Professional Documents
Culture Documents
Segregation in Casting
Segregation in Casting
by
1. Introduction ……………………………3
2. Microsegregation……………………….5
3. Macrosegregation………………………8
4. Dendritic segregation………………….12
5. Gravity segregation……………………14
6. Reference ……………………………...17
2
Abstract
Introduction
3
removed by diffusion In general, therefore, whatever
macrosegregation occurs has to be lived with. [1]
4
Microsegregation
5
(a)
(b)
6
Where microsegregation results in the appearance of a new
liquid interdendritic phase, there are a number of
consequences that may be important: [1]
1. The presence of a eutectic phase reduces the
problem for fluid flow through the dendrite mesh.
2. The alloy may now be susceptible to hot tearing,
especially if there is only a very few percent of the
liquid phase.
3. A low-melting-point phase may limit the
temperature at which the material can be heat
treated.
4. A low-melting-point phase may limit the
temperature, at which an alloy can be worked, since
it may be weakened, disintegrating during working
because of the presence of liquid in its structure. [1]
7
Macrosegregation
8
The positive segregation is often found at the top and is the
result of segregated liquid flow toward the top and the
negative zone with more pure material at the bottom of the
ingot is explained by sedimentation of equiaxed crystals
formed in the bulk liquid. [4]
Figure 2 shows a plot over the segregation ratio, C/C0 of
carbon and sulphur in the rectangular ingot. As to be
expected the macrosegregations follow the well known
behavior. [4]
In the figure, the concentration along three horizontal lines,
representing three height levels, from surface to centre are
shown to the left, the centerline segregation is shown in the
middle and the position of each drill sample are shown to
the right. [4]
A sulphur print of the corresponding surface is shown in
figure 3. In this ingot, an increase of the segregation ratio is
seen toward the top. At the bottom of the ingot a somewhat
increasing negative segregation is found. [4]
9
Figure 2: Segregation ratio of S and C. Sample location is shown in the right figure.
10
Figure 3: Sulphur print of vertical cross-section of rectangular ingot.
11
Dendritic segregation
Figure 4: Normal dendritic segregation (usually misleadingly called inverse segregation) arising as a result
of the combined actions of solute rejection and shrinkage during solidification in a temperature gradient.
12
all the flow is in the direction towards the wall,
concentrating the segregation here. Thus the presence of a
temperature gradient is necessary for a significant build-up
of segregation. [1]
Dendritic segregation is observable but is not normally
severe in sand castings because the relatively low
temperature gradients allow freezing to occur rather evenly
over the cross-section of the casting; little directional
freezing exists to concentrate segregates in the direction of
heat flow.
It will by now be clear that this type of segregation is in
fact the usual type of segregation to be expected in
dendritic solidification. [1]
13
Gravity segregation
14
Figure 5: Development of segregation in a killed steel ingot (a) during solidification and (b) in the final ingot.
15
On sectioning the ingot transversely, and etching to reveal
the pattern of segregation, the A and V segregates appear as
a fairly even distribution of clearly defined spots, having a
diameter in the range of 2-10 mm. probably depending on
the size and shape of the ingot, they may be concentrated at
mid-radial to central positions in zones, or evenly spread. [1]
Negative segregation is distributed in a cone at the base of
the ingot. [6]
Negative segregation has less solute than the average for
the ingot and it increasing by increasing the width of the
ingot. [1]
Although few ingots are cast in modern steelworks, large
steel castings continue to be made in steel foundries. Such
castings are characterized by the presence of channel
segregates, in turn causing extensive and troublesome
macrosegregation. Channel segregates can be controlled
by:
1. Decreasing the time available for their formation by
increasing the rate of solidification.
2. Adjusting the chemical composition of the alloy to
give a solute-rich liquid that has more nearly neutral
buoyancy at the temperature within the freezing zone.
[1]
16
Reference
17