Steel Castings

C F F P
Tushar Dave
Sr. DGM
October 24th, 2017 NTPC Noida / CFFP/BHEL CFFP/BHEL 1
• Basics of casting manufacture & foundry friendly design
• Product range of steel castings for power plant equipment
• Steel casting manufacturing process
• Challenges in meeting QUALITY requirements of large steel

castings
• Common defects and their causes in large steel castings
October 24th, 2017 NTPC Noida / CFFP/BHEL 2

Correct Geometry
Chemical composition, mechanical

properties and microstructure
Internal soundness – Defects within

acceptable limits.
 Casting as a forming process involves pouring
of liquid metal into a cavity called mould
which on solidification takes the shape of the
mould.


LIQUID
• Superheat in the liquid steel
STATE
• Riser
LIQUID +
SOLID STATE
• Chills and feeding pads
• Contraction allowances on pattern

SOLID STATE

 During the liquid-solid conversion, the
shrinkage in volume has to be compensated
by a liquid pool which is called riser.
 The temperature drop of liquid metal in riser

has to be slower than that in casting.
 There is no direct formula for calculating

solidification time of casting.
 Concept of Modulus (ratio of volume to
effective cooling surface area) as
representative of solidification time is used
for risering purpose.
 Higher the modulus, higher will be the

solidification time.
 The riser is so designed so as to keep its

modulus at least 20% of the casting modulus.
 It is not just enough to take care of the
volumetric shrinkage.
 Directional solidification in the casting has to

be ensured in order to have correct gradient
of heat flux from the first region to cool upto
the last region (riser).
 The requirements of feeding distances has to

be ensured.
CASTABILITY
CASTABILITY
• Ease of producing a casting

• Minimising cost
implies
• Minimising defects
• Minimising lead time
• Lower energy requirements

PRODUCT DESIGN AND CASTABILITY
Aspects of
product •Material selection
design •Geometry Planning
influencing •Quality
its specification
castability:

PRODUCT FOUNDRYMAN
DESIGNER
To satisfy the functional Pouring temperature,
requirement of the product fluidity, volumetric
based on mechanical, shrinkage during
physical and chemical solidification, slag/dross
properties (UTS, melting forming tendency. These
point, corrosion resistance, influence the casting
etc.) quality in terms of
dimensional stability and
internal integrity
PRODUCT FOUNDRYMAN
DESIGNER
To satisfy the •Directly influences the complexity
application and number of tooling elements
requirements (patterns/cores) and hence its cost.
•Location of parting line.
•Progressive direction solidification
(from thin to thicker to thickest
regions) which in turn governs the
internal integrity.
Part complexity
• Simplification of product shape
Parting line
• Designing the product considering a particular draw direction,
minimising undercuts and drafts for easy withdrawal of pattern
Cored features
• Aim to reduce number of holes and reduce their complexity to
the extent possible.
• Thickness of core compared to thickness of metal around it is an
influential factor.
Filling characteristics
• Design to minimise turbulence during filling and to promote complete filling of
all sections
• Avoid sudden variation in section thickness and sharp corners
• Avoiding long thin sections in casting.
Solidification characteristics
• Avoid/minimise isolated hot spots – regions of higher modulus surrounded by
regions of lower modulus.
• Boss on an annular section, Small fillet radius at internal edge where two
sections meet, sections between two or more cores close to each other, etc.
• Progressive directional solidification
• Gradual variation of section thickness from end sections to thickest sections.
• Last solidifying sections to be designed such that placement of feeder is
facilitated and its removal is easy after casting is made.

CASTINGS FOR POWER
PLANT EQUIPMENTS

 CASTINGS FOR 120/210/250/500/660/800
MW STEAM TURBINES
 Inner and Outer Casings for HP, IP turbines
 Castings for governing systems like IV&CV Casing,
ESV & CV Casings, Valve Covers, Diffusers,
 Strainer Housings
 WEIGHT RANGE: 1000 KG TO 50000 KG

