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In a casting process, the material is first heated to completely melt and then poured into a
cavity of the mold. As soon as the molten metal is in the mold, it begins to cool. When the
temperature drops below the freezing point (melting point) of the material, solidification starts.
Solidification involves a change of phase of the material and differs depending on whether the
material is a pure element or an alloy. A pure metal solidifies at a constant temperature, which is its
melting point (freezing point). For alloys, the solidification occurs over a temperature range
depending upon the composition. A typical cooling curve for Ni-Cu system is given in Figure 6.2.
(a) (b)
Figure 6.3. Characteristic grain structure of (a) a pure metal, and (b) an alloy.
Objective:
1. To identify the importance of phase diagram.
2. To illustrate the use of cooling curves to determine chemical compositions of alloys using a
series of Sn-Pb solder alloys.
3. To calculate the amount of heat extracted from pure Sn during various stages of
solidification.
2 January 9, 2010
IE 337: Materials and Manufacturing Processes Lab # 6
Casting and Solidification Process
Equipment & Materials:
1. Compositions of Sn-Pb solder
a. Pure Sn
b. Mystery composition
c. 40/60 (Sn/Pb)
d. Eutectic composition
2. 4 crucibles
3. Butane torch
4. Digital multi-meter with temperature probe
5. Safety glasses and gloves
Procedure:
1. Get four samples of solder from lab instructor. Weigh and label each sample.
2. Place the work piece in the crucible and ignite the butane torch.
3. Slowly and carefully heat the bottom of the crucible until the solder is completely molten.
(DANGER! Crucible will shatter if heated too quickly!)
4. Turn the multi-meter on and place the end of the temperature probe in the crucible.
5. When the temperature stabilizes, remove the flame and immediately record the temperature.
6. Record the temperature every 10 seconds until the sample is completely cooled.
7. Repeat steps 1-6 for other three compositions of solder.
Lab Deliverables:
1. Prepare a report detailing the lab activity, observations, results and difficulties faced
(follow the lab report instructions).
2. Plot the temperature vs. time graph for each of the four samples.
3. Determine the composition of mystery alloy from the phase diagram provided.
4. Describe the dendrite structure formation in a pure metal and an alloy. Why the structures
are different?
5. What is the difference between a pure metal cooling curve and an alloy cooling curve?
Support your answer with clear diagrams.
6. Compare heat transfer rates for pure tin at three different time intervals using the cooling
curve plots obtained and the equations given.
T Temperature (K)
t time (min)
m Mass (g)
C specific heat (J/(g·K))
L latent heat of fusion (for Sn = 14.5 cal/g)
Q˙ heat transfer rate (J/min)
References:
1. M.P. Groover, “Fundamentals of modern manufacturing,” 3rd edition, (2007).
2. Metals Handbook, 9th edition, vol. 16, ASM International, Materials Park, Ohio, 1989.
3. www.wikipedia.org
3 January 9, 2010