Casting Processes

Fundamentals of Casting

Quoc-Nguyen Banh, PhD

Faculty of Mechanical Engineering
Ho Chi Minh City University of Technology

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Ship’s propeller Pudding cake
Casting processes
• Pouring molten metal in a mold
• Allow the metal to solidify
• Remove the part form the mold
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Fundamentals of Casting

• Surface Tension vs Viscosity

• Basic Rules of fluid flow
• Solidification of Metals

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Surface tension vs Viscosity

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Surface tension

• Surface tension elastic-like

force existing in the surface
of a body, especially a
liquid, tending to minimize
the area of the surface
𝐹
𝛾=
𝐿
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 flow with no viscosity
flow with viscosity
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Viscosity
Viscosity: friction due to momentum
transfer between adjacent fluid layers
or between fluid & wall.
The viscosity is a fluid property of
resistance to flow. The viscosity of
liquids arises primarily from the
intermolecular forces within the liquid.
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Q-N Banh, Dept. Manufacturing Engineering
 Surface tension vs Viscosity

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Effects of surface tension and viscosity on fluidity
source: courtesy of MIT, USA 8
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Testing Fluidity for Casting

Fluidity index = how far metal can go along spiral pathway

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Bernoulli’s theorem

• Energy conservation 10
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Conservation of Mass
Conservation of mass:
1 A1 v1   2 A2 v2

Equation of continuity for steady flow:

Mass flow rate =  A v  const   v  A

Liquid: [  v A ] = kg / s

Volume flow rate = A v  const  vA

A1 V 1  A2 V 2
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Solidification of Molten Metal

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Pure Metal vs Alloys

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 Chrivonov’s rule

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 THANK YOU
FOR YOUR ATTENTION!

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