Some casting methods are suited to mass
production

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


Overview of Casting Technology

 Casting is usually performed in a foundry
Foundry = factory equipped for making molds,
melting and handling molten metal, performing
the casting process, and cleaning the finished
casting
 Workers who perform casting are called
foundrymen

The Mold in Casting

 Contains cavity whose geometry
determines part shape
 Actual size and shape of cavity must be
slightly enlarged to allow for shrinkage of
metal during solidification and cooling
 Molds are made of a variety of materials,
including sand, plaster, ceramic, and metal

Open Molds and Closed Molds

 Two forms of mold: (a) open mold and (b) closed
mold for more complex mold geometry with
gating system leading into the cavity

Categories of Casting Processes

1. Expendable mold processes – use an
expendable mold which must be destroyed to
remove casting
 Mold materials: sand, plaster, and similar
materials, plus binders
2. Permanent mold processes – use a
permanent mold which can be used to produce
many castings
 Made of metal (or, less commonly, a ceramic
refractory material

Advantages and Disadvantages

 More intricate geometries are possible with
expendable mold processes
 Part shapes in permanent mold processes are
limited by the need to open the mold
 Permanent mold processes are more economic in
high production operations

Fundamental of Casting
 Solidification
 Fluid Flow
 Heat Transfer
 Pouring

Heating the Metal

 Heating furnaces are used to heat the metal to
molten temperature sufficient for casting
 The heat required is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired
temperature for pouring

Pouring the Molten Metal

 For this step to be successful, metal must flow
into all regions of the mold, most importantly the
main cavity, before solidifying
 Factors that determine success
 Pouring temperature
 Pouring rate
 Turbulence

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

Cooling Curve for a Pure Metal

 A pure metal
solidifies at a
constant
temperature
equal to its
freezing point
(same as
melting point)

Solidification of Pure Metals

 Due to chilling action of mold wall, a thin skin of
solid metal is formed at the interface immediately
after pouring
 Skin thickness increases to form a shell around
the molten metal as solidification progresses
 Rate of freezing depends on heat transfer into
mold, as well as thermal properties of the metal

Solidification of Pure Metals
 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
 Phase diagram for a copper-nickel alloy system and
cooling curve for a 50%Ni-50%Cu composition

Solidification of Alloys
 Characteristic grain
structure in an
alloy casting,
showing
segregation of
alloying
components in
center of casting

Lever Rule
 Component composition can be
learned in Lever Rule :
S C0  CL L Cs  C0
 or 
S  L Cs  C L S  L Cs  C L

Case 01 : Solidification Alloys

Solidification Time
enthapy
Use Flemings
result here

Solidification 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
n
V 
TTS  Cm  
 A
where TTS = total solidification time; V = volume of
the casting; A = surface area of casting; n =
exponent with typical value = 2; and Cm is mold
constant.
Mold Constant in Chvorinov's Rule

 Mold constant Cm depends on:
 Mold material
 Thermal properties of casting metal
 Pouring temperature relative to melting point
 Value of Cm for a given casting operation can be
based on experimental data from previous
operations carried out using same mold material,
metal, and pouring temperature, even though the
shape of the part may be quite different

What Chvorinov's Rule Tells Us

 Casting with a higher volume-to-surface area
ratio cools and solidifies more slowly than one
with a lower ratio
 To feed molten metal to the main cavity, TTS
for riser must be greater than TTS for main
casting
 Since mold constants of riser and casting will be
equal, design the riser to have a larger
volume-to-area ratio so that the main casting
solidifies first
 This minimizes the effects of shrinkage

Can You Explain Why ?
RI 1321 - Proses Manufaktur - Minggu 2 30

Shrinkage during Solidification & Cooling

(0) starting level of molten metal immediately after
pouring;
(1) reduction in level caused by liquid contraction
during cooling

Shrinkage during Solidification & Cooling

(2) reduction in height and formation of shrinkage
cavity caused by solidification;
(3) further reduction in volume due to thermal
contraction during cooling of solid metal

