M2794.

001800 M A T E R I A L A N D M A N U F A C T U R I N G P R O C E S S E S

Chapter 5. Metal-Casting
Processes and Equipment;
Heat Treatment

Prof. Ahn Sung-Hoon ( )

School of Mechanical and Aerospace Engineering
Seoul National University
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Historical casting parts

Korean bronze dagger( ( )) Bronze bell( )

& molds( )

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Casting
 Casting is a manufacturing process by which a molten material such as metal or
plastic is introduced into a mold made of sand or metal, allowed to solidify within
the mold, and then ejected or broken out to make a fabricated part.

 Advantages
 Making parts of complex shape in a single piece.
 Producing large number of identical castings within specified tolerances.
 Good bearing qualities and jointless product.

 Disadvantages
 Limitations of mechanical properties because of the polycrystalline grain structure.
 Poor dimensional accuracy due to shrinkage of metal during solidification.
 If the number of parts cast is relatively small, the cost per casting increases rapidly.

 Fundamental aspects in casting operations

 Solidification of the metal from its molten state.
 Flow of the molten metal into the mold cavity.
 Heat transfer during solidification and cooling of the metal in the mold.
 Mold material and its influence on the casting process.

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Solidification of Metals

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Solid solution
 Solute( )
 Solvent( )

 When the particular crystal structure of the solvent is maintained during alloying,
the alloy is called solid solution.
 Substitutional solid solution( )
 Interstitial solid solution( )

 5.2.2 Intermetallic compound( )

 Complex structures in which solute atoms are present among solvent atoms in certain specific
proportions.

 5.2.3 Two-phase system( )

 Phase: a homogeneous portion of a system that has uniform physical and chemical characteristics

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Polycrystalline alpha brass

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Phase diagram ( )
Graphically illustrates the relationships among temperature, composition,
and the phase present in a particular alloy system.

Lever Rule
S C  CL
 O
S  L CS  CL
L C  CO
 S
S  L CS  CL

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Lever-Rule ( )

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Eutectic system, Pb-Sn

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Types of 3-phase invariant reactions

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Iron-carbon system (1)

 Pure iron( ) : 0.008% C
 Steels( ) : 2.11% C
 Cast irons( ) : ~6.67% C
 a-ferrite( ): BCC, soft and ductile
 d-ferrite: BCC, stable only at very high temperatures
 Austenite( ) : FCC, ductile
 Cementite( ): Fe3C, C 6.67%, iron carbide( ), brittle

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a-ferrite & austenite

a-ferrite (x 90) Austenite (x325)

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Iron-carbon system (2)

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Eutectoid steel
 a- ferrite: white
 Fe3C: dark

 Lamellar structure
(pearlite)

 (x 500)

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1% carbon (hypereutectoid) pearlite steel

 a- ferrite - white
 eutectoid - cementite -
blue
 proeutectoid -
cementite - violet

 (x 500)

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Classification of ferrous alloys

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Composition and naming steels

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Amount of phases in carbon steel

Casting 1040 steel 10kg, calculate a phase and g phase at (a) 900 C,
(b) 728 C and (c) 726 C

(a) Austenite:100% g

 Cg  Co 
(b) a (%)   100   0.77  0.40 100  50%, that is 5kg,
C C   0.77  0.022 
 g a 

 Co  Ca 
g (%)   100   0.40  0.022 100  50%, that is 5kg,

 Cg  Ca   0.77  0.022 

6.67  0.40 
(c) a   100  94%, that is 9.4kg
 6.67  0.022 

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Cast irons
 Fe, C 2.11~4.5%, Si ~3.5%

 According to solidification
morphology :

Gray cast iron( )

 Flake graphite( )
 Gray fracture surface( )
 Damping( )
Ductile(nodular) iron( )
 Ductile
White cast iron( )
 Large amount of Fe3C
 Brittle
 White fracture surface( )
Malleable cast iron( )
 Obtained by annealing white cast iron
Compact graphite iron( )

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Cast irons

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Cast irons

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Ternary phase diagram

 Fe-Cr-Ni

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Cast structures
 Pure metal vs. alloys

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Dendrites ( )

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Dendrites

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Fluid flow

v  c 2 gh
p v2
h   constant
g 2 g
2 2
p v p v
h1  1  1  h2  2  2  f
g 2 g g 2 g
Q  A1v1  A2 v2
A1 h
 2
A2 h1
vD
Re 


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Solidification time & shrinkage

 Chvonrinov’s rule
Solidification time
= C(volume/surface area)2

 Shrinkage occurs at
 Molten metal
 Phase change
 Solid metal

 Cast iron expands

 Graphite has high volume/mass
 Net expansion during
precipitation

 Similarly Bi-Sn alloys expand

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Defects/DFM

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Casting alloys

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Applications

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Properties

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Casting processes
 Expendable mold,
permanent pattern
 Sand casting
 Shell-mold casting
 Plaster mold casting
 Ceramic mold casting
 Vacuum casting

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Casting processes (2)

 Expendable mold, expendable pattern
 Evaporative-pattern casting (lost foam)
 Investment casting (lost wax)

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Investment casting

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Casting processes (3)
 Permanent mold
 Slush casting
 Pressure casting
 Die casting
 Centrifugal casting
 Squeeze casting
 Semisolid metal forming
 Casting for single crystal
 Rapid solidification
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 In permanent-mold casting, a mold are
made from materials such as steel,
bronze, refractory metal alloys, or
graphite. Because metal molds are better
heat conductors than expendable molds,
the solidifying casting is subjected to a
higher rate of cooling, which turn affects
the microstructure and grain size within
the casting.
 Cooling methods : water, air-cooled fin
 Used for aluminum, magnesium, and
copper alloys due to their lower melting
points
 Pros : good surface finishing, close
dimensional tolerances, and uniform and
good mechanical properties
 Cons : not economical for small
production runs, not good for intricate
shapes
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Pressure casting/centrifugal casting

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Die casting
 Hot-chamber process
 Cold-chamber process

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Squeeze casting/single crystal

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Casting for single crystal

Crystal-pulling method floating-zone

(Czochralski process) method

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Heat treatment-ferrous alloys

 Pearlite
 Spheroidite
 Bainite
 Martensite
 Quenching( )
 Body Centered Tetragonal(BCT)
 Retained austenite
 Tempered martensite

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Transformation-ferrous alloys

Austenite

Slow cooling Quenching

Moderate
cooling
Pearlite Martensite
(a+Fe3C)
(+proeutectic a) Bainite
reheat

(a+Fe3C)
Tempered
martensite

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Ferrous alloys

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Shape memory alloy (SMA)

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Quenched AISI 9310 steel

 The white strikes are
excess proeutectoid
cemetite
 Cream color is
retained austenite
 Gray area is bainite
 Blue/brown regions
are martensite

 (x 320)

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Nonferrous alloys/stainless steel (1)

Precipitation hardening Age hardening( )

( ), Al-Cu alloy

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Nonferrous alloys/stainless steel (2)

 Solution treatment
 Precipitation hardening
 Aging
 Maraging(martensite + aging)

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Case hardening
 Surface hardening
 Carburizing ( )
 Carbonitriding ( )
 Cyaniding ( )
 Nitriding ( )
 Boronizing ( )
 Flame hardening ( )
 Induction hardening ( )

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Annealing ( )/ tempering ( )
 Normalizing( )

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Design consideration (1)

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Design consideration (2)

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Design consideration (3)

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Economics of casting

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Case study

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Bridge design

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Material of the bridge

Another bridge

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