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You are in the following session:

SESG3024/SESM6044 Manufacturing and Materials
W8 Monday Tutorial 05 Casting
The session will start at 17:00 20 Nov. Attend.
Code: 322 655

How is everyone? take me back to yr 1

Draw! Write! good! loving life

I don't know what

homogenous
nucleation is :(

Ok, we'll talk about it :)

how did manufacturing suddenly become hard

feels the same.

;(
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 Manufacturing and Materials

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Draw! Write!

4
 Manufacturing and Materials

Module Schedule Summative assessments:

(Tests 10% & CW 20%)
Formative assessments:
(helps learn, no mark)
Week Lecture Topic Question Sets BB Tests & Coursework Tutorial Sessions
(W/C) (live & in-person) (independent study) (deadlines in red) (live & online)
W1 01: Introduction 1/2 (AH) T01a: EduPack 01: Intro. None
(2 Oct.) 01: Introduction 2/2 (AH)
W2 02: Polymer Processing 1/3 (AH) T01b: Introduction EduPack Software Demo
(09 Oct.) 02: Polymer Processing 2/3 (AH) (No submission)
W3 02: Polymer Processing 3/3 (AH) T02: Polymers 02: Polymers T01a: EduPack Exercises
(16 Oct.) 03: Bulk Forming 1/2 (AH) (Formative submissions begin)
W4 03: Bulk Forming 2/2 (AH) T03: Bulk Forming 03: Bulk Forming T01b: Introduction
(23 Oct.) 04: Sheet Forming 1/2 (AH)
W5 04: Sheet Forming 2/2 (AH) T04: Sheet Forming 04: Sheet Forming T02: Polymers
(30 Oct.) 05: Solid. & Casting 1/4 (PR)
W6 05: Solid. & Casting 2/4 (PR) T03: Bulk Forming
(6 Nov.) 05: Solid. & Casting 3/4 (PR)
Today: Formative
W7 05: Solid. & Casting 4/4 (PR) T05: Solid. & Casting 05: Solid. & Casting T04: Sheet Forming
06: JoiningTasks
submission
(13 Nov.) this
& Welding 1/2week!
(PR)
W8 06: Joining & Welding 2/2 (PR) T06: Joining & Welding 06: Joining & Welding T05: Solid. & Casting
(20 Nov.) 07: Weld Microstructure 1/2 (PR)
W9 07: Weld Microstructure 2/2 (PR) T07: Weld Microstructure 07: Weld Microstructure T06: Joining & Welding
(27 Nov.) 08: Powder Metallurgy 1/1 (PR) T08: Powder Metallurgy 08: Powder Metallurgy
W10 09: AM 1/2 (AH) T09: AM 09: AM T07: Weld Microstructure
(4 Dec.) 09: AM 2/2 (AH)
W11 10: Machining 1/2 (PR) T10: Machining 10: Machining T08: Powder Metallurgy
(11 Dec.) 10: Machining 2/2 (PR) Fri. 15 Dec. at 16:00: T09: AM (video)
Assignment now released Coursework Submission T10: Machining (video)
-- ================================= Winter holiday closure =================================
W15 Revision (AH, PR) Revision Fri. 12 Jan. at 16:00: Revision
(8 Jan.) BB Test Submission
W16,17 Exam timetables will be released by the University for all modules later on (as per usual)
5
EXAMS
 Manufacturing and Materials

SESG3024
Manufacturing and Materials

Tutorial 05

6
 Manufacturing and Materials

Q1
1. Use EduPack to compare the roughness and tolerance achieved by
casting processes. (Create plot using selection of 1. Casting by “Tree”
stage, 2. “Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.
[6 self-assessed marks]

[Up to 3 marks for quantitative comparing, 3 marks for explaining]

7
My plot seemed to have all other processes greyed Manufacturing and Materials
out after selecting casting as a tree. Is there a trick
to get a plot without that like yours?
Q1
(Create plot using selection of 1. Casting by “Tree” stage, 2. “Chart” stage.)

Note rough correlation & recall Green sand casting, manual

from Tutorial 01a that tolerance is Green sand casting, automated
20
related to roughness (several
orders of magnitude larger).
10
Roughness (µm)

Shell casting

5
Gravity die casting
Investment casting, manual
Investment casting, automated
Low pressure die casting
2

High pressure die casting

0.05 0.1 0.2 0.5 1 2 5

Tolerance (mm)

Image used courtesy of ANSYS, Inc. 8

*Ansys GRANTA EduPack software, ANSYS, Inc., Cambridge, UK, 2021 (www.ansys.com/materials)
 Manufacturing and Materials

Q1
1. Use EduPack to compare the roughness and tolerance achieved by
casting processes. (Create plot using selection of 1. Casting by “Tree” stage,
2. “Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.

