02PATTERNS.ppt-DSS-(NIT)Calicut.ppt

STRUCTURE  FOR PURE METALS: At the mould walls, metal cools rapidly. Produces solidified skin or shell (thickness depends on composition, mould temperature, mould size and shape etc) These are of equiaxed structure. Grains grow opposite to heat transfer through the mould These are columnar grains Driving force of the heat transfer is reduced away from the mould walls and blocking at the axis prevents further growth PURE METALS- Have clearly defined melting/freezing point, solidifies at a constant temperature.  Eg: Al - 6600C,  Fe - 15370C,  and W- 34100C.  FOR ALLOYS: Alloys solidify over a range of temperatures Begins when temp. drops below liquidous, completed when it reaches solidous. Within this temperature range, mushy or pasty state (Structure as in figure) Inner zone can be extended throughout by adding a catalyst.- sodium, bismuth, tellurium, Mg (or by eliminating thermal gradient, i.e. eliminating convection. (Expts in space to see the effect of lack of gravity in eliminating convection) (refresh dendritic growth- branches of tree, interlock, each dendrite develops uniform composition, etc) CHVORINOV’S RULE solidification time (t) is a function of volume of the casting and its surface area t = C ( volume/ surface area )2C is a constant [depends on mould material, metal properties including latent heat, temperature]A large sphere solidifies and cools at a much slower rate than a small diameter sphere. (Eg- potatoes, one big and other small)  Volume ? cube of diameter of sphere,  surface area ? square of diameter Solidification time for various shapes: SOLIDIFICATION CONTRACTION FOR VARIOUS METALSMETAL Volumetric Solidification Contraction Al 6.6 Grey cast Iron Expansion 2.5 Carbon Steel 2.5 to 3 Copper 4.9Magnesium 4.2