MECH2305 Casting Fundamentals

Prof Andrej Atrens

A.Atrens@minmet.uq.edu.au

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Casting Fundamentals - Overview

IMPORTANCE CASTABILITY ALLOY SOLIDIFICATION
macrostructure segregation dentrites

FLUIDITY
test metal factors casting

MOLD DESIGN CAST ALLOYS

cast irons Al-Si

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Alloy Usage 1980 USA, million metric tonnes

Material Steel Timber & concrete Grey CI Wrought Al Alloys Ductile CI Malleable CI White CI Cast Al Alloys Zinc die castings Mg die castings Usage 120 Similar 16 5 2 1 1 1 0.03 0.04
Castability, cost, good strength, damping, brittle Cost higher than steel, lower density Strength ~ Grey CI + ductility, need innoculation Strength ~ Grey CI + ductility, need HT High hardness, cost due to alloying elements Higher cost than CI, lower density Easy to cast, acceptable mechanical properties Low density, high fluididy (easy to cast)

Comment
Moderate properties, easy to work, reasonable cost

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Castability
Ease of production of quality casting at acceptable cost Inter-related factors
Alloy (e.g. Mg easier to cast than CI because of lower melt temp) Mold design (e.g. hard to cast thin long sections) Type of casting (sand -v- investment)

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Casting Fundamentals - Overview

IMPORTANCE CASTABILITY

ALLOY SOLIDIFICATION
macrostructure segregation dentrites

FLUIDITY
test metal factors casting

MOLD DESIGN CAST ALLOYS

cast irons Al-Si

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Solidification of pure metal [K10.1(a)]

Pour metal into cold mold Heat extracted from mold wall Chill zone forms at mold wall lots of nuclei gives lots of small grains

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Solidification of pure metal [K10.2]

Grains grow fastest in fast growth directions. Grains can only grow out into melt. Grow in some directions cut off.

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Solidification of pure metal [K10.1(a)]

Formation of zone of large columnar grains. Large gains have typically poor strength & poor ductility

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Solidification of alloys [K10.1(b)]

chill zone at mold wall due to rapid nucleation as for pure metal Subsequent macrostructure similar to that of pure metal different solidification mechanism! zone of large columnar grains due to dendritic growth zone of small grains in center lots of nuclei by end of solidification

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Solidification of alloys

[K10.1(c)]

structure if add artificial nucleation agent eg Ti NB in Al alloys grain size still relatively large

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Solidification of alloys

[K10.1(b)]

chill zone at mold wall due to rapid nucleation as for pure metal Subsequent macrostructure similar to that of pure metal

different solidification mechanism! zone of large columnar grains due to dendritic growth
zone of small grains in center lots of nuclei by end of solidification
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Dendritic Morphology

[T7-35]

Morphology revealed by interrupting solidification and pouring out remaining liquid/mush Structure tree-like

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Denritic morphology [T7.34]

structure - tree like

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Segregation During Solidification

Assume relatively fast cooling so that there is not enough time for equilibrium
no diffusion in solid no mixing of liquid, diffusion is possible in liquid (Dliquid >> Dsolid)

Consider solidification of alloy composition Co

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Segregation During Solidification

[T7.31]

First solid at Ti has composition Ci Next solid at T2 has composition C2: Ave Solid Composition = (Ci + C2)/2 Ave Solid Composition goes along line to left of solidus

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Segregation During Solidification

[T7.31]

First solid at Ci, has less solute than liquid, Solute rejected at S/L interface, into liquid Establishment of solute profile at S/L interface, T7.36
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Solute profile at S/L interface

C4 at S/L interface C0 some distance ahead of S/L interface

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Segregation During Solidification

T >> TMP

[T7.31]

C4 at S/L interface, C0 some distance ahead of S/L interface, T = TMP Planar interface not stable, ie dendrites
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Constitutional Undercooling [C4.21]

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Constitutional Undercooling [C4.20]

transition from planar, to cellular & to dendritic gowth as there is an increasing amount of constitutional undercooling

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Casting Fundamentals - Overview

IMPORTANCE CASTABILITY ALLOY SOLIDIFICATION
macrostructure segregation dentrites

FLUIDITY
test metal factors casting

MOLD DESIGN CAST ALLOYS

cast irons Al-Si

MECH2305_06_B.3_Va

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Fluidity - Test [K10.8]

Capability of molten metal to fill intricate mold cavities. Fluidity = length of solidified metal in standard spiral Fluidity depends on
characteristics of molten metal, and characteristics of casting parameters

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Fluidity decreases with increasing Viscosity, and its temperature sensitivity (viscosity index). Surface tension. Oxide films on metal surface (eg Al alloys) further reduce fluidity. Inclusion content. (A slurry has a higher viscosity than the pure fluid). Freezing range of alloy & solidification pattern of alloy (details later).
High fluidity for short freezing range alloys, eg pure metals & eutectics Lower fluidity for alloys with long freezing ranges.