Increasing roughness: Pressure die < investment < gravity die < shell < sand casting (roughest)
Increasing tolerance: Investment < pressure die < gravity die < shell < sand casting (worst tolerance)

Remember, EduPack data are typical values, not necessarily fundamental physical limits, so
what we are doing here is surmising likely explanations. Contributing factors include:
• Mould material surface finish (dies can be smooth; investment, shell, sand are increasingly rough).
• Contact with mould surface (pressure maintains contact with die, better replicates surface & shape)
• Mould material rigidity/stability (dies and investment very rigid/stable & distort less than binders
for shell & sand under pressure & thermal expansion/contraction).
• Rapid cooling & heat transfer in metal dies can cause differential shrinkage of moulded parts
(distortion, porosity, hot cracking).
• Permanent moulds/patterns can deteriorate over time, and permanent moulds need a parting line
for removal (reduces surface finish, tolerance).

9
 Manufacturing and Materials

Q2
2. Use EduPack to compare the mass and thickness achieved by casting
processes. (Create plot using selection of 1. Casting by “Tree” stage, 2.
“Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.
[6 self-assessed marks]
[Up to 3 marks for quantitative comparing, 3 marks for explaining]

10
 Manufacturing and Materials
how do we get the graphs - abhilash

Q2
(Create plot using selection of 1. Casting by “Tree” stage, 2. “Chart” stage.)

Green sand casting, automated

10000
Green sand casting, manual

1000
Mass range (kg)

100
Low pressure die casting Gravity die casting
High pressure die casting
10

Investment casting, automated

Shell casting
0.1

Investment casting, manual

0.01

1 10 100 1000
Range of section thickness (mm)

Image used courtesy of ANSYS, Inc. 11

*Ansys GRANTA EduPack software, ANSYS, Inc., Cambridge, UK, 2021 (www.ansys.com/materials)
 Manufacturing and Materials

Q2
2. Use EduPack to compare the mass and thickness achieved by casting
processes. (Create plot using selection of 1. Casting by “Tree” stage, 2.
“Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.

Increasing mass: Investment < pressure die < shell < gravity die < sand casting
Increasing thickness: Pressure die < investment < shell < gravity die < sand casting

Contributing factors:
• Mould rigidity/stability and accuracy needed for thin sections
• Pressure/vacuum enables liquid metal flow into thin sections (can be higher with rigid moulds)
• Heat transfer & rapid cooling:
– might limit filling (choking due to solidification), might cause unacceptable differential
shrinkage (distortion, porosity, hot cracking) esp. in large parts.
– can reduce cycle time (time related costs) if it can be tolerated.
• Cost and practicality of
– large dies, patterns and moulds with sintered/cured binders
– equipment for high clamping forces, pressure/vacuum 12
(limits mass range)
 Manufacturing and Materials

Q3
3. Use EduPack to compare the relative cost index (under default
assumptions) and economic batch size achieved by casting processes.
(Create plot using selection of 1. Casting by “Tree” stage, 2. “Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.
Note that relative cost index assumes a batch size (1000 by default), and
would vary between processes under different assumptions.
[6 self-assessed marks]
[Up to 3 marks for quantitative comparing, 3 marks for explaining]

13
 Manufacturing and Materials

Q3
(Create plot using selection of 1. Casting by “Tree” stage, 2. “Chart” stage.)

Rate=114GBP/hr, Batch Size=1e3, Component Mass=1kg, Material

Relative cost index (per unit) (GBP)
Load Factor=0.5, Capital Write-off Time=5yrs, Overhead

1000

Investment casting, manual

High pressure die casting

100
Investment casting, automated

Low pressure die casting

Gravity die casting

Shell casting
Green sand casting, manual
Green sand casting, automated
10

0.1 1 10 100 1000 10000 100000 1e6 1e7

Economic batch size (units)

Image used courtesy of ANSYS, Inc. 14

*Ansys GRANTA EduPack software, ANSYS, Inc., Cambridge, UK, 2021 (www.ansys.com/materials)
 Manufacturing and Materials
are we asked to/recomend to use edupack in exam

Q3
3. Use EduPack to compare the relative cost index (under default
assumptions) and economic batch size achieved by casting processes.
(Create plot using selection of 1. Casting by “Tree” stage, 2. “Chart” stage.)
Compare the results for sand & shell casting, gravity & pressure die casting,
and investment casting, and explain differences.
Note that relative cost index assumes a batch size (1000 by default) and
would vary between processes under different assumptions.

