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    MFE 230 WK 1

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    Francisco Rodriguez
    Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. It involves three stages: liquid, liquid and solid, and solid. The solidification process depends on factors like cooling rate, time, and grain formation. Proper gating, riser placement, and mold design are important to minimize issues like shrinkage and porosity. Computer simulation can be used to optimize the casting process.

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    MFE 230 WK 1

    Uploaded by

    Francisco Rodriguez
    51 views14 pages
    Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. It involves three stages: liquid, liquid and solid, and solid. The solidification process depends on factors like cooling rate, time, and grain formation. Proper gating, riser placement, and mold design are important to minimize issues like shrinkage and porosity. Computer simulation can be used to optimize the casting process.

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    MFE 230 Wk 1

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    MFE 230 Wk 1

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    Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. It involves three stages: liquid, liquid and solid, and solid. The solidification process depends on factors like cooling rate, time, and grain formation. Proper gating, riser placement, and mold design are important to minimize issues like shrinkage and porosity. Computer simulation can be used to optimize the casting process.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    51 views14 pages

    MFE 230 WK 1

    Uploaded by

    Francisco Rodriguez
    Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. It involves three stages: liquid, liquid and solid, and solid. The solidification process depends on factors like cooling rate, time, and grain formation. Proper gating, riser placement, and mold design are important to minimize issues like shrinkage and porosity. Computer simulation can be used to optimize the casting process.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 14

    MFE 230

    CASTING I

    David Berdahl
    Cal Poly
    Pomona
    MFE 230
    WHAT IS CASTING?

    Casting is a manufacturing process in which a


    liquid material is usually poured into a mold,
    which contains a hollow cavity of the desired
    shape, and then allowed to solidify.
    Process:
    Make a hole -> melt metal -> pour it into the hole ->
    solidify -> remove and clean
    THE SOLIDIFICATION PROCESS

    3 Stages
    Stage 1
    Liquid

    Stage 2
    Liquid + Solid
    Stage 3
    Solid
    SOLIDIFICATION: GRAIN FORMATION
    Nucleation
    The 3 Zones
    Solid/Chill (TS)
    Mushy Zone
    Liquidus (TL)

    Freezing Range
    F = TL - TS
    SOLIDIFICATION: COOLING RATE AND TIME

    Slow Cooling Rate


    Result in course/large dendritic grain structure
    Less ductile and less strength and more porosity
    High Cooling Rate
    Result in finer grain structure
    Higher ductility, more strength, less voids, less porosity
    Solidification Time
    Chvorinovs Rule
    T = C (Volume/ Surface Area)^n
    C is the casting constant and n is usually 2
    SOLIDIFICATION: MICRO/ MACROSEGREGATION
    When material cools at a fast rate, alloyed
    materials have:
    Microsegregation
    Core of dendrite is different than its outer
    edges
    Macrosegregation
    Differences in the alloy are throughout the
    casting
    Can combat by adding a inoculant to the
    alloy so that the alloy does not sepparate
    PARTS OF A CASTING
    SOLIDIFICATION AND ISSUES

    Shrinkage
    Worst phase is liquid to solid
    Porosity
    Discontinuities/ Tears

    Cavities

    Incomplete casting/ Cold Shut


    FLUID FLOW AND CASTING DESIGN
    Gating design
    Bernoullis Theorem
    2
    + + =
    2
    h = height above reference level
    p = pressure at height
    = density of metal
    v = velocity of fluid

    Law of Continuity
    Q = v1A1 = v2A2
    USE OF THE 2 EQUATIONS AND SPRUE DESIGN

    Fluid flow is essential to mold fill


    If path is not designed properly, fluid can
    aspirate/ cause turbulence or have air infused
    This can cause porosity

    Can be combated by a tapered sprue or


    choking the sprue
    FLUIDITY/ FILLABILITY

    Temperature and superheat affect viscosity of


    liquid and amount of heat to be removed
    mold design-V/SA ratios and, mold material
    (sand vs. metal) affect heat transfer rates,
    pouring rate
    Spiral Test
    SHRINKAGE

    Can cause
    Partdimensional change
    Porosity

    Can be minimized by optimizing gating and


    strategically sizing and placing risers
    Use mold design software
    PROCESS SIMULATION (CASTING)
    THE RESULT

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