Volumetric contraction due to:
Solidification Solid Thermal

Metal Shrinkage, % Contraction, %
Aluminum 7.0 5.6
Al alloy 7.0 5.0
Gray cast iron 1.8 3.0
Gray cast iron, high C 0 3.0
Low C cast steel 3.0 7.2
Copper 4.5 7.5
Bronze (Cu-Sn) 5.5 6.0

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 correct for solidification shrinkage
and thermal contraction by making the 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

Directional Solidification
 To minimize 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 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

Achieving Directional Solidification

 Directional solidification is achieved using
Chvorinov's Rule to design the casting, its
orientation in the mold, and the riser system that
feeds it
 Locate sections of the casting with lower V/A ratios away
from riser, so freezing occurs first in these regions, and
the liquid metal supply for the rest of the casting
remains open
 Chills - internal or external heat sinks that cause rapid
freezing in certain regions of the casting

External Chills
(a) External chill to encourage rapid freezing of the
molten metal in a thin section of the casting;
and
(b) (b) the likely result if the external chill were not
used
Riser Design
 Riser is waste metal that is separated from the casting and
re-melted 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 shape of the riser is normally designed to maximize
the V/A ratio, this allows riser volume to be reduced to the
minimum possible value
Fluidity
 Metal flow characteristics, a measurement of how
fast boiled metal fill the mold before becoming
solid.
 Fluidity is inversely proportional with viscosity.
 Some factor that affect fluidity :
 Pouring temperature,
 Metal composition,
 Viscosity,
 Heat transfer occur around the process.

Fluid Flow Characteristics

 Mass Continuity Q  A1v1  A2v2
 where Q is the volumetric rate of flow, m3/s, A
is the cross sectional area of the liquid stream,
and v is the velocity of the liquid in that
location. vD
Reynolds number Re 
 
 where v is the velocity of the liquid, D is the
diameter of the channel,  is the density, and 
is the viscosity.
 For casting, Re = 2,000 – 20,000

Mold Filling Example (1 of 2)

Mold Filling Example (2 of 2)

Bernoulli’s Theorem
 Under steady well-developed flow conditions, the
total energy of a unit volume of material must be
a constant at every part of the system.
v02 v12
p0   gh0  p1   gh1  f
2 2
 where p is the pressure, v is the velocity, h is the height
above a reference plane, f is the energy losses due to
friction, and  is the density.

Heat Transfer
Heat energy required: H  V C T T  H  C T T 
s m o f l p m
 Heat to raise the
temperature up to
melting point. H  Total heat required; J
 Heat fusion to   density; g/cm3
change solid to Cs  weight specific heat for the solid metal; J/g- o C
liquid/melted.
Tm  melting temperature; o C
 Heat to raise melted
metal up to desired To  starting temperature; o C
pouring H f  heat of fusion; J/g
temperature. Cl  weight specific heat of the liquid metal; J/g- o C
Tp  pouring temparature; o C
V  volume of metal being heated; cm3

Pouring
 Factors that affect pouring :
 Pouring temperature
 Determining the need of reduction temperature to be hardened
metal.
 Superheat : the difference between pouring temperature and
hardened metal temperature.
 Pouring speed
 If too slow, melted metal will be hardened before filling the mold.
 If too fast, there will be a turbulence.
 Turbulence
 Uncontrolled fluid speed and flow
 Accelerate the formation process of metal oxide in hardening
process. So that the casting quality is decreased.
 Mold erosion straighlty happened.

