Creating Quality Casting

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1 MME 6203 Lecture 01 Creating Quality Casting AKMB Rashid Professor, Department of MME BUET, Dhaka Topics to discuss today. 1. Defects in casting 2. How to create quality casting 3. Introducing MME

2 Metal castings are fundamental building blocks, the three-dimensional integral shapes indispensable to practically all other manufacturing industries. Castings can be difficult to get right. Creating things never is easy. The production of good castings can be highly economical and rewarding. The production of bad castings is usually expensive and damaging. The good casting can be defined as one that meets or exceeds the customer s specification. Creating good casting every time, without any defect is a challenge to behold! In this lecture, we shall first see the type of defects commonly ruin a casting and then discuss, generally, the method of obtaining a good casting. 2

3 1. Defects in Casting Porosity (gas hole, pin hole, blow hole) Slag, inclusion, oxide film Metal penetration Hot tear Shrinkage cavity Cold shut and miss run Porosity 3

4 Hot tear Shrinkage Cavity 4

5 Cold shut Miss run 2. How to Create Quality Casting 1. Making a perfect mould 2. Preparing a clean melt 3. Pouring efficiently of liquid metal into the mould cavity 5

6 2.1 Making a perfect mould Conical cup Cope Sprue Gate Feeder/ Riser Drag Sand Mould Core Mould Cavity Cross-section of a typical mould An Open Mould Top surface not required Liquid metal poured directly into the mould cavity Skill of moulder important A Closed Mould (Partially Sectioned) cope drag Represents the greatest of challenge Flow of liquid is controlled by the laws of fluid dynamics Skill of moulder is not important 6

7 Why is a perfect mould necessary? High temperature of liquid metal High pressure of liquid metal and dissolved gases Expansion of sand due to high temperature Reaction of liquid metal with the mould Velocity of liquid metal inside the mould cavity Turbulence of liquid metal inside the mould cavity Requirements of an ideal mould Adequate strength and hardness Adequate refractoriness Adequate permeability Appropriate design of the gating/running system Adequate use of feeder, if necessary 7

8 Method of making an ideal mould 1. Use of an appropriate moulding and casting process and use of appropriate moulding raw materials Greensand (sand-clay-water) system Dry sand (sand-chemical binder) system Gravity die / Pressure die (metal mould - high/low pressure) system 2. Use of appropriate gating and feeding design Top pouring vs. bottom pouring system Pressurised vs. unpressurised system Directional solidification vs. progressive solidification Streamlining gating system 2.2 Making a clean melt Use of appropriate, clean and dry raw materials Use of appropriate furnace Use of clean and dry furnace, ladle, and tool Removal of dissolved gas and dross from melt 8

9 Removing dissolved gases from the melt (a) (b) Flushing of inert gas Use of solid degasser Rotary degasser Removing oxide film, slag and inclusion from the melt Oxide film Slag and inclusion Screen and filter used to remove oxide film and inclusions 9

10 2.3 Efficient pouring of melt into the mould No turbulence in the liquid metal Pouring of liquid as quickly as possible Pouring of melt without any interruption MME 6203 Advanced Topics in Foundry Engineering 3.00 Credits Two 90-min classes per week Assessment Process 1. Quiz, report & presentation 20 marks 2. Mid-term examination 40 marks 3. Term final examination 40 marks 10

11 Tentative Lecture Topics 1 Introduction 2 5 Structures, defects and properties of finished castings 6 13 Ten rules of castings Treatments of liquid aluminium-silicon alloys The metallurgy and production of ductile irons References 1. J Campbell. Casting Practices The 10 Casting Rules 2. J Campbell. Castings, 2nd Edition 3. J E Gruzlesik. The Treatment of Liquid Aluminium-silicon Alloys 4. BCIRA. The Metallurgy and Production of Ductile Iron 11

12 Next Class MME 6203, Lecture 02 Structure, Defects and Properties of Finished Castings 1 Oxide film, bubble damage and shrinkage problem 12

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