G17Cr G17Cr G17CrMoV GX12CrMo GX12CrMoW
GP-240 GH G20Mo5 Mo55 Mo9-10 510 VNbN9-1 VNbN10-1-1
C 0.18-0.23 0.15-0.23 0.15-0.20 0.13-0.20 0.15-0.20 0.11-0.14 0.11-0.14
P 0.030 max 0.025 max 0.020 max 0.020 max 0.020 max 0.020 max 0.020 max
S 0.020 max 0.02 max 0.020 max 0.020 max 0.015 max 0.01 max 0.01 max
Si 0.60 max 0.60 max 0.60 max 0.60 max 0.60 max 0.20-0.50 0.20-0.40
Mn 0.50-1.20 0.50-1.00 0.50-1.00 0.50-0.90 0.50-0.90 0.40-0.80 0.80-1.20
Cr 0.30 max 0.30 max 1.00-1.50 2.00-2.50 1.20-1.50 8.0-9.50 9.20-10.20
Mo 0.12 max 0.40-0.60 0.45-0.65 0.90-1.20 0.90-1.10 0.90-1.05 0.90-1.05
V 0.03 max - 0.05 max - 0.20-0.30 0.18-0.25 0.18-0.25
Ni 0.40 max 0.40 max 0.50 max 0.50 max 0.70 max 0.40 max 0.60-0.80
Al 0.025 max 0.040 max 0.04 max 0.040 max 0.040 max 0.020 max 0.020 max
Cu 0.30 max 0.30 max 0.030 max 0.30 max 0.30 max 0.30 max 0.30 max
Ti 0.025 max 0.025 max 0.025 max 0.025 max
Sn 0.025 max 0.025 max 0.025 max 0.025 max 0.025 max
N 0.04-0.06 0.04-0.06
Nb 0.05-0.08 0.05-0.08
October 24th, 2017 NTPC Noida / CFFP/BHEL
W 0.95-1.0517
GP-240 G17Cr G17Cr G17CrMo GX12CrMo GX12CrMoW
GH G20Mo5 Mo55 Mo9-10 V510 VNbN9-1 VNbN10-1-1
YS
N/SQMM
240 245 315 400 440 500 520
UTS
N/SQMM
420-600 440-590 490-690 590-740 590-780 630-750 680-850
%EL
22 22 20 18 15 16 15
RA
40 40 40 40 40 40 40
IMPACT
J 27 27 27 40 27 36 35

IP VALVE CASING UH (600 MW)
WT approx 8 MT IP OUTER CASING UH (500 MW)
GRADE : GX12CrMoWVNbN10-1-1 WT approx 25 MT
GRADE : G17CrMo910

 Runners – Francis, Pelton
 Runner Blades and Runner Hub
 Guide Vanes, Stay Vanes
 Labyrinths, sealing rings
 Castings for governing systems – US Body, DS
Body, Butterfly Valve Door, Spherical Valve Door,
etc.
 WEIGHT RANGE: FEW HUNDRED TO 50000
KG
GX4CrNi 13-4
C 0.06 max YS
P 0.035 max N/SQMM
S 0.025 max 550
Si 1.00 max UTS
Mn 1.00 max N/SQMM
Cr 12.00 to 13.50 760
Mo 0.70 max %EL
V - 15
Ni 3.50 – 5.00 IMPACT
J at 0 degree 120

FRANCIS RUNNER CASTING
WEIGHT: 5 to 80 MT BF VALVE DOOR TRUNNION
GRADE : 13%Cr-4%Ni STAINLESS WT approx 23 MT
STEEL GRADE : 1.5% Mn STEEL

 Higher pouring temperature
 Difficult solidification morphology
 Shapes and contours of the casting
 Stringent quality requirements
 Increasing difficulties with increasing size and

thickness of castings.
METHODING PATTERN MAKING MOULDING
HIGH TEMPERING KNOCK OUT POURING
RISER CUTTING HEAT TREATMENT MARKING
DEFECT REMOVAL NON

ROUGH
AND WELD DESTRUCTIVE
MACHINING
REPAIR TESTING
STRESS FINAL
DISPATCH
RELIEVING INSPECTION
MELTING & DEOXIDATION & 70- TAPPING IN
DEPHOSPHO 95% ALLOY VAD/LRF
RISATION IN ADDITION IN EAF LADLE
EAF
SECONDARY REFINING,
POURING IN THE VD AND ALLOY
MOULD ADJUSTMENT AT VAD/LRF

MELTING & ADDITION OF TAPPING IN
CHROMIUM REDUCING MIXTURE VAD LADLE
ADJUSTMENT IN EAF
IN EAF
TEMPERATURE & DECARBURISATION AT