Casting Processes
Manufacturing System Laboratory
Dept of Industrial Engineering - ITS
2019
Shape Casting Processes

 Expendable Mold  Permanent Mold
 Permanent Pattern  Die
 Sand Casting  Hot Chamber
 Plaster Molding  Cold Chamber
 Expendable Pattern  Thixotropic
 Lost Foam
 Lost Wax (investment
casting)
TI091302 - Manufacturing Process #03 48

Popular Casting Methods
• Sand Casting • Investment Casting • Die Casting

High Temperature Alloy, High Temperature Alloy, High Temperature Alloy,
Complex Geometry, Complex Geometry, Moderate Geometry,
Rough Surface Finish Moderately Smooth Surface Smooth Surface
Finish

Overview of Sand Casting

 Most widely used casting process, accounting for a
significant majority of total tonnage cast
 Nearly all alloys can be sand casted, including metals
with high melting temperatures, such as steel, nickel,
and titanium
 Castings range in size from small to very large
 Production quantities from one to millions
Figure 11.1 A large sand casting weighing over

680 kg (1500 lb) for an air compressor frame
(photo courtesy of Elkhart Foundry).
TI091302 - Manufacturing 50
Process #03

Making the Sand Mold

 The cavity in the sand mold is
formed by packing sand
around a pattern, then
separating the mold into two
halves and removing the
pattern
 The mold must also contain
gating and riser system
 If casting is to have internal
surfaces, a core must be
included in mold
 A new sand mold must be
made for each part produced
Process #03
Steps in Sand Casting

The Pattern
A full-sized model of the part, slightly enlarged to account for
shrinkage and machining allowances in the casting
 Pattern materials:
 Wood - common material because it is easy to work, but
it warps
 Metal - more expensive to make, but lasts much longer
 Plastic - compromise between wood and metal
Top center is the clay original, then the two part

plaster mold used for casting the lead at above, and
wax cast from mold, sprued for better brass casting,
not yet cast. 2008-01-12.
homepages.waymark.net/mikefirth/tapper6881b.jpg
Process #03
Types of Patterns
Figure 11.3 Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) match-plate pattern
(d) cope and drag pattern
Process #03
Pattern in sand mold

 Pattern is made bigger than expected product to tolerance:
 Shrinkage
 Finishing
 Pattern material:
 Wood
 Plastic
 Metal
 Wood pattern
 Advantages: easy to made
 Disadvantage: less strength for sand abbration
 Metal pattern: stronger but more expensive
 Plastic pattern ?

Casting with internal cavity

a) Core held in the mold cavity by chaplets
b) Possible chaplet design
c) Casting with internal cavity
Note:
• Chaplet is made from a material that has higher melting
temperature than the metal

How to make sand mold

 Kind of sand used:
 Silica (SiO2) or silica+other material
 Resists to high temperature (refractory)
 Sand bonding:
 Water and soil (bonding clay)
 90% sand, 3% water, 7% soil/clay
 Another bonding clay can be used:
 Organic resin (phenolic resins)
 Non oprganic resin (sodium silicate, phosphate)

How to make sand mold (2)

 Steps:
 Sand mold compression through the pattern for cope
and drag in a container/flask
 Compression method:
 Hand ramming
 Machining
 By using pneumatic compression
 Jolting action: flask being fallen down in several time to
compress
 Slinging action: press the sand granules with high pressure
and speed


 Sand mold quality indicator:
 Strength: shape resistance through destruction
 Permeability: able to minimize hot gas and temperature inside
of mold
 Thermal stability: resist to surface cracking and buckling while
molten metal flowing
 Collapsiblity: easy to be separated with casting product and
can be destruct without any product defect
 Reusability: ability of destructed mold to be reuse


 Sand mold classification:
 Green-sand mold
 Mixing: sand, soil and water
 “Green”: mold has good condition while molten metal flowing (moisture)
 Good in Strengh, collapsibility, permeability and resuability
 Dry-sand mold
 Using organic resin and heated in 200 C - 300C to increase mold
strength and hardness
 Better in dimension control but more expensive and requires longer time
 Suitable for medium to big size product and low to medium production
volume
 Skin-dried mold
 Green-sand mold surface principle, being heated until 10-22mm depth,
using torches, heating lamp
 Using specific bonding clay so that being similar with dry-sand mold

