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METALLURGY
Solidification
In a casting process, the material is first
Homogeneous Nucleation
Homogeneous Nucleation Formation of
Mostmetalsandalloysshrinkas
the
material
changes from a liquid state to a solid state.
Therefore, if liquid material is not available to
compensate for this shrinkage ashrinkage
defectforms. When progressive solidification
dominates over directional solidification a
shrinkage defect will form.
progressive
solidification, the cooling and
solidifying process begins at the walls of the
casting and works its way inward. With directional
solidification, the process of solidification begins
at the bottom of the casting and works its way to
the top.
Degasification
frommolten metal.
If they can not escape they may form vacancies in the
material, causing porosity in the metal casting.
Prevention Of Gas Defects When Manufacturing A
Part By Casting
Gases being expelled by the material during solidification
can be eliminated by a proper venting system in the mold.
This can be planned out during the manufacturing design
phase of the metal casting process.
Removal of slag will help eliminate gases and other
impurities in the casting.
Gases may be removed by flushing a metal melt with inert
gas.
Elimination of gases may also be accomplished by pouring
the metal casting in a vacuum.
Castability
Castabilityis the ease of forming acasting.
Castability (Fluidity) is the ability of the molten metal to
b) Degree of Superheat:Superheating
is
the
improvement
of
temperature above the melt point of the alloy.
Superheat improves the fluidity by delaying
solidification.
c) Mould material and its surface
characters:Mould material should have low thermal
conductivity and fine surface. Higher the
thermal conductivity of mould and rougher the
surface the lower will be the castability.
Example: Dry sand mould has high castability
than green sand mould.
2.Geometry Planning:
Designing the geometry of the product is quite
cost effective & it depends upon the
complexity of the process. It also depends on
the tools used.
3. Quality:
Quality of the casting product means free of
alluminium alloys.
Zinc-based alloys:- These have good