82 ATEXTBOOK OF MANUFACTURING TECHNOL
2.9 COOLING AND SOLIDIFICATION
After the mould cavity is filled with the molten metal, the metal is allowed to solid:/
into the desired shape. The solidification process decides the structural features of coet
material, and controls the properties of casting.
The liquid metal is poured into the mould cavity at a temperature much higher than he
freezing temperature (it is the temperature above which pure metals are completely
liguid and below it completely solid, also called equilibrium melting temperature) to
allow sufficient time for the liquid metal to flow into0 all corners of the mould cavity
before it begins to freeze (the difference between the pouring temperature and freezing
temperature is known as superheat).
e Refer to Fig. 2.32. For proper understanding of Equiaxed
solidification mechanism and rate of heat loss /crystals
from the material to the mould etc. it is neces
sary to predict how the casting will solidify
which avoids casting defects such as seams, gas
holes and hot tears etc. !
Wall
We know, solidification requires energy to produce of
Direction
mould
a crystalline structure, some supercooling (below freezing of growth
point) is required before the liquid metal starts solidify
ing. This cooling is provided by the mould which pro
vides sites around which crystals can grow initially and Columnar
subsequently by the solidified particles, and the metal crystals
itself. Fig. 2.32
In the case of casting, after pouring of the molten metal in the mould, the temperature falls
steadily until freezing commences at a particular point. During solidification, the temperature
more or less remains constant due to release of latent heat. In fact there may be a slight increase
in temperature if supercooling has occurred. The temperature again starts falling steadily in case
of pure metal. In the case of alloy, commencement of crystallization is followed by a period of less
step temperature reduction while the metal is passing through the mushy state.
Since an alloy does not have a sharply defined freezing temperature solidification takes
place over a range of temperature. The solids separating out at different temperatures therefore
possess different compositions. The direction of crystal growth is thus dependent upon the compo
sition gradient within the casting variation of solids, temperature with composition and thermal
gradient within the mould. The crystal grouth in the case of alloys is of dendritic structure.
During cooling many characteristics such as crystal structure and alloy composition at
different parts of the casting are decided. Unless a proper care is taken during cooling,
defects like shrinkage, cavity, cold shut, misrun and hot tear occur. Due to all these
reasons, the direction of erystal growth depends on the various factors such as :
() The variation of temperature with composition.
() The thermal gradient within the mould.
() Composition gradient within the casting.
The cooling patterns of an ordinary mould are shown in Fig. 2.33.
The cooling curves are useful to find out the too low pouring temperature which will
cause partially filled cavities. Also these are used to find the too high pouring tempera
ture whih will create hard casting, etc.
83
CASTING PROCESSES
Mould End of
Centre freezing
line
Mould Start of
face freezing Solid
mould.
Fig. 2.33. The cooling patterns of an ordinary
structure of metals.
Fig. 2.34 shows the cast
(6) Alloys (c) Through addition of
(a) Pure metals
nucleating agents
Fig. 2.34. Cast structure of metals.
castings) the solidification
In directional solidification (aimed at producing sound solidifies first towards the risers
continues progressively from the thinnest section which
which should be last to solidify.
Directional solidification can be ensured by:
) Designing and positioning the gating system and risers properly;
(the
(ii) Increasing the thickness of certain sections of the casting by the use of padding
tapering of thinner section towards the thicker section):
(ii) Using exothermic materials in the risers Or in the facing sand around certain portions of
the casting ;
(iv) Using chills in the moulds.
Chills :
Chills are provided in the mould so as to increase the heat extraction capability of the
sand mould. A chill provides a steeper temperature gradient so that directional solidi
fication as required in a casting be obtained.
ATEXTBOOK OF
84 MANUFACTURING
The chills are metallic objects having a higher heat absorbing capability TECHNOL
mould. These can be of two types :
adjoining the mould cavity
in the mould cavity at any
() External chills (placed
position).
mould cavity where an external chill
Tequite
(placed inside the
() Internal chills cannot be pto
vided). or impossible to use riser
may be either impractical
when it However
sectionsareof used
These the casting. they can be used along with risers if possible. on thick
joint effect which
massive portions produce a enables
Chills and risers placed on contraction voids. the pro-
completely free from
duction of castings
Chills are metal objects in the form of rods, wire and nails. either cast or made
rolled stock.
Fig. 2.35 shows use of chills.
Internal
chills
cope
Parting
line
Drag
Direct
Indirect
[External chills]
Fig. 2.35. Use of chills.
Example 2.3. Assuming uniform cooling in all directions, determine the dimensions of a
90 mm cube casting after it cools down to room temperature. The solidification shrinkage for the
cast metal is 5% and the solid contraction is 7.5%.
Solution. Given : Side of the cube = 90 mm
Solidification shrinkage = 5%
Solid contraction =7.5%
Dimension of each side of the cube after cooling :
Volume of casting, V= (90)= 7,29,000 mm³
Volume after solidification shrinkage = 7,29,000 1 = 6,92,550 mm3
7.5
Volume at room temperature =6,92,550 1-. = 6,40,609 mm3
100
Dimension of each side of the cube = (6,40,609)/3
= 86.2 mm. (Ans.)
CASTING PROCESSES
85
mm diameter and 88 mm
Erample 2.4. What will be the solidification time for a 1100
seclmm ?
the mould constant is 2.2
thick casting of aluminium if
Solution. Diameter of casting, d=
1100 mm
Height/thickness of casting, h =33 mm
Mould constant, C= 2.2 sec/mm2
Solidification time, t :
Volume of the casting, "xh
4
= x (1100)2 x 33 = 31,360,948 mm³
A= 2x d
Surface area of the casting, 4
= 2x*4 x (1100)2= 1,900,663 mm²
2
31,360,948
= 2.2. X =598.95 s or 9.98 min. (Ans.)
1.900,663
area. One casting is
Example 2.5. Two castings of the same metal have the same surface
for the sphere
What is the ratio of the solidification time
in the form of sphere and other is a cube. (GATE)
to that of a cube.
Solution, Let, V= Volume of casting, and
A = Surface area of casting ..(Given)
Also, Asphere = Aube
According to Chvorinov's rule,
Solidification time,
sphere to that of cube,
Ratio of solidification time for the
tsphere Vsphere
teube cube a
4
161°R (Ans.)
9a
where, R=Radius of sphere, and
a=Side of the cube.
3