Casting operation
 Process: pouring, hardening, and freezing
 Problem: in pouring steps, using archimedes
Fb  Wm  Wc
Fb  gaya apung
Wm  berat logam lebur
Wc  berat inti
 Finishing: destruct the mold, clean the product and

inspection

Sand casting
 Advantages  Disadvantages
 Inexpensive mold  Cost per part is
 Complex geometry higher
Labor intensive
 All alloys 
 Slower production
 Unlimited size rate
 Economical in low  Rough surface finish
quantities
 Loose tolerances
 Requires relatively
thick walls (0.120”)

Other expandable mold (1)
 Shell molding
(1) a match-plate or cope-and-drag metal pattern is heated and placed over a box
containing sand mixed with thermosetting resin; (2) box is inverted so that sand and
resin fall onto the hot pattern, causing a layer of the mixture to partially cure on the
surface to form a hard shell; (3) box is repositioned so that loose, uncured particles
drop away; (4) san shell is heated in oven for several minutes to complete curing; (5)
shell mold is stripped from the pattern; (6) two halves of the shell mold are
assembled, supported by sand or metal shot in a box and pouring is accomplished.
The finished casting with sprue removed is show in (7)
65
Other expandable mold (2)
 Vacuum molding
(1) a thin sheet of preheated plastic is drawn over a match-plate or cope-and-drag
pattern by vacuum - the pattern has small vent holes to facilitate vacuum forming; (2) a
specially designed flask is placed over the pattern plate and filled with sand and a sprue
and pouring cup are formed in the sand; (3) another thin plastic sheet is place over the
flask and a vacuum is drawn that causes the sand grains to be held together, forming a
rigid mold; (4) the vacuum on the mold pattern is released to permit pattern to be
stripped from the mold; (5) this mold is assembled with its matching half to form the
cope and drag, and with vacuum maintained on both halves, pouring is accomplished.
The plastic sheet quickly burns away on contacting the molten metal. After solidification,
nearly all of the sand can be recovered for reuse.
66
Investment
Casting
The investment-
casting process, also
called the lost-wax
process, was first used
during the period 4000-
3500 B.C. The pattern is
made of wax or a plastic
such as polystyrene. The
sequences involved in
investment casting are
shown in Figure 11.18.
The pattern is made by
injecting molten wax or
plastic into a metal die in
the shape of the object.

Investment Casting
Description: Metal mold makes wax or plastic replica. There
are sprued, then surrounded with investment material, baked
out, and metal is poured in the resultant cavity. Molds are
broken to remove the castings.
Metals: Most castable metals.
Size Range: fraction of an ounce to 150 lbs..
Tolerances:
 .003 to 1/4
 .004 to 1/2,
 .005 per inch to 3
 .003 for each additional inch
Surface Finish:
63-125RMS
Minimum Draft Requirements: None
Normal Minimum Section Thickness:
.030 (Small Areas)
.060 (Large Areas)
Ordering Quantities:
Aluminum: usually under 1,000
Other metals: all quantities
Normal Lead Time:
Samples: 5-16 weeks (depending on complexity)
Production 4-12 weeks A.S.A. (depending on subsequent
operations).
Talbot Associates Inc.
Investment Casting Adv/Disadv.

 Good dimensional  Long production
accuracy cycle
 Relatively  leads to high cost per
inexpensive mold part
 Rapid production  Mold is not reusable

rates possible
 Complex shapes
 Very high temp
materials - Titanium

Permanent mold
 Move the mold, not

destruct it
 Using gravitation
 Slow metal flow
 Mold made from metal
with good thermal
conductivity

Casting with permanent mold

 Permanent mold depends on 2 different side
made from metal and designed to make the
open/close part works easily
 Mold material: steel or cast iron
 Molten metal: aluminum, magnesium, copper-
based alloy dan cast iron

Casting with permanent mold (2)
(1) mold is preheated and coated; (2) cores (if used) are inserted and
mold is closed (3) molten metal is poured into the mold (4) mold is
opened. Finished part is shown in (5)