ALLOY ADJUSTMENT VOD STATION
AT VAD
POURING IN THE
MOULD
POSES CHALLENGES FOR
FOUNDRYMEN AT EVERY
STAGE OF MANUFACTURING

 With ever increasing quest for increasing efficiencies of
power equipments, casting designs have become more
complicated and foundry un-friendly.
 Larger thicknesses pose greater challenges for correct

solidification gradient and large size risers
 Poor yield of castings
 Designs often constrains methods-man in proper

placement of risers
 Use of simulation softwares are helpful in method design

 Few alternatives for Pattern material – wood and
polyesterene
 With large size and intricacy of components, the
patterns are made in 4-5 parts and number of core
boxes can go as high as 15-20 for some castings.
 In some cases, core-assembly mode has to be
resorted to.
 Mechanisation/automation in pattern making is still a
distance in India particularly for large size castings.
 Handling capacities – large size mould boxes and pits
required.
 Sand – High grade silica sand is not sufficient to
extract heat from heavy section thickness castings.
Use of Chromite sand (South African origin) as facing
sand becomes essential.
 Binder system – Use of self setting organic binders
are most prevalent. Furan, Acid and Alkaline phenolic
resins binder systems are favourites.
 Need for continuous sand mixers
 Moulding preheating
 Loading of moulds
becomes essential due
to large ferrostatic
pressure created during
pouring of liquid metal
to the tune of 30 to 100
MT.

 Correct selection of scrap
 Use of secondary refinining – VAD and VOD
 Strict control on chemical composition – Sulphur,

Phosphorus
 Control of Oxygen, Nitrogen and Hydrogen
 Control on active oxygen in the melt – avoid hot

tears & segregation
 Aim should be minimum pouring time.
 Use of multiladle and multinozzle pouring.
 Selection of correct nozzle size and design of

gating system
 Quality of refractory hollowares
 Foundry ladles need to be so designed that high

pressure head is obtained.
 Shake out temperature
 Handling of martensitic castings after shake-

out.
 Soft-annealing treatment before riser cutting

 Prolonged heat treatment cycles
 Use of water/forced air/oil quenching
 Sometimes double tempering may have to be

resorted to.
 Difficulty in maintaining uniform property

across the varying cross-section of the
casting.
 All castings are subjected to stringent quality
check
 100% Ultrasonic Testing to QL ½
 100% Magnetic Particle Testing to QL ½
 Even 1.5 mm defects are not permitted in

certain zones of castings
 Well laid down procedures needs to be
established for repair welding of defects.
 Strict control on welding parameters is

essential
 Post weld heat treatment needs to be carried

out.

 Casting/rigging design features:  Deposition of sulphide and phosphide
opposing flanges or appendages, gating along grain boundary.
system runners  Hot shakeout, fast cooling, rough
 isolated heavy section, or large thermal handling
gradient, ingate or riser contact  Casting quenched too cold, or not
 Stresses developed by Excess tempered soon enough after quench i.e.
mould/core strength or sand density high quenching rate.
 High hot-strength (binder% more)  Gas cutting at improper temp.
 Inclusions, C and Mn segregations under  Incomplete phase transformation.
the riser and shrinkage  Waiting of quenched casting before
 High knock out temp. tempering.
 Mechanical strike in as cast condition.  High rate of heating or cooling in heat
 High pouring temperatures treatment.
 Precipitate of aluminium nitride at prior  Excessive weldment in particular spot.
austenite grain boundaries.  Abrupt section thickness variation in
 Hydrogen pickup in liquid steel from casting geometry.
moisture in refractories, alloys, mould,  Less collapsibility of mould or core.
atmosphere, etc.
 High alumina content.

 Low refractoriness of sand  Insufficient drying of mould / core --
 Low sintering point. introduce a prime source (penetration-
 Excessive fines % in sand. water).
 Presence of alkaline oxides (Cao, Na2O, K2O  Quality of mould wash, e.g. low sp.
etc.) Gravity of the paint, low refractoriness.
 High Turbidity (presence of colloidal material  Coarse grain may attract increased
particularly in chromites sand). tendency of sand fusion- it is also known
 High loss on ignition (>2%- commonly as ‘Wetting’.
observed in reclaimed sand)  Improper mixing of resin / catalyst or
 High pouring temperature and/ or time. improper ratio.
 Less sand wall thickness in comparison to  Over drying / burning of localized mould
metal e.g. cases arise around volute /core surface as found in case of organic
portions of castings, riser neck, thick binders, particularly after repairing work.
flange junctions.
 Poor workmanship e. g.
 Non uniform sand hardness ( loose ramming )
 Non uniform mould wash coating.
 Excessive compactness in core
(insufficient hollowness) / permeability /
collapsibility.

