Solutions MSc January 2020
Q.No1. What is Nucleation? Describe homogeneous and heterogeneous nucleation.[05]
Nucleation refers to the process in which the tiny solid particles, called “nuclei” are formed
when liquid metals cools below its liquidus temperature.
Nucleation is a process of formation of stable crystallization of a new phase.
Homogeneous Nucleation
When a solid forms within its own liquid without aid of foreign materials nucleate
homogeneously .
Homogeneous nucleation requires a large driving force (undercooling) because of the relatively
large contribution of surface energy to the total free energy of small particles.
Heterogeneous Nucleation
Nucleation occurs on preferential sites , such that a solid forms in contact with a impurity
particles, i.e. nucleation agent or mold walls
heterogeneous nucleation. Many liquid metals start solidification in a few degrees of
supercooling.
(a)Formation of stable nuclei (b) Growth of crystals (c) Grain structure
Q 2. What is solidification in casting? A pure aluminium door handle is to be manufactured by
a foundry and a foreman is asked by the management to give the complete solidification details
of pure aluminium. What would be complete technical report of foreman give with neat
sketches? [05]
Solidification is defined as the process of forming solid from liquid phase upon cooling after
molten metal int mould.
The former gives report on solidification of pure aluminium as below.
3