Solidification Processes
Fundamentals of metal casting
• To create a part through solidification process which is initially in
liquid or highly plastic condition, are called casting or molding.
Classification of solidification processes
according to engineering material used
• Metals
• Ceramics specially glasses
• Polymers and polymer matrix composite
Casting
• Casting is a 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 is also applied to the part that is made by this
process.
• It is one of the oldest shaping processes, dating back 6000 years.
Principle of casting
• The principle of casting seems simple: melt the metal, pour it into a
mold, and let it cool and solidify; yet there are many factors and
variables that must be considered in order to accomplish a successful
casting operation.
Classification of solidification processes
Advantages of casting
• Casting can be used to create complex part geometries, including both external and
internal shapes.
• Some casting processes are capable of producing parts to net shape. No further
manufacturing operations are required to achieve the required geometry and
dimensions of the parts. Other casting processes are near net shape, for which some
additional shape processing is required (usually machining) in order to achieve
accurate dimensions and details.
• Casting can be used to produce very large parts. Castings weighing more than 100
tons have been made.
• The casting process can be performed on any metal that can be heated to the liquid
state.
• Some casting methods are quite suited to mass production.
Disadvantages of casting
• Limitations on mechanical properties
• Porosity
• Poor dimensional accuracy
• Poor surface finish
• Safety hazards
• Environmental problems
Foundry
• A foundry is a factory equipped for making molds, melting and
handling metal in molten form, performing the casting process, and
cleaning the finished casting.
• The workers who perform the casting operations in these factories are
called foundry-men.
Casting process according to mold
• Open mold casting
• Close mold casting
Broad categories of casting according to mold
• Expandable mold
Sand, plasters or similar materials
• Permanent mold
Metals
Sand casting mold
• Cope
• Drag
• Flask
• Parting line
• Pattern
• Gating system
• Down-sprue
• Runner
Heating and pouring
• To perform a casting operation, the metal must be heated to a
temperature somewhat above its melting point and then poured into
the mold cavity to solidify.
• Various kinds of heating furnaces are use for casting.
Heat energy required for casting
• Heat energy required for casting is sum of many
1. the heat to raise the temperature to the melting point
2. the heat of fusion to convert it from solid to liquid
3. the heat to raise the molten metal to the desired temperature for
pouring
H= ρV {-
Pouring of molten metal
• Introduction of molten metal into the mold, including its flow
through the gating system and into the cavity, is a critical step in the
casting process. For this step to be successful, the metal must flow
into all regions of the mold before solidifying.
Factors affecting pouring operation
• Pouring temperature
• Pouring rate
• Turbulence
Engineering analysis of pouring
• Bernoulli's theorem
• Continuity law
• Time required to fill mold cavity
Fluidity
• The molten metal flow characteristics are often described by the term
fluidity, a measure of the capability of a metal to flow into and fill the
mold before freezing.
• Fluidity is the inverse of viscosity.
• Spiral mold test,
Factors affecting fluidity
• Pouring temperature relative to melting point
• Metal composition
• Viscosity of the liquid metal
• Heat transfer to the surroundings
Solidification and cooling
• Solidification involves the transformation of the molten metal back
into the solid state. The solidification process differs depending on
whether the metal is a pure element or an alloy.
Cooling curve for pure metal
Cooling curve for alloy