Other Casting with permanent mold

 Low pressure casting
The diagram shows how air pressure is used to force the molten metal in the ladle
upward into the mold cavity. Pressure is maintained until the casting has
solidified

Die Casting
 Die casting Die casting
is a process involving
the injection of molten
metal at high
pressures, as opposed
to casting by gravity
pressure, (7 –
350MPa)

Die casting characteristic

Description: Molten metal is injected, under pressure, into
hardened steel dies, often water cooled. Dies are opened,
and castings are ejected.
Metals: Aluminum, Zinc, Magnesium, and limited Brass.
Size Range: Not normally over 2 feet square. Some foundries
capable of larger sizes.
Tolerances:
Al and Mg  .002/in.
Zinc  .0015/in.
Brass  .001/in.
Add  .001 to  .015 across parting line depending on
size
Surface Finish: 32-63RMS
Minimum Draft Requirements:
Al & Mg: 1° to 3°
Zinc: 1/2° to 2°
Brass: 2° to 5°
Normal Minimum Section Thickness:
Al & Mg: .03 Small Parts: .06 Medium Parts
Zinc: .03 Small Parts: .045 Medium Parts
Brass: .025 Small Parts: .040 Medium Parts
Ordering Quantities:
Usually 2,500 and up.
Normal Lead Time:
Samples: 12-20 weeks
Production: ASAP after approval.

Types of Die Casting

 Hot Chamber  Cold Chamber
 Zn or Zn alloys only
 Al, Mg, Zn
 Higher production rate 15 cycles
per minute for small parts  Melt is poured into
 Metal injected directly from melt cylinder, which is then
zone shot into chamber

Die Casting – Hot-Chamber Casting

Cycle in hot-chamber
casting: (1) with die
closed and plunger
withdrawn, molten
metal flows into the
chamber; (2) plunger
forces metal in
chamber to flow into
die, maintaining
pressure during cooling
and solidification; and
(3) plunger is
withdrawn, die is
opened, and solidified
part is ejected.
Finished part is shown
in (4).

Die Casting – Cold-Chamber Casting
Cycle in cold-chamber casting: (1) with die closed and ram withdrawn, molten metal is poured
into the chamber; (2) ram forces metal to flow into die, maintaining pressure during the
cooling and solidification; and (3) ram is withdrawn, die is opened, and part is ejected. Used
for higher temperature metals eg Aluminum, Copper and alloys

Thixotropic Process

Adv/Disadv of Die Casting

 High production rates  High tooling cost
possible, with high level  Long lead times
of automation (months)
 Very thin walls possible  Limited size (<25 lbs)
(0.020” for Mg die  Limited in alloys (low
casting) temperature only)
 Good surface finish  Zn
 Economical in large  Al
quantities  Mg
 Better control of mold  Cu
temps

Types of stoves
 Cupolas
 Used for cast iron
 Energy: coal

Types of stoves
 Directed fuel-fired furnace
 Metal is melted directly by fuel burner
 Used for non-ferrous metal: copper-based
alloys and aluminum

Types of stoves
 Crucible furnace
 Metal melted with no direct heat from fuel burner
(indirect fuel-fired furnace)
 Energy: kerosene, gas or powder coal
 Used for non-ferrous metal: bronze, brass and alloy of
zinc & aluminum

Types of stoves
 Electric-arc furnace
 Using electrical power (electric arc) to melt the
metal
 For cast steel

Types of stoves
 Induction furnace
 Using electricity (AC) that flows in a coil to built
magnetic field for melting process
 Kind of metal: steel, cast iron, aluminum alloy

Casting Quality(1)
 Kind of defects in casting process
(a) misrun; (b) cold shut; (c) cold shot (d) shrinkage cavity (e)
microporosity (f) hot tearing/hot cracking

Casting Quality(2)
 Kind of defects in sand casting
(a) sand blow (b) pin holes (c) sand wash (d) scabs (e) penetration (f) mold
shift (g) core shift (h) mold crack

Design for casting product:

 Simple geometric design
 Simplify making a mold
 Avoiding the use of core
 Increase the strength of mold
 Avoiding sharp in corners
 Is a source of stress concentration
 Source of cracks
 Design using radius (fillet)
 Machining tolerance
 Low dimensional precision
 If it requires dimensional precision, so that needs 1.5-
3.0 mm tolerances.

