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    Solidification Shrinkage

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    Sherif El-soudy
    Solid metals undergo shrinkage as they cool from liquid to solid form. There are three main stages of shrinkage: as the liquid cools, during solidification, and as the solid cools further. The amount of shrinkage depends on properties like thermal contraction and superheat level. Risers are designed to feed extra metal to compensate for shrinkage. They are located to promote directional solidification away from the riser. Riser design considers factors like shape, location, and ability to remain liquid long enough to feed the casting. Calculations using casting modulus can determine proper riser size.

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    Solidification Shrinkage

    Uploaded by

    Sherif El-soudy
    304 views16 pages
    Solid metals undergo shrinkage as they cool from liquid to solid form. There are three main stages of shrinkage: as the liquid cools, during solidification, and as the solid cools further. The amount of shrinkage depends on properties like thermal contraction and superheat level. Risers are designed to feed extra metal to compensate for shrinkage. They are located to promote directional solidification away from the riser. Riser design considers factors like shape, location, and ability to remain liquid long enough to feed the casting. Calculations using casting modulus can determine proper riser size.

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    casting lec

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    lec 4

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    Solid metals undergo shrinkage as they cool from liquid to solid form. There are three main stages of shrinkage: as the liquid cools, during solidification, and as the solid cools further. The amount of shrinkage depends on properties like thermal contraction and superheat level. Risers are designed to feed extra metal to compensate for shrinkage. They are located to promote directional solidification away from the riser. Riser design considers factors like shape, location, and ability to remain liquid long enough to feed the casting. Calculations using casting modulus can determine proper riser size.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    304 views16 pages

    Solidification Shrinkage

    Uploaded by

    Sherif El-soudy
    Solid metals undergo shrinkage as they cool from liquid to solid form. There are three main stages of shrinkage: as the liquid cools, during solidification, and as the solid cools further. The amount of shrinkage depends on properties like thermal contraction and superheat level. Risers are designed to feed extra metal to compensate for shrinkage. They are located to promote directional solidification away from the riser. Riser design considers factors like shape, location, and ability to remain liquid long enough to feed the casting. Calculations using casting modulus can determine proper riser size.

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    Solidification Shrinkage

    Most metals undergo


    noticeable volumetric
    contraction when cooled
    Three principle stages of
    shrinkage:
    Shrinkage of liquid as it cools
    from the solidification
    temperature
    Solidification shrinkage as the
    liquid turns into solid
    Solid metal contraction as the
    solidified metal cools to room
    Figure 1- Dimensional changes experienced by a
    temperature metal column as the material cools from a
    superheated liquid to a room-temperature solid.
    Note the significant shrinkage that occurs upon
    solidification.
    Solidification Shrinkage
    Amount of liquid metal contraction depends on the
    coefficient of thermal contraction and the amount of
    superheat
    As the liquid metal solidifies, the atomic structure normally
    becomes more efficient and significant amounts of shrinkage
    can occur
    Cavities and voids can be prevented by designing the casting
    to have directional solidification
    Hot tears can occur when there is significant tensile stress on
    the surface of the casting material
    Risers and Riser Design
    Risers are reservoirs of liquid metal that feed extra metal to the
    mold to compensate for shrinkage
    Risers are designed to conserve metal
    Located so that directional solidification occurs from the
    extremities of the mold toward the riser
    Should feed directly to the thickest regions of the casting
    Yield: the weight of the casting divided by the weight of metal
    in the pour (i.e. the casting, gating systems, and all associated
    risers)
    A good shape for a riser is one that has a longer freezing time.
    Risers and Riser Design
    Blind risers - contained entirely within the mold
    cavity
    Open risers are exposed to the air
    Live (or Hot) risers - receive the last hot metal that
    enters the mold
    Dead (or Cold) risers receive metal that has
    already flowed through the mold cavity
    Top risers sit on top of a casting
    Side risers located adjacent to the mold cavity,
    displaced along the parting line.
    Risers and Riser Design

    Figure 11-13 Schematic of a sand casting mold, showing a) an open-type top riser and b) a
    blind-type side riser. The side riser is a live riser, receiving the last hot metal to enter the
    mold. The top riser is a dead riser, receiving metal that has flowed through the mold cavity.

    Riser must be separated from the casting upon


    completion so the connection area must be as small as
    possible
    Solidification Time (Chvorinov's rule)

    2
    Volume V 2
    t=C =C
    Surface Area SA

    t = Solidification time
    C = a constant that reflects mold metals, metal
    properties (including latent heat) and temperature.
    V/SA = M = the casting modulus
    Example 1
    Q: Three pieces being cast have the same volume but different shapes.One is a sphere,one a
    cube and the other a cylinder(Height = Diameter). Which piece will solidify the fastest and
    which the slowest.

    Solidification time 1/(surface area)2


    Assume volume to be unity
    Sphere V = (4/3) r3, r=(3/4)1/3 and A = 4r2 = 4(3/4)2/3 = 4.84
    Cube V = a3, a=1, A= 6a2 = 6
    Cylinder V = r2h = 2r3, r=(1/2)1/3, A = 2r2 + 2rh = 6r2 = 6(1/2)2/3 = 5.54
    Thus respective solidification times are
    Tsphere = 0.043 C
    Tcube = 0.028 C
    Tcylinder = 0.033 C
    C is a constant
    Risering

    Risering is a process designed to prevent shrinkage voids


    that occur during solidification contractions
    Aluminum 6.6%
    Steel 2.5 to 4%
    Criteria for Riser design
    Riser must remain molten until casting is completely
    solidified
    Riser should have enough liquid metal to feed casting
    Riser should be kept at proper distance from the casting
    Improving Riser( feeder) efficiency :
    - The riser efficiency ( feeding distance can be improved by applying internal and or external
    Metallic objects (chills) that produce directional solidification of the molten metal.
    -Applying exothermic compound powder materials, that chemically react to produce heat
    on the top of the riser
    Exothermic powder

    Using of internal or external chill Using exothermic powder


    Example:
    Calculate the size of riser to feed the shown casting applying modulus method.
    Mr= 1.2 Mc
    Mr = Vr/Ar= /4( d2rxHr)/( 2x /4xd2r+ drxHr) assuming dr= Hr
    then Mr= dr/6
    Mc= Vc/Ac
    From volume and area calculation we get Vc= 600 Cm3 and the surface area of
    casting is 635 Cm2
    hence:
    Mr=dr/6= 1.2 Mc= 1.2(600/635)= 1.134
    then dr= 6x1.134=6.8 cm 7 cm

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