Deep Drawing Too High Pressure -failures Strip Causes caus exit v, the - Cooling Racks higher strip the Lower - spray temp delts, the The thinner the top at exit fux Hot through lower designed to Risors blocking Patton discussions casting product than slightly larger contraction after finish Tandor are ranges short thus of worst surface finish any casting technique -Molten metal evaporates being held still with sand a focus sold the gat -Durcusing the super hat accelerates solidification also the in tools pastrate fracturing Mieroporosity - hydrogen in multi supposed in the atmosphere humidy Mold -Most segregation prone Hot Tea Discontinuity High - - Cool Rak coarse - when i will five dendrites Fine = in casting Factors contributing to Hot too -stress Risces -coarse grainSiza boundaries - woak grain occurs stage of a casting being because generally during occurs Less - the is cast is part as want to a process. Hot When the tear occurs that for along grain boundaries can Thurnally be in a likely to give - extra Hot four can casting - elimate have add height - a rise to due to formation solidification small sprun riser now the location the metal pressure Intraind to the be intensified by Increasing the spoke a Increasing mitigated by heat outside of hold Adding casting cannot shrink contract. Happens solid and to matural solidifies and contract. obtained feeding Gas Porosity operation induced tensile stresses and strain - Isotropic Process that the material Liquid dendritic strength and Finer dendritics high ductility - solidification - casting as casting pressure of the parts all Envistment well as of Misrus upon largest freening range slow cool Rate - it reaches cavity. rise High cooling rate fraczs loc - has Dis Casting retal occurs when the molten solidification upon at lower Surface Misruns formation of Microlgast before aluminum cause porosity of volume accelerates Class to any eutectic point largest supphcut diameter of the top Riss solidification Dacuse the chanc Burnish entrapped (Shrinkage microstructor The zone where the Cutting -At Lower cooling the of shrinkage into the sheet metal prior chance is coarse more Ishcow zon formation (Shrinkage the Account solidification of -High solubility diagram most fluid at the and casting Lost four mushy less a us Fine and blanking obtained on the surface smother finish is Show Zo to closely controlled Phase with smalle Casting of alloys zou virtually elimated be traditional - - atmosphere freezing may due levels in the Sinn Erickson list - solidification Porosity out -suppressed if casting carried - shot metals various by: Bulge test, Cupping test, Limiting Done night test rates high cooling humidity Diagrams Limit be obtain for and Micro at lower disposable fire blanking to account for thermal highwhat a eliented The bur way be virtually has improve surface Fine sand casting having properly the bolts Tow casting sand grains strip shape used to is Forming can - -Develops due after solidification Gas pattern wax Ceramic mold. Ceramic mold broken off duc A poor surface finish is obtained to hold walls contracted out of course ↳ the The colder water spray, - A - - sand Missons upon solidification nrcusing the superheat strip formation of Gives Rise to shrinkage porosity occurs higher locations accused by at CurUcs Investment Casting -Macro The hot flux through the belts is affected by the melt superhont strip top is affected by the water Porosity formationof itcanbe supposeit spot, exit top at - zone * the belts, The thinks - fracture over being Cust spad higher casting at verus Micro bolt Location along the top Smoother finish Formation Limit inndeformation condition (major and enino for flo where failure occurs is reasured around the location after the cupping tast on the short traditional of burnish due to the Dominance Casting but thickness, Metal The finish earing and wrinkling - casting function of belt material, - Blanking Fine Gas porosity to Elinate have cust supahant a larger turbulent metal flow during casting and aspiration - Due to Disadvantages Important consideration metal -Flow of poor dimensional accuracy - Environmental - Affecting solidification and Cooling Rat -Metallurgical and thermal properties of the metal Factors Casting Operation properties -low mechanical Hazards of cavity molten the the metal in natural hold of Entune of the type of solidification and cooling - - mold Type of mold - solidification and cooling Rate Influme shape, uniformly and Microstructure -size, -our all -> solidification of pure Metals The top - at remains is shrinkage Shrinkage Taue the freezing top until all associated with liquid solidific metal As freezing hold range - zone is when exist frazing -large frazing zone is perpendicular Mold wall will grow Liquid - of mushy Extend - solid and determined by In alloys an Wall