 Molten metal contains excess flux or  Avoid possibility of mechanical shock/
foreign oxides. vibration to a closed mould before
 Erosion of refractory material from ladle pouring, such as transfer of closed mould
or refractory gating lining. from one to another as happening at light
foundry and sometimes in steel foundry.
 While filling up of mould, the metal
should not strike the mould/ core.  Stop entry of nozzle filling compound
(refractory combination) to enter the
 Both low/ high pouring temperature is mould at the start of pouring.
likely to increase inclusion content.
 Never pour through riser.
 There should not be mismatch of gating
system.  Clean gating system thoroughly before
core setting, after core setting and
 The mould binder should not get totally closing.
burned till the mould is filled.
 After mould closing keep risers and
 Pouring time should be as low as possible pouring basing covered till ladle for
without creating turbulence. pouring approached the mould.
 The moulding activity should be within
the bench life.
 The liquid metal should be free from
inclusion and gases

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Steel Castings

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What are the main steps involved in the steel casting manufacturing process?

What are the main steps involved in the steel casting manufacturing process?

What are some of the challenges in meeting quality requirements for large steel castings?

What are some of the challenges in meeting quality requirements for large steel castings?

C F F P

• Product range of steel castings for power plant equipment

• Steel casting manufacturing process

• Challenges in meeting QUALITY requirements of large steel

• Common defects and their causes in large steel castings

October 24th, 2017 NTPC Noida / CFFP/BHEL 2

Chemical composition, mechanical

Internal soundness – Defects within

October 24th, 2017 NTPC Noida / CFFP/BHEL 4

• Contraction allowances on pattern

October 24th, 2017 NTPC Noida / CFFP/BHEL 5

 The temperature drop of liquid metal in riser

 There is no direct formula for calculating

 Higher the modulus, higher will be the

 The riser is so designed so as to keep its

 Directional solidification in the casting has to

 The requirements of feeding distances has to

• Ease of producing a casting

October 24th, 2017 NTPC Noida / CFFP/BHEL 9

October 24th, 2017 NTPC Noida / CFFP/BHEL 10

October 24th, 2017 NTPC Noida / CFFP/BHEL 14

October 24th, 2017 NTPC Noida / CFFP/BHEL 15

 WEIGHT RANGE: 1000 KG TO 50000 KG

October 24th, 2017 NTPC Noida / CFFP/BHEL 16

October 24th, 2017 NTPC Noida / CFFP/BHEL 18

October 24th, 2017 NTPC Noida / CFFP/BHEL 19

October 24th, 2017 NTPC Noida / CFFP/BHEL 21

October 24th, 2017 NTPC Noida / CFFP/BHEL 22

 Difficult solidification morphology

 Shapes and contours of the casting

 Stringent quality requirements

 Increasing difficulties with increasing size and

HIGH TEMPERING KNOCK OUT POURING

RISER CUTTING HEAT TREATMENT MARKING

DEFECT REMOVAL NON

October 24th, 2017 NTPC Noida / CFFP/BHEL 25

TEMPERATURE & DECARBURISATION AT

October 24th, 2017 NTPC Noida / CFFP/BHEL 27

 Larger thicknesses pose greater challenges for correct

 Poor yield of castings

 Designs often constrains methods-man in proper

 Use of simulation softwares are helpful in method design

October 24th, 2017 NTPC Noida / CFFP/BHEL 39

 Use of secondary refinining – VAD and VOD

 Strict control on chemical composition – Sulphur,

 Control of Oxygen, Nitrogen and Hydrogen

 Control on active oxygen in the melt – avoid hot

 Use of multiladle and multinozzle pouring.

 Selection of correct nozzle size and design of

 Quality of refractory hollowares

 Foundry ladles need to be so designed that high

 Handling of martensitic castings after shake-

 Soft-annealing treatment before riser cutting

October 24th, 2017 NTPC Noida / CFFP/BHEL 43