Unit 3

Melting Practice
 Contents
➢ Melting Practice: Principle of melting

➢ Construction and operation of hot and cold blast cupola

➢ Recent trends in cupola

➢ Melting of steel and alloy steels in Arc and Induction furnace

➢ Melting, and casting practice of aluminum, copper and their alloys

➢ S.G. Iron foundry Finishing

 The Melting Process
The melting process is a physical change that occurs when a solid substance is heated to a
certain temperature, called the melting point, at which it transitions into a liquid state. This
transition involves the absorption of heat energy, which increases the kinetic energy of the
particles within the solid, causing them to vibrate more vigorously.

At lower temperatures, the intermolecular forces between the particles in the solid are strong
enough to maintain a fixed, ordered structure, resulting in a solid state with a definite shape
and volume. However, as heat is applied, the kinetic energy of the particles increases, leading
to a disruption of these intermolecular forces.

As the temperature rises and approaches the melting point, the vibrational motion of the
particles becomes more energetic, eventually overcoming the intermolecular forces that hold
them in place. At the melting point, these forces are weakened enough to allow the particles
to move more freely, transitioning from a fixed, ordered arrangement in the solid to a more
disordered, fluid arrangement in the liquid.
During the melting process, the absorbed heat energy is used to overcome the
intermolecular forces rather than raising the temperature of the substance. This is why
the temperature remains constant during the melting process until all of the solid has
been converted into liquid. Once melting is complete, further heating will raise the
temperature of the liquid.

In summary, the melting process involves the transition of a solid substance into a liquid
state through the absorption of heat energy, causing the particles to overcome
intermolecular forces and move more freely.

Principle of Melting:

The principle of melting is based on the relationship between heat energy, molecular
motion, and the intermolecular forces within a substance. Here's a breakdown of the
principle:
1.Intermolecular Forces: In a solid state, molecules are held together by strong
intermolecular forces, which keep them in a fixed, ordered arrangement. These forces can
be ionic, covalent, metallic, or intermolecular (such as hydrogen bonds, dipole-dipole
interactions, or van der Waals forces), depending on the substance.

2.Kinetic Energy: When heat energy is applied to a solid substance, it increases the
kinetic energy of its molecules. This increased kinetic energy causes the molecules to
vibrate more vigorously around their fixed positions.

3.Overcoming Intermolecular Forces: As heat is applied and the kinetic energy of the
molecules increases, they start to overcome the intermolecular forces that hold them in
place. This weakening of intermolecular forces allows the molecules to move more freely.

4.Melting Point: The temperature at which the intermolecular forces within a solid
substance are weakened enough for the solid to transition into a liquid state is called the
melting point. At this point, the substance exists in equilibrium between its solid and
liquid phases.
5. Absorption of Heat: During the melting process, the heat energy absorbed by the
substance is primarily used to overcome the intermolecular forces holding the
solid together, rather than increasing the temperature of the substance. As a result,
the temperature remains constant during the melting process until all of the solid
has been converted into liquid.

6. Liquid State: Once the intermolecular forces are sufficiently weakened, the solid
substance transitions completely into a liquid state. In the liquid state, the
molecules have more freedom of movement compared to the solid state, but they
are still close together and maintain some degree of attraction to each other.
 S.G. Iron Castings
S.G. iron, also known as ductile iron, nodular cast iron, or Spheroidal Graphite Iron,
is a type of cast iron that has improved mechanical properties due to the spherical
(nodular) shape of the graphite within its structure. This shape results from adding
small amounts of magnesium or cerium to molten iron.

Key Characteristics:
•Graphite Structure: The graphite in S.G. iron is in
the form of spheroids rather than flakes, which is the
case in gray iron. This spheroidal structure provides
significant improvements in strength and ductility.
•Mechanical Properties: S.G. iron offers a combination of high strength,
toughness, and wear resistance. It can withstand higher impact and fatigue stresses
compared to other types of cast iron.

•Machinability: It has good machinability, making it suitable for manufacturing

complex components.

•Corrosion Resistance: S.G. iron has better corrosion resistance compared to

gray iron, making it suitable for outdoor and marine applications.
Applications: S.G. iron is used in various industries due to its advantageous properties.
Some typical applications include:

•Automotive Components: Crankshafts, gears, pistons, and various engine parts.

•Piping and Valves: Pipes, fittings, and valves for water and sewage systems.

•Heavy Machinery: Parts for construction and agricultural machinery, such as housings
and brackets.

•Aerospace and Marine: Components requiring high strength and toughness under
stress.
Production Process:

1.Melting: Iron is melted in a furnace.

2.Magnesium/Cerium Addition: A controlled amount of magnesium or cerium is added
to the molten iron to modify the shape of the graphite.
3. Pouring: The treated molten iron is poured into molds to form the desired shapes.

4. Solidification: The iron solidifies with spheroidal graphite, leading to the desired
mechanical properties.

Advantages:
•Strength and Ductility: S.G. iron combines the strength of steel with the castability
of iron.