oriented towards tempurtun a range to the fastest equiaxid over casting deudritus wall warns up, bigin to grow -crystals oriented c -large the Center of the solidification of alloys normally takes place called -Mushy the Gold columnar grains Solidification of Alloys - of Pure metals Grain structure Randomly oriented grains of small size now solidification, called solidification metal of properties of chemical camp zone will form zone range longer rusly the Micro-Segregation ZOr Cataline The Segregation alloying elements are normally center of the front towards the surface - segregation flow of enriched between the dendrites Due to the in fast cooling rates -under Relatively pushed by the liquid in convective flow Agitation arms or the liquid mechanical and promotes shrinkage cavities are uniform Chanical with large fracking ranges nuckate helps to the alloy metal helps breaking up grains the columnar grains vibration of the hold breaks finer grain moon up work which is Elcralive Bernoulli's Theore dendrit +2 h+ sizes Q = = constant p v = A,V, Suctional Area Avcragn Velocity P is a Velocity liquid density gravity the is 9 is flow Rat higher t = casting drop Ag Thx Towards End A= vRunnv the of the the Renumber, the greate he tandency for tubulat flow The ↑ his distance from the press i n is v is volunatic & c composition casting Ascross - enough solid dendritics time to diffuse within the ↳ croaks within the back into the (acuting agents) in solidification casting alloys Normally occurs Refinement Tacheigus Add inoculants not have whoe solute elcants do URamos c Eigh the base to the basin eargy losses friction factor incorporating I of Re up to 2000 Leeming In casting betwose 2000(R=<20000 R.values Represent grantorhanzon sour turbulence at height Reynolds l x number in a casting system determines whitea fluid flow is laminar Re = or U, Turbulent Hout transfer casting in natural being cast Thermal properties of the material and hold ( parameters (such as velocity - -process thin section casting When must be -Melt velocity high Redum heat transfer por premature solidification be not -Melt velocity must to mass to as so to avoid high excessive turbukne cause Hot Tou occurs distribution depends on the thermal properties Tshape of the curve for temperature material of the metal and the mold Chroninov's Rule solidification of Ts = CI time is is a function solidification The total - a of the material The thunal properties cast and mold material being The shape of the casting cis a that reflects properties, hold constant the metal material and (volumn to SA casting top in casting is the result of casting cannot shrink,contract freely during cooling tea Factors thatcontribute to - casting design cows - grain work grain Sitc boundaries Solution at critical sections controlled cooling Grain Ratiol Shrinkage who the refinement 1)facts develop Due to design Quality of material casting h -casting paranates to porosity-develop due of intrapment -bases, solidification Shrinkage metal bases. Due to turbulent Entained The largest contraction ↳ Reduce it: use is owing lasting due to solidification shrinkage of Risers, pressure feeding, modification of Dissolved solubility Mold must -Design considerations pattern casting dimensions Liquid metal gases has to release the Patterns the for aspiration and basis. are and as has a flow highe it solidifies it dissolved gases account for metal Shrinkage larger than the actual slightly dimensions Riser Vatical channels that provide metal to the elimate shrinkage casting a as continuous flow of molten solidification occurs during process solidification Shrinkage metal shrinks as it transforms for liquid to solid sigaid Rogia where Risa can surface for compasate and the designed right if - Shrinkage with solidification discontinuities porcs internal stresses. around material if andal in -pores present your -porosity are prom part the pass thus decrease under to rises to avoid - kept a Area the strength open ate in result a that the grouter load tha Results part being cast. ate pressure order to function into the metal or loused conductivity - Risa it cannot situation in food the has to be kept properly - Gas will sufficial pressure contrary mold cavity open become build up to back into ranges Segregation are solidification font Casting air shrinkays open to requires as and elastic modulus solidifies first purpose. Risu dissolved Alloys Large freezing the liquid Shrinkage cavities Centertian unde electrial both the thermal and KIS Rise propagate decreases fusion support because of the pressance of Large to Toughness of material porosity. of enriched -The alloying elements Tamp Decrcusc extral segregation -Due to flow of Shrinkage from superhent temp to solidification sup shrinkag solidification · - effection Risces normally pushed by towards the Center of
