制造工程及技术(热加工)10章.ppt

CHAPTER 10 Topics Introduction Solidification of Metals Fluid Flow Fluidity of Metals Heat Transfer Defects Overview of Casting Casting uses the idea that a liquid metal can take the shape of any vessel containing it. When the metal cools it has taken the shape of its container Casting is one of the most versatile manufacturing processes Advantages of Casting Low cost and quick Easier to manufacture Can produce intricate shapes and internal openings Can produce parts in one piece Best suited for composite components Introduction Important Considerations Flow of Molten Metal Solidification and Cooling Type of Mold Material Solidification of Metals Involves liquid metal turning back in to solid metal The process is different for Pure metals and alloys Can be divided into two steps: Formation of stable nuclei Growth of crystals Pure Metals Have a clearly defined melting point Temperature remains constant during freezing Solidifies from the walls of the mold toward the center of the part Grain Structure for Pure Metals Two types of grains are formed for a pure metal Fine equiaxed grains Columnar Rapid cooling at the walls produces fine equiaxed grains Columnar grains grow opposite of the heat transfer throughout the mold following the chill zone Equiaxed Grains If crystals can grow approximately equally in all directions – equiaxed grains will grow. Large amounts of under cooling is needed near the wall of the mold. Illustration of Cast Structures Alloys Solidification in alloys begins when the temperature drops below the liquidus TL and is complete when it reaches the solidus, TS. Alloys Within the TL and TS Temperature range, the alloy is like a slushy with columnar dendrites Effects of Cooling Rates Slow cool rates results in course grain structures (102 K/s) Faster cooling rates produce finer grain structures (104 K/s) For even faster cooling rates, the structures are amorphous (106 – 108 K/s) Grain size influences strength of a material Smaller