Design for casting product:
(a) Thick section at intersection can result in a shrinkage cavity

(b) redesign to reduce thickness
(c) use of a core
Design change to eliminate the need for using a core:

(a) Original design
(b) Redesign
Variations and Developments

 Continuous casting
 Lost foam molding
 3D Printing of Investment tooling
 Direct printing with metal droplets
 Uniform metal spray

Continuous casting ref AISI
Steel from the electric or basic oxygen furnace is tapped into a ladle and taken to
the continuous casting machine. The ladle is raised onto a turret that rotates the ladle
into the casting position above the tundish. Referring to Figure 2, liquid steel flows out
of the ladle (1) into the tundish (2), and then into a water-cooled copper mold (3).
Solidification begins in the mold, and continues through the First Zone (4) and Strand Guide
(5).
In this configuration, the strand is straightened (6), torch-cut (8), then discharged (12)
for intermediate storage or hot charged for finished rolling.

3D Printing
of Investment cast tooling

Shell and part (Turbine blade)

Microcasting of droplets
MIT
CMU
Environmental Issues
 Smelting
 Energy
 Off-gassing
 Cooling water
 Waste sand disposal
 Off shore locations

Metal Smelting; reducing oxides and sulfides

to metal
http://www.steel.org/learning/howmade/blast_furnace.htm

Environmental loads by manufacturing

sector
Carbon Dioxide and Toxic Materials per Value of Shipments
5
4.5
4
Weight/Dollars
3.5
3 CO2 (metric ton/$10,000)
2.5
2
1.5 Toxic Mat'ls (lb/$1000)
1
0.5
0
Primary Metal
Fabricated
Transportation
Plastics and
Petroleum
Machinery
and Coal
Chemicals
Electronic
Metal
Rubber
Manufacturing industries EPA 2001, DOE 2001

The estimated environmental performance of various mfg

processes (not including auxiliary requirements)
*Energy per wt. normalized

by the melt energy
** total raw mat’l normalized
by the part wt.

#02 CastingTeory 2019 PDF

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TI184308

Fundamental of Metal Casting

Casting since about 4000 BC…

Ancient Greece; bronze

TI091302 - Manufacturing Process #02

TI091302 - Manufacturing Process #02

Parts Made by Casting

Capabilities and Advantages of Casting

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TI091302 - Manufacturing Process #02

TI091302 - Manufacturing Process #02

Overview of Casting Technology

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The Mold in Casting

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Open Molds and Closed Molds

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Categories of Casting Processes

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Advantages and Disadvantages

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Heating the Metal

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Pouring the Molten Metal

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TI091302 - Manufacturing Process #02

Cooling Curve for a Pure Metal

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Solidification of Pure Metals

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Solidification of Pure Metals

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TI091302 - Manufacturing Process #02

TI091302 - Manufacturing Process #02

Case 01 : Solidification Alloys

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Mold Constant in Chvorinov's Rule

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What Chvorinov's Rule Tells Us

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Can You Explain Why ?

RI 1321 - Proses Manufaktur - Minggu 2 30

Shrinkage during Solidification & Cooling

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Shrinkage during Solidification & Cooling

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Volumetric contraction due to:

Solidification Solid Thermal

Aluminum 7.0 5.6

Al alloy 7.0 5.0

Gray cast iron 1.8 3.0

Gray cast iron, high C 0 3.0

Low C cast steel 3.0 7.2

Copper 4.5 7.5

Bronze (Cu-Sn) 5.5 6.0

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TI091302 - Manufacturing Process #02

TI091302 - Manufacturing Process #02

TI091302 - Manufacturing Process #02

Achieving Directional Solidification