fundamentalsofmetalcasting-DepartmentofMechanical.ppt

* The pressure is maintained during liquid cooling and solidification Because the die material does not have natural permeability (like sand has), vent holes at die cavity needs to be made * Injection pressure: 7-35MPa * Injection pressure: 14-140MPa * Maraging steel - are iron alloys which are known for possessing superior strength and toughness without losing malleability. Aging refers to the extended heat-treatment process. The common, non-stainless grades contain 17–19% nickel, 8–12% cobalt, 3–5% molybdenum, and 0.2–1.6% titanium * Formation of flash: During injection, the molten metal (called flash) sticks to the surface between two halves of die, also around core. On solidification, this flash needs to be removed. * 1. Shrinkage allowance is not considerable factor in centrifugal casting because centrifugal force causes the metal to flow to compensate shrinkage 2. Horizontal axis centrifugal casting is more common. Because, in vertical axis, gravity causes more metal to flow towards bottom of mold. As a result, bottom becomes thicker than the top of casting. * D is inside diameter of mold or outside diameter of casting If GF is very low, the molten metal will not remain forced against the mold, rather it will rain inside cavity Therefore, GF must be kept between 60-80 (based on experiments) * Reasons: Fluidity of molten metal is insufficient Pouring temperature is too low Pouring is done too slowly Cross section of mold cavity is too thin Mold design is not in accordance with Chvorinov’s rule: V/A at the section closer to the gating system should be higher than that far from gating system * Reasons: Same as for misrun * Gating system should be improved to avoid splashing * The cavity (containing liquid metal) remains at upper level because liquid metal has low density as compared to solid metal. But it is not at the top because the layer of the metal has already solidified at the top due to rapid cooling there * Graphitization is the conversion of Fe3C in