Increasing cost (N=1000): sand < investment < shell < gravity die < pressure die
Increasing batch size: investment < sand/shell < gravity die < pressure die
(automation and cost index assumptions can change these orders)

Contributing factors:
• Tooling cost (for dies, patterns, mould materials) strongly affects economic batch size, and can
push up cost especially at low volumes (note default batch size of 1000 is somewhat low).
• High production rates can reduce costs (capital, overheads, energy, labour, rent) especially at
high volumes (again note default batch size of 1000 is somewhat low).
– Affected by time to fill mould and solidify (higher production rate for pressure/vacuum 15
flow, and rapid cooling/solidification).
Ok glad to hear it about the exam because it seemed like a lot of analysis for 6 marks
 Manufacturing and Materials

Q4
if we don't reach Q9, then will some extra material be
released so we can allocate marks for the self
assessments that say refer to this live tutorial
4. A casting of the compressor wheel in the figure is found to contain porosity
defects. Explain why this may have occurred and suggest how it may be
prevented (distinguish between gas porosity and shrinkage porosity).
[5 self-assessed marks (2 basic + 3 for explanations]
Gas porosity

chemical reactions in the melt can produce

High pressure die casting (or similar high pressure
process) will close voids gases
the complex shape will lead to turbulance
Feeder heads will continue to feed flow when pouring -> pourosity
throughout solidification
gas particles also nucleate on bad nucleating agents
Shrinkage porosity

uneven shrinkage -> macroporosity

16
hot tearing = macroporosity? Gas bubbles nucleate on inclusions
 Manufacturing and Materials

Q4

4. A casting of the compressor wheel in the figure is found to contain porosity

defects. Explain why this may have occurred and suggest how it may be
prevented (distinguish between gas porosity and shrinkage porosity).
Gas porosity
• Cause: Nucleation of bubbles from dissolved gas (on surfaces, oxides/contaminates).
• Prevention: Vacuum degassing, scavenging gas (insoluble), weir and dross trap to catch
oxides/contaminates (which are poorly wetted by liquid, hence nucleate gas pores).

• Cause: Turbulence.
• Prevention: Tapered sprue (avoid aeration), slow, upward filling, sprue/runner/gate system with
increasing cross-section (avoid turbulence).

Shrinkage porosity
• Cause: Volumetric contraction upon liquid-to-solid transformation.
• Prevention: Riser with high casting modulus (solidifies last), mould design (Heuver’s construction).
17
Just to be clear, what exactly is an inclusion? Is it an oxide? or nondescript foreign particle e.g. dust?
 Manufacturing and Materials

Q5
5. Why does homogeneous nucleation not normally occur during the
solidification of an alloy, and how do nucleation agents influence
nucleation?
[5 self-assessed marks (2 basic + 3 for explanations]

18
 Manufacturing and Materials

Q5
5. Why does homogeneous nucleation not normally occur during the
solidification of an alloy, and how do nucleation agents influence
nucleation?
• Solidification will occur when it is energetically favourable (depends
on temperature, undercooling, nucleation sites):
• Free energy decrease from solidification (proportional to volume, r3)
must be >= free energy increase from forming solid-liquid interface
(proportional to surface area, r2).
• Occurs for a large enough cluster of atoms (embryo), at which point
homogeneous solidification will occur (no foreign agents needed).
• Nucleation agents reduce the number of atoms required to form an
embryo of the required size (r) by forming a spherical cap, thus
solidification can occur more readily with less undercooling.
• *Good nucleation agents have small contact angle, θ, thus large r. *Good to use figures,
but your answer
should talk about &
Liquid explain them!
Solid

g CL - g CS
θ = contact cos q =
angle g SL 19

Theta needs to be near 1, so ySL + yCS ~= yCL?

 Manufacturing and Materials

Q6
6. Why does an alloy normally solidify with a non planar interface while a pure
metal normally solidifies with a planar interface?
[7 self-assessed marks (4 basic, which is a bit hard + 3 for explanations]

20
 Manufacturing and Materials

Tutorial 2 Q6
6. Why does an alloy normally solidify with a non planar interface while a pure
metal normally solidifies with a planar interface?

• Long freezing range in alloys causes a concentration

gradient & lower freezing temp. ahead of solidification front.
• Constitutional undercooling in an alloy will occur if:
(1) the temperature gradient is lower than the gradient in
the liquidus temperature
(2) the solidification rate is faster than diffusion of the
concentration gradient. A B
• Constitutional undercooling makes solidification front
unstable, thus perturbations grow faster leading to non-
planar, interface.

21
Solid Liquid
Perturbation grows
 Manufacturing and Materials

Q7
7. An alloy with a long freezing range is found to contain porosity from
incomplete filling and hot tearing defects. What is the likely cause and how
can this be prevented?
[5 self-assessed marks (2 basic + 3 for explanations]

22
 Manufacturing and Materials

Q7
7. An alloy with a long freezing range is found to contain porosity from
incomplete filling and hot tearing defects. What is the likely cause and how
can this be prevented?
• Long freezing range alloys are susceptible to dendritic growth
due to constitutional undercooling.
(Why? Refer to Question 6 answer, what is effect of longer
freezing range?)
• High viscosity and reduced area for liquid to flow due to
dendrites can hinder complete filling of moulds.
• Hot tearing due to inability to feed gaps due to solidification
shrinking.