FLUIDITY

Metal factors

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Fluidity Data for Lead-Tin alloys [C2.53]

High fluidity for short freezing range alloys, eg pure metals & eutectics Lower fluidity for alloys with long freezing range alloys
L +

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Solidification mechanisms
[C2.52(a)] pure metals (or eutectic)
Solidification front migrates from walls towards center, until channel is blocked. Ie: solidification needs to be 100% at one point v = flow velocity along channel (assume constant) t = time for section to completely solidify Fluidity = v/t

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Solidification mechanisms
[C2.52(b)] long freezing range alloy
Growth of dendrites in liquid metal When dendrites impinge on one another, the viscosity increases dramatically & fluid stops. Dendrite impingement when solid fraction 50 to 60% Fluidity ~ v/2t, ie fluidity significantly lower than for short freezing range alloys

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Fluidity - casting factors

Fluidity increases with degree of superheat, T = Tactual Tmelting Fluidity decreases with
Slower rate of pouring. More time for cooling, & lower metal temperature. Better heat transfer at mold-metal interface, & lower metal temperature. Higher thermal conductivity of mold material, & lower metal temperature. Increasing mold cavity surface roughness, = higher flow resistance. Mold design, eg long narrow passages are harder to fill MECH2305_06_B.3_Va
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Casting Fundamentals - Overview

IMPORTANCE CASTABILITY ALLOY SOLIDIFICATION
macrostructure segregation dentrites

FLUIDITY
test metal factors casting

MOLD DESIGN CAST ALLOYS

cast irons Al-Si

MECH2305_06_B.3_Va

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Mold Design
Need to make a cavity that represents required part Running, gating & feeders control flow of metal into cavity & metal solidification Control macrostructure: large grains, shrinkage porosity & gas porosity & centerline/final solidification

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PATTERNS, UNDERCUTS & CORES

Patterns oversize to allow for metal shrinkage Pattern must be removable from mold leaving the cavity
Square sides need taper to avoid sand sticking to sides K11.5 undercuts give problems need skill in choosing mold parting line(s) W2.2

Hollows made by cores K11.6

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Shrinkage

[KT12.1]
Metals shrink on cooling T7.40
Liquids shrink on cooling There is usually a contraction of solidification Solid contracts during cooling

Pattern needs to be larger than cast part Typical KT12.1 shrinkage allowances

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Solidification of rectangular cavity without feeding [C5.27]

Not enough liquid, so there are internal voids, (shrinkage cavities) Do not want such situations. Prevent hot spots by casting design see later

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particularly H in Al & Mg alloys [K10.14] Hydrogen has appreciable solubility in melt Molten Al (& Mg) is reactive reacts with H2O in moist air & absorbs H Hydrogen has low solubility in solid Al Tendency for formation of gas porosity on solidification
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GAS SOLUBILITY

Metal Pouring & Mold Filling

Falling liquid stream contracts as it falls, [C2.11], so sprue shaped accordingly, otherwise gas is entrained in liquid stream Falling liquid tends to splash if it hits bottom, C2.14. Overcome with well

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RUNNERS, GATES & FEEDERS

Control mold filling at appropriate speed
too fast flow leads to turbulence and entrainment of gases & oxides too slow possibility of metal solidification before mold is full

Control of mold filling pattern

down sprue should fill quickly & stay full, delivering only metal into cavity
do not want entrained gas, or sand particles from mold erosion

base of down sprue should be lowest point in system. All subsequent liquid flow should be uphill, displacing air in a controlled and progressive advance. After base of sprue, liquid should be in expanding system, slowing as it goes. This maximises chances for turbulence to disappear before liquid enters mold cavity

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A poor running & gating system

[C2.3]

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A satisfactory running & gating system

[C2.3]

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RUNNERS, GATES & FEEDERS

Control mold filling at appropriate speed
too fast flow leads to turbulence and entrainment of gases & oxides too slow possibility of metal solidification before mold is full

Control of mold filling pattern

down sprue should fill quickly & stay full, delivering only metal into cavity
do not want entrained gas, or sand particles from mold erosion

base of down sprue should be lowest point in system. All subsequent liquid flow should be uphill, displacing air in a controlled and progressive advance. After base of sprue, liquid should be in expanding system, slowing as it goes. This maximises chances for turbulence to disappear before liquid enters mold cavity

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FEEDER FUNCTION
Feeder is a better name than riser. Its function is to feed molten metal into the mold cavity so that last solidification (& defects) are in the feeder NOT the cast part

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FEEDER (RISER) SIZE & DESIGN ISSUES

Solidification time. The feeder must solidify after the casting. Feed volume. There must be sufficient volume to feed the casting. Sufficient head or pressure for required feeding. Junction between feeder and casting must not form a hot spot and solidify last. Feeding path. Fluidity determines distance that molten metal can be fed. An additional feeder is needed if the feeding distance is too long
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Casting Fundamentals - Overview

IMPORTANCE CASTABILITY ALLOY SOLIDIFICATION
macrostructure segregation dentrites

FLUIDITY
test metal factors casting

MOLD DESIGN CAST ALLOYS

cast irons Al-Si

MECH2305_06_B.3_Va

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