the new metallurgy of cast metals
TRANSCRIPT
![Page 1: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/1.jpg)
Casting Technology
AFI Conference
John Campbell
University of Birmingham UK
2020
![Page 2: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/2.jpg)
![Page 3: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/3.jpg)
![Page 4: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/4.jpg)
![Page 5: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/5.jpg)
![Page 6: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/6.jpg)
Top gated turbulent filling
![Page 7: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/7.jpg)
Bottom gated laminar filling
![Page 8: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/8.jpg)
Entrainment Defects
1. Bifilms
2. Bubbles
![Page 9: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/9.jpg)
Surface Turbulence
generating
Bifilm Cracks
in the Liquid Metal
![Page 10: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/10.jpg)
![Page 11: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/11.jpg)
Bifilms in Al-5Mg alloy
![Page 12: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/12.jpg)
10 mm 10 mm
RPT Before and After Reduced Pressure
![Page 13: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/13.jpg)
The range of ingate velocities
![Page 14: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/14.jpg)
Optimum Filling Speed Range
0.5 to 1.0 m/s
for all liquid metals
![Page 15: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/15.jpg)
Al-4.5Cu fracture surfaces
1. Oxide covered 2. Ductile fracture
(0.3 % Elongation) (3 % Elongation)
![Page 16: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/16.jpg)
Bubble Damage
![Page 17: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/17.jpg)
Bubbles plus Bubble Trails
![Page 18: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/18.jpg)
![Page 19: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/19.jpg)
Bubble and trail in Zn alloy
high pressure die casting
![Page 20: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/20.jpg)
![Page 21: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/21.jpg)
Bubble trail in
Al-7Si-0.4Mg Alloy
![Page 22: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/22.jpg)
Bubble trail in Al alloy
![Page 23: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/23.jpg)
Silicate glass bubble trails in grey iron
![Page 24: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/24.jpg)
Silicate glass bubble trails in grey iron
![Page 25: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/25.jpg)
Casting Technology
![Page 26: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/26.jpg)
10 Rules(The 10 Commandments by JC)
1. Use good metal
2. Not too fast (no turbulence)(0.5m/s)
3. Not too slow (no stopping)
4. No entrained bubbles
5. No core blows
6. Feed shrinkage if necessary
7. Avoid convection
8. Avoid segregation
9. Avoid stress
10. Provide pick-up locations
![Page 27: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/27.jpg)
Temporary
Damage
![Page 28: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/28.jpg)
Permanent
Damage
![Page 29: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/29.jpg)
Gravity Filling
Systems
![Page 30: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/30.jpg)
Top gated turbulent filling
![Page 31: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/31.jpg)
![Page 32: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/32.jpg)
Typical
vacuum
melting
and casting
furnace
Hopeless!
![Page 33: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/33.jpg)
Top Gated Bad
Top Gated
from side Bad
Gated at
Joint
Probably bad
Bottom gated
from side Possibly acceptable
Bottom
gated Acceptable
True
Counter
Gravity
Excellent
![Page 34: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/34.jpg)
Top Pour
Ladle
Pouring stream
Mould
![Page 35: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/35.jpg)
Top Pour Bottom Gate
Conical
Pouring
Basin
![Page 36: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/36.jpg)
Top Bottom Contact
Pour Gating Pour
Air-sealed
contact
![Page 37: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/37.jpg)
![Page 38: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/38.jpg)
Practical Design
of
Filling and Feeding Systems
![Page 39: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/39.jpg)
Poor filling system
Cope
and
drag
![Page 40: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/40.jpg)
Correctly
bottom-
gated
but
awful!
No
control
of speed.
![Page 41: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/41.jpg)
Air entrainment by a
Conical Pouring Basin(Common bad
practice for steels)
![Page 42: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/42.jpg)
We need to control
1. Speed (less than 1 m/s)
2. Air entrainment
![Page 43: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/43.jpg)
Vortex
Gate
![Page 44: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/44.jpg)
Trident
Gate
![Page 45: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/45.jpg)
![Page 46: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/46.jpg)
Side Filter
Sholes system
(3 or 4-part mould)
![Page 47: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/47.jpg)
![Page 48: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/48.jpg)
The latest
development
in gravity
pouring to
achieve a
defect-free
casting
![Page 49: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/49.jpg)
Side Filters
2-part mould
![Page 50: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/50.jpg)
Counter-Gravity
![Page 51: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/51.jpg)
Bottom gated laminar filling
![Page 52: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/52.jpg)
Low Pressure Die Casting
![Page 53: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/53.jpg)
![Page 54: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/54.jpg)
Cosworth
Mark II
![Page 55: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/55.jpg)
Al Alloy Continuous Production of
Castings using Sedimentation
![Page 56: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/56.jpg)
The End
![Page 57: The New Metallurgy of Cast Metals](https://reader030.vdocuments.site/reader030/viewer/2022012013/6158aba807e3441e4011353b/html5/thumbnails/57.jpg)