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MELTING PRACTICES

MELTING PRACTICES

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Sundaramali Govindaswamy G
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9 views

MELTING PRACTICES

MELTING PRACTICES

Uploaded by

Sundaramali Govindaswamy G
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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SEMINAR

mahendra v
19BME0108
METAL CASTING
TECHNOLOGY
MELTING PRACTICES
• Melting processes are vital because they have direct affect
on casting quality
• Some are :
• Fluxing
• Heat treatment
• Inoculation
• Degassing
• Grain refinement process
Fluxing
• Fluxes are inorganic compunds that remove the dissolved
impurities
• They hae several function which include
• Cover fluxes
• These fluxes form a barrier to oxidation
• Cover flux is applied on the surface of molten aluminum
where it melts forming a continuous layer protecting the
liquid metal from oxidation and absorption of atmospheric
hydrogen.
Drossing flux

•
Drossing fluxes promote separation of molten aluminum
entrapped
• Heat generated by drossing flux improves wettability
and fluidity of the entrapped aluminum, drops of which
coalescence and flow down to the melt.
Cleaning fluxes
• Cleaning fluxes
• Cleaning fluxes remove oxides suspended in the melt.
Wall cleaning fluxes
• Wall cleaning fluxes
• Wall cleaning fluxes soften oxides built up on the
furnace walls.

Silicate fluxes are commonly used in industries except for


lead processing due to its higher melting point
Heat treatment
• Castings are made to be undergone heat treatment
processes to improve to enhance properties
Types:
Annealing
Quenching
Surface hardening
Percipitation hardening
Inoculation

• “Inoculation” refers to the introduction of nuclei into the


melt in order to influence the solidification process or
structural formation in the casting in a specific way. Nuclei
are fine particles that are ≤ 4 µm in size and which serve
as crystallization centers for the graphite precipitation
• The most common alloy is ferrosilicon based alloy
• The use of rusty raw material may provide in good oxygen
potential
• Pouring time should be minimised to prevent fading
losses
degassing
Degassing is a crucial step after mixing (sometimes
degassing is also required after casting) to eliminate
residual pores in the slurry. These pores can be
introduced during either mixing or the chemical reaction,
or they can form as a result of entrapped air during
casting
It is expected to obtain minimised porosity
Grain • When a high end products are

refinem done there has to be a finer


grain finish

ent • To achieve finer grain finish we


require grain refinement
treatme treatments

nts
methods
• Using
• grain refiners
• Spray forming etc
Grain refiners
• When grain refiners are added the dendritic structure will result
in faster growth and provide no time for pore formation
• Grain Refinement is meant for NON EUTECTIC Alloys Like Steel
& Al-Cu. Where as Modifier are Used For Eutectic Alloys-Like
Cast Iron With Graphite & Al-Si Alloys.For Example For Steels
Use Vanadium & Niobium as Grain Refiners.Grain Refiners
Increase the NUMBER OF GRAINS.Thus Making the Alloy
Stronger.Sodium in Al-Si
• Alters the Shape of Eutectic Silicon From Harmfull NEEDLES to
BLUNTED SILICON,Which Makes the Alloy Stronger(Grain
Modifier).Mg Changes Grey Cast Iron to S.G.Iron,where in It's
Spray forming
• Spray forming, also known as spray casting, spray
deposition[1] and in-situ compaction,[2] is a method
of casting near net shape metal components with
homogeneous microstructures via the deposition of
semi-solid sprayed droplets onto a shaped substrate. In
spray forming an alloy is melted, normally in an
induction furnace, then the molten metal is slowly
poured through a conical tundish into a small-bore
ceramic nozzle.
Concept of solidification of
metals
• A metal in molten state possess high energy. As the melt cools it
loses energy to form crystals
• Since heat loss is more rapid near mold walls than any other place
first nuclei form here
• Melt experiences difficulty in starting to crystallites if no nuclei in
the form of impurities are present to start crystallization
• However in such condition melt undercools and thus nuclei or seed
crystals form
• The crystal growth proceeds with release of crystal melt interface
• The crystal growth occur in a dendrirtic manner
• Dendritic growth takes place
by the evolution of small arms
• Then they give rise to grains
eventually more atoms are
attached to dendrites
And they form a unit cell on
repitition which arrange
themselves
• The dendrites grow
until they meet the
other dendrite and
form a grain
boundary and
finally the
dendrites become
thicker and solidify.
• Finally something like this is formed
TIME OF SOLIDIFICATION
• Chvorinov's rule is a mathematical relationship first expressed by Czech engineer
Nicolas Chvorinov in 1940,[1][2] that relates the solidification time for a simple casting to the
volume and surface area of the casting. In simple terms the rule establishes that under
otherwise identical conditions, the casting with large surface area and small volume will cool
more rapidly than a casting with small surface area and a large volume. The relationship can be
written

• SOLIDIFIACTION TIME=(VOLUME/SURFACE AREA)^n


nucleation
• Nucleation, the initial process that occurs in the
formation of a crystal from a solution, a liquid, or a
vapour, in which a small number of ions, atoms, or
molecules become arranged in a pattern characteristic
of a crystalline solid, forming a site upon which
additional particles are deposited as the crystal grows.
Homogen • Homogeneous nucleation
• Formation of a critically sized
eous solid from the liquid by the
clustering together of large
nucleation number of atoms at a high
undercooling
• Homogenous nucleation is one
occuring in perfectly
homogeneous materials such as
pure liquidmetals
• Nucleation of super cooled liquid
depends upon two factors
• 1) The free energy available from the solidification
process
• 2)the energy required to form a liquid solid interface
Heterogen • Heterogeneous
nucleation
eous • Heterogeneous
nucleation nucleation involves the
introduction of a foreign
phase or surface, typically
the nucleating agent, for
the crystal to grow on.

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