MY4130 Mid-term Exam-Key Wednesday, Oct.

8, 2003

Name:___________________
1. (14 pts) Given the following information for pure aluminum:
CS(solid) = 917 J kg-1 oC-1, CL(liquid) = 1,080 J kg-1 oC-1, H(fusion) = 395,995 J kg-1
The melting point of aluminum is 660 oC.
Given the following information for pure iron:
CS(solid) = 456 J kg-1 oC-1, CL(liquid) = 795 J kg-1 oC-1, H(fusion) = 272,090J kg-1
The melting point of iron is 1536 oC
Compute the heat in Joules needed to melt and heat to 100 oC superheat, 1000 kg of pure Fe and Al .

Assume room temperature: T0 = 20 oC

QAl = W[CS(Tm-T0) + H + CL(Tp-Tm)] = 1000[917(660-20) + 395,995 + 1080 x 100] = 1.09 x 109 Joul
QFe = W[CS(Tm-T0) + H + CL(Tp-Tm)] = 1000[456(1536-20) + 272,090 + 795 x 100] = 1.04 x 109 Joul

2. The Al-Si phase diagram is given below:

Al-Si System
1414 C

660 C
A
C
B 577 C
D
T (C)

1.65 12.6

Co WT. % Si

a. (10 pts) Label the blank phase fields in the above phase diagram
A: _______L__________, B: ________L + (Al)__________, C: _________L + Si___________,
D: _______(Al)__________, E: _______ + Si___________,
b. (6 pts) Briefly describe the microstructure in a sand-casting of alloy Co?

(Al) dendrites + eutectic silicon flaks (or eutectic silicon fibers if mdified with Sr, Na etc.)

c. (10 pts) If rheocasting process is used for alloy Co briefly describe the process in steps. What are the
advantages of this process?
 Process: 1. Melt alloy (heat alloy to A region – above TL), 2. Hold alloy at T in B region (+L)
and stir the semi-solid melt, 3. casting
 Advantages: 1. fine globular microstructure – good mechanical properties; 2. Energy saving.
2. (10 pts) What are the two possible causes for porosity formation in castings? What are the technical 
solutions to prevent such a defect?
  Gaseous porosity: Degassing & improve the gating system design
 Shrinkage porosity: Risering

4. Pure Al has the following physical properties
liquid density at 760 oC = 2.35 g/cm3,            liquid density at 660 (melting point) = 2.385 g/cm3
solid density at 660 = 2.544 g/cm3,                 solid density at room temperature = 2.7 g/cm3
linear expansion coefficient of solid aluminum ,  = 23.9 x 10­6/oC
A  casting with dimensions of 250 x 250 x 60 mm below was to be poured with pure molten aluminum at 
760 oC. 

Plate Casting: 250 x 250 x 60 mm

a. (6 pts) What should be the length of the pattern for this casting if there is no need for machining?
(L – LC)/LC = (Tm­T0)
L = LC[1 + (Tm­T0)] = 250[1 + 23.9 x 10­6(660­20)] = 253.824 (mm) 25.38 cm
b. (10 pts) This casting (not including the one riser needed) above needs to be poured in less than 10
seconds. Assuming that there is no friction, turbulence or heat loss in this pouring operation, with a
constant head of 25 cm, determine the ingate area, A, which would do the job in 9 seconds. Assume in
this instance that the ingate area is the smallest cross sectional area in the gating system. Recall that the
energy along a line of flow E = h + v2/2g + P/, where g = 975.3 cm/sec2, h = head, v = velocity, P =
pressure and  = density. Recall also the law of continuity, A1v1 = A2v2
Velocity at Ingate: v = (2gh)1/2 = (2 x 975.3 x 25)1/2 = 220.83 (cm/sec)
Volume: V = 25.4 x 25.4 x 6 = 3871 cm3
Filling Time: t = V/(vA), Ingate Area: A = V/(tv) = 3871/(9 x 220.83) = 1.95 (cm2)
c. (6 pts) Estimate the modulus of this casting.
MC = V/A = 250 x 250 x 60/(250 x 250 x 2 + 250 x 60 x 4) = 20.3 (mm)
d. (8 pts) If insulating sleeve was used for riser and the Solidification Constant, B(Sleeve)/B(Mold) = 1.5,
estimate the riser size (side riser with H = 2D) needed to satisfactorily feed this casting.
Method I:
t(Riser) > t(Casting)  BSleeveMR2 > BMoldMC2  MR2 > 1/1.5 x (20.3)2 = 274.73 (mm2)
MR>16.57 mm  MR = 1.1 x 16.57 = 18.23 mm = /2 x D3/(/2 x D2 + D x 2D) = D/5 (Side Riser)
 D = 91.16 mm & H = 2D = 182.32 mm
Method II:
Without sleeve: MR’ = 1.1 MC = 1.1 x 20.3 = 22.33 (mm)
With sleeve: BMR2 (Sleeve) = B’MR’2 
 MR (sleeve) = [B’(Mold)/B(Sleeve)]1/2 MR’ = (1.5)­1/2 x 22.33 = 18.23 (mm)
e. (4 pts) Determine the weight in kg of the plate casting (not including the riser) at the instant it is filled
at 760oC.
 WC =  L x V = 2.35 x 25.38 x 25.38 x 6 = 9.08 (kg)
f. (5 pts) Determine the weight in kg of the riser at the instant it is poured at 760oC.
WR =  L x VR = 2.35 x /2 x 9.1163 = 2.8 (kg)
g. (5 pts) Determine the total weight of aluminum poured assuming that 1 kg was involved in the gating
system (assume that the gating system solidifies first, independent of the riser and the casting).
WT = WC +WR + WG = 9.08 + 2.8 +1 = 12.88 (kg)
h. (6 pts) Determine the casting yield.
CY =  SVC/WT x 100% = 2.7 x 25 x 25 x 6/12880 x 100% = 78.6%