Prevent by:
• different alloy with shorter freezing range, A B
• higher temp. gradient (undercooling reduced),
• slower solidification (concentration gradient reduced by
diffusion).

23
 Manufacturing and Materials

Tutorial 2 Q8
8. When a molten metal is poured into a mould what is the limiting thermal
resistance factor for:
a) gravity die casting

b) sand casting

c) pressure die casting

[5 self-assessed marks (2 basic + 3 for explanations]

24
 Manufacturing and Materials

Q8
8. When a molten metal is poured into a mould what is the limiting thermal
resistance factor for:
a) gravity die casting
b) sand casting
c) pressure die casting

a. Air gap between part and mould

(due to solidification shrinkage).
Mould is good conductor.

b. Mould material, which is poor

conductor.

c. Mould/solidifying part more

important, since air gap will be
less (due to pressure).
25
 Manufacturing and Materials

Q9
9. What is casting modulus and why is it important in the design of castings?
[5 self-assessed marks (2 basic + 3 for explanations]

26
 Manufacturing and Materials

Q9
9. What is casting modulus and why is it important in the design of castings?

• V/A (volume to surface area ratio) of cast shape. Temperature profile required

• Higher modulus = slower cooling (less surface area to

Temperature
B
A C
remove heat, more volume to retain heat). D
E
• Used to design and position feeder heads that cool last and
feed liquid to compensate solidification shrinkage (thus B
preventing solidification porosity and hot tearing).
C D E
• Affects cooling/solidification rate (influences constitutional A
Solidification front
undercooling, as well as production rate of solidification
processes).
C D E
B Ideal temperature profile

A Solidification front

27
 Manufacturing and Materials

Module Schedule Summative assessments:

(Tests 10% & CW 20%)
Formative assessments:
(helps learn, no mark)
Week Lecture Topic Question Sets BB Tests & Coursework Tutorial Sessions
(W/C) (live & in-person) (independent study) (deadlines in red) (live & online)
W1 01: Introduction 1/2 (AH) T01a: EduPack 01: Intro. None
(2 Oct.) 01: Introduction 2/2 (AH)
W2 02: Polymer Processing 1/3 (AH) T01b: Introduction EduPack Software Demo
(09 Oct.) 02: Polymer Processing 2/3 (AH) (No submission)
W3 02: Polymer Processing 3/3 (AH) T02: Polymers 02: Polymers T01a: EduPack Exercises
(16 Oct.) 03: Bulk Forming 1/2 (AH) (Formative submissions begin)
W4 03: Bulk Forming 2/2 (AH) T03: Bulk Forming 03: Bulk Forming T01b: Introduction
(23 Oct.) 04: Sheet Forming 1/2 (AH)
W5 04: Sheet Forming 2/2 (AH) T04: Sheet Forming 04: Sheet Forming T02: Polymers
(30 Oct.) 05: Solid. & Casting 1/4 (PR)
W6 05: Solid. & Casting 2/4 (PR) T03: Bulk Forming
(6 Nov.) 05: Solid. & Casting 3/4 (PR) Self-assessment now
W7 05: Solid. & Casting 4/4 (PR) T05: Solid. & Casting 05: Solid. & Casting T04: Sheet Forming
available
(13 Nov.) 06: JoiningTasks this
& Welding 1/2week!
(PR)
W8 06: Joining & Welding 2/2 (PR) T06: Joining & Welding 06: Joining & Welding T05: Solid. & Casting
(20 Nov.) 07: Weld Microstructure 1/2 (PR)
W9 07: Weld Microstructure 2/2 (PR) T07: Weld Microstructure 07: Weld Microstructure T06: Joining & Welding
(27 Nov.) 08: Powder Metallurgy 1/1 (PR) T08: Powder Metallurgy 08: Powder Metallurgy
W10 09: AM 1/2 (AH) T09: AM 09: AM T07: Weld
Next Microstructure
formative
(4 Dec.) 09: AM 2/2 (AH)
submission
W11 10: Machining 1/2 (PR) T10: Machining 10: Machining T08: Powder Metallurgy
(11 Dec.) 10: Machining 2/2 (PR) Fri. 15 Dec. at 16:00: T09: AM (video)
Assignment now released Coursework Submission T10: Machining (video)
-- ================================= Winter holiday closure =================================
W15 Revision (AH, PR) Revision Fri. 12 Jan. at 16:00: Revision
(8 Jan.) BB Test Submission
W16,17 Exam timetables will be released by the University for all modules later on (as per usual)
28
EXAMS