•Cost-Effective: It offers a cost-effective alternative to steel in many applications

while providing comparable mechanical properties.

•Versatility: It can be used in a wide range of applications due to its excellent

combination of mechanical properties.
 Importance of Finishing Operations in S.G.
Iron Castings
1. Surface Quality:

•Removal of Surface Defects: Finishing operations like grinding, polishing, and shot
blasting remove surface defects such as scales, burrs, and rough spots, resulting in a
smoother surface finish.

•Improved Appearance: A smooth, polished surface enhances the aesthetic appeal of

the castings, which is particularly important for visible components.

•Reduced Friction: Improved surface finish reduces friction, which is beneficial for
components in contact or moving against each other, leading to better performance
and longevity.
2. Dimensional Accuracy:

•Precision Machining: Operations such as milling, turning, and drilling ensure

that the final dimensions of the castings meet tight tolerances. This is crucial for
components that must fit precisely within assemblies.

•Consistency and Repeatability: Finishing processes provide consistent results

across multiple castings, ensuring uniformity and interchangeability of parts.

•Tolerance Control: Techniques like CNC machining allow for precise control
over dimensions, reducing the risk of errors and the need for rework.

3. Mechanical Properties:

•Stress Relief: Heat treatment processes such as annealing or tempering are often
part of finishing operations to relieve internal stresses induced during casting. This
improves the mechanical properties, such as strength and toughness.
•Surface Hardening: Processes like carburizing or nitriding can be used to harden
the surface of S.G. iron castings, enhancing wear resistance and fatigue life.

•Fatigue Resistance: Finishing operations like shot peening introduce compressive

stresses on the surface, which can significantly improve fatigue resistance.

4. Examples of Finishing Operations:

•Grinding and Polishing: These processes remove surface irregularities and improve
the surface finish, making the casting smoother and more visually appealing.

•Shot Blasting: This process cleans the surface, removes any remaining sand from
the casting process, and improves surface texture, preparing the castings for further
processing or final use.

•Machining: Precision machining operations, including turning, milling, and drilling,

refine the dimensions and shape of the casting to meet exact specifications.
•Heat Treatment: Techniques such as annealing, normalizing, and quenching
improve the internal structure, enhance mechanical properties, and ensure
dimensional stability.

•Coating and Plating: Applying protective coatings or plating (e.g., zinc, nickel)
improves corrosion resistance and extends the lifespan of the castings.

5. Importance in Industrial Applications:

•Automotive Industry: Ensures that critical components like engine parts and
crankshafts meet the necessary strength, durability, and fitment criteria.

•Piping and Valves: Guarantees that pipes and valves used in water and sewage
systems are free from defects, have smooth internal surfaces, and meet stringent
dimensional standards.
•Heavy Machinery: Assures that components used in construction and agricultural
machinery can withstand heavy loads and harsh conditions without premature
failure.

Grinding Operation:
Grinding is a machining process that
uses an abrasive wheel to remove
material from a workpiece, achieving a
high level of surface finish and
dimensional accuracy.

Applications:
•Used to finish surfaces of castings,
achieving precise dimensions and
smooth finishes.
Commonly employed in the production of components requiring tight tolerances
and fine surface quality.

Advantages:
•Provides excellent surface finish and high precision.
•Capable of working with hard materials.
•Can produce complex shapes and fine details.

Shot Blasting:
Shot blasting involves propelling abrasive
particles at high velocity against a surface to
clean, smooth, or prepare it for further
processing.

Applications:
•Cleaning castings by removing scale, rust,
and other surface contaminants.
•Preparing surfaces for painting or coating by creating a rough texture that improves
adhesion.
•Strengthening surfaces through peening, which introduces compressive stresses to
improve fatigue resistance.

Advantages:
•Efficiently cleans and prepares large surfaces.
•Enhances surface properties, including texture and strength.
•Environmentally friendly when using recyclable media.

Machining:
Machining is a broad term encompassing
various processes (e.g., turning, milling,
drilling) that remove material to shape a
workpiece to precise dimensions.
Applications:
•Used to produce intricate shapes and features in castings.
•Essential for achieving final dimensions and surface finish specifications.

Advantages:
•High precision and accuracy.
•Versatile, applicable to a wide range of materials and geometries.
•Capable of producing complex parts with fine details.

Surface Treatment
•Surface treatment encompasses various processes that alter the surface of a material
to improve its properties, including hardness, corrosion resistance, and aesthetics.

Applications:
•Processes like coating, plating, and heat treatment are used to enhance the
performance and durability of castings.
•Common in industries requiring high-performance parts with extended service life.
Advantages:
•Enhances properties like wear resistance, corrosion resistance, and fatigue
strength.
•Improves the appearance of the final product.
•Can be tailored to specific application requirements.
Feel free to contact me for any
query
Dr. Mrinal Sahu
Assistant Professor
Department of Metallurgy Engineering
Shri Rawatpura Sarkar University, Raipur
Chhattisgarh, India (PIN 492015)
Contact: 8697154729
dr.mrinalsahu@sruraipur.ac.in
mrinalsahu22@gmail.com