Casting Analysis - 1: Melting and Pouring

Casting Analysis - 1
Melting and Pouring

ver. 1
ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2011
Overview
Processes
Analysis
Melting
Pouring
Solidification and cooling
Surface tension
Gas solubility and porosity
Defects
Design rules
Economics
Casting Steps
quick route from raw material to finished
product
Melt metals
Pour / force liquid into hollow cavity
(mold)
Cool / Solidify
Remove
Finish
Temperature vs. Time

Temperature
pouring
melting
solidification
removal
initial
time

Melting
Raw material (charge)
Furnace
Heat
Atmosphere
scrap, alloying materials
Atmosphere
Raw materials
Air (oxygen), vacuum, inert gas (argon)
Heating
External - electric, gas, oil
Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with steel
Furnace material - refractory

high melting point metals, ceramics
Heat to melt
H rV cs Tmelt Tinitial H f cl Tpour Tmelt
H = heat [J]
r = density
V = volume
c = specific heat (s = solid, l = liquid)
Hf = heat of fusion
Melting Time
Estimate by
Energy
time
Power
Take into account oven efficiency
Melting Ex. 1-1

Calculate the time required to raise the
temperature of a 120 kg aluminum billet
from 20oC to 50oC above its melting
point using a 20 kW furnace that is 75%
efficient.

Melting Ex. 1-2

H = 120 * [0.9 * (660-20)
+ 396 + 1.05 * (710 660)]
= 123 MJ = 1.17 x 105 BTU
density = 2700 kg/m3

melting point = 660oC
heat of fusion = 396 kJ/kg
specific heat of liquid = 1.05 kJ/kg-K
specific heat of solid = 0.9 kJ/kg-K
Melting Ex. 1-3

time = 123 MJ / (20 kW * 75%)
time = 2.3 hours
Should probably buy a bigger furnace

10
Pouring - Fluid Flow

Reynolds number
Bernoullis equation
Continuity

11
Reynolds number (Re)

ratio of momentum (inertia) to viscosity
rVd
Re
density velocity diameter
viscosity

12
Critical Reynolds number

Re < 2,000
viscosity dominated, laminar flow
Re > 20,000
inertia dominated, turbulent flow
Controlled through gate and runner

design

13
Bernoullis Equation
Used to calculate flow velocities
Assumptions: steady state, incompressible, inviscid
flow
Po
rv
2
o
P = pressure
r = density
v = velocity
rgho P1
rv
2
1
rgh1 f
g = gravity
h = height
f = losses due to friction

14
Continuity
Q0 = Q1
A0v0 = A1v1
where:
Q = volumetric flow rate
A = area
v = velocity
Assumption: incompressible flow
15
Pouring Ex. 2-1

Determine the geometry of the sprue, so that
there is no air aspiration (the pressure never
is less than atmospheric).
pouring basin
sprue
1
hc
2
ht
1 = free surface of metal

2 = spue top
3 = sprue bottom

16
Casting Ex. 2-2

P1
rv12
2
Assuming
rgh1 P3
rv32
2
rgh3
entire mold is at atmospheric pressure (no

point below atmospheric)
metal in the pouring basin is at zero
velocity (reservoir assumption)
v3 2 ght
17
Casting Ex. 2-3

Similarly
P1
rv12
2
rgh1 P2
rv22
2
rgh2
v2 2 ghc

18
Casting Ex. 2-4

By continuity
A2v2 = A3v3
Hence
A3 v2
A2 v3
hc
ht

19
Mold Filling Time Estimate

Using continuity
Q = Ag vg =A3 v3
Assuming Ag = A3
vgate v3 2ght
Hence
Volume of mold
Mold filling time
Agatevgate
20
Pouring Ex. 3-1

Given
height of sprue (ht) = 20 cm
area of sprue (A3) = 2.5 cm2
volume of mold cavity (V) = 1560 cm3
Find
vsprue
Flow rate (Q)
Mold filling time
21
Pouring Ex. 3-2

vbase of sprue 2 ght 2 * 981 * 20 198.1 cm/s
Q = vbase of sprue *A3

= 198.1 * 2.5 = 495 cm3/s
Mold filling time = V/Q =1560 / 495 = 3.2 s
22
Bottom Gated Systems

Air forced up and out of mold
Reduced splashing and oxidation
As metal is poured into the system,
effective head is reduced.
Ag = gate cross-sectional area
Am = mold cross-sectional area
ht
h hm
23

In time dt,
height of metal in mold increases dh
flow rate in mold, Qm = Amdh/dt
flow rate of metal delivered by gate to mold,
Qg = Agvg, where
vg 2 g ht h

24

Equating Qm = Qg,
Amdh Ag 2 g ht hdt
If tf = filling time,
1
2g
hm
tf
Ag
dh
dt
ht h Am 0
2 Am
t f
Ag 2 g
ht ht hm

25
Pouring - Ex. 4-1

You are pouring liquid iron into a mold.
The mold has a sprue height of 2 inches.
The bottom of the sprue has a diameter
of 0.2 in.
Risers
Cope
Sprue
Gate
Parting Line
Drag
Casting

26
Pouring - Ex. 4-2

You wish to pour the metal so that you do
not entrain air.
What should the diameter of the gate
(dgate) be?

27
Pouring - Ex. 4-3

Here we need to use:
Reynolds number
Values below 20,000 are OK in casting
To prevent entrainment of air resulting from
turbulence
Bernoullis equation
Continuity

28
Pouring - Ex. 4-4

Iron data:
density (r = 7860 kg/m3

viscosity at pouring temp ( = 2.25 cp
= 2.25 x 10-3 N*s/m2
h0 = 2 in. = 0.051 m
h1 = 0 m
g = 9.8 m/s2
A1 = pr2 = 3.14 * 0.002542 =
2.03 x 10-5 m2
29
Pouring - Ex. 4-5

Now we need to determine the
velocity at the bottom of the sprue
(v1) using Bernoullis equation.

30
Pouring - Ex. 4-6

We can assume that the velocity
at the top of the mold (vo) is zero,
if there is a pouring basin, which is
typical.

31
Pouring - Ex. 4-7

Ignore friction effects (f=0).
Assume the mold is open to
atmospheric pressure
(P0=P1=Patm).
Ignore the effect of the height of
the metal in the mold.

32
Pouring - Ex. 4-8

Substituting into Bernoullis equation:
Po
rvo2
2
rgho P1
rv12
2
rgh1 f
7860 02
Patm
7860 9.8 0.051
2
7860 v12
Patm
7860 9.8 0 0
2

33
Pouring - Ex. 4-9

And solving:
v1 = 1 m/s
Checking Reynolds number
Re = 7860*1*0.00508/2.25x10-3
=17,746 < 20,000

34
Pouring - Ex. 4-10

Now using continuity:
A1v1 = Agatevgate =
2.03 x 10-5 * 1 = Agatevgate
and Agate = prgate2

35
Pouring - Ex. 4-11

Now, Reynolds number < 20,000
rVd 7860 vgate d gate

Re
20,000
-3
2.25 10
Solving gives:
vgate*dgate = 5.72 x 10-3 m2/s

36
Pouring - Ex. 4-12

Combining the following equations:
2.03 x 10-5 * 1 = Agatevgate
Agate = prgate2
vgate*dgate = 5.72 x 10-3 m2/s

37
Pouring - Ex. 4-13

And solving gives:
dgate = 4.5 mm = 0.18 in.
A not unreasonable answer, given
the sprue is 5 mm in diameter.
38
Data for Solid Materials

Room Temperature
Material
Sand
Aluminum
Nickel
Magnesium
Copper
Iron
Steel
Specific heat Density

(kJ/kg-oC)
(kg/m3)
1.16
0.90
0.44
1.03
0.38
0.46
0.434
1500
2700
8910
1740
8960
7860
7832
Thermal
conductivity
(W/m-oC)
0.60
222
92.1
154
394
75.4
59

39
Data for Liquid Metals

Material
Melting Density Latent heat Thermal

Specific Viscosity
conductivity heat
point (oC) (kg/m3) of
(mPa-s)
solidification (W/m-oC)
(kJ/kg-oC)
(fusion)
(kJ/kg)
Aluminum
660
2390
396
Nickel
1453
7900
297
Magnesium
650
1585
384
Copper
1083
7960
220
Iron
1537
7150
211
94
1.05
4.5
0.73
4.1
139
1.38
1.24
49.4
0.52
3.36
0.34
2.2

40
Summary
Analysis
Melting
Pouring
Solidification and cooling
Surface tension
Gas solubility and porosity

41

42

Casting Analysis - 1: Melting and Pouring

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Casting Analysis - 1

Melting and Pouring

ME 6222: Manufacturing Processes and Systems

Temperature vs. Time

ME 6222: Manufacturing Processes and Systems

scrap, alloying materials

Air (oxygen), vacuum, inert gas (argon)

Furnace material - refractory

H rV cs Tmelt Tinitial H f cl Tpour Tmelt

Melting Ex. 1-1

ME 6222: Manufacturing Processes and Systems

Melting Ex. 1-2

density = 2700 kg/m3

Melting Ex. 1-3

ME 6222: Manufacturing Processes and Systems

Pouring - Fluid Flow

ME 6222: Manufacturing Processes and Systems

Reynolds number (Re)

density velocity diameter

ME 6222: Manufacturing Processes and Systems

Critical Reynolds number

Controlled through gate and runner

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Pouring Ex. 2-1

1 = free surface of metal

ME 6222: Manufacturing Processes and Systems

Casting Ex. 2-2

entire mold is at atmospheric pressure (no

Casting Ex. 2-3

ME 6222: Manufacturing Processes and Systems

Casting Ex. 2-4

ME 6222: Manufacturing Processes and Systems

Mold Filling Time Estimate

Pouring Ex. 3-1

Pouring Ex. 3-2

Q = vbase of sprue *A3

Bottom Gated Systems

Bottom Gated Systems

ME 6222: Manufacturing Processes and Systems

Bottom Gated Systems

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-1

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-2

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-3

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-4

density (r = 7860 kg/m3

Pouring - Ex. 4-5

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-6

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-7

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-8

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-9

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-10

ME 6222: Manufacturing Processes and Systems

Pouring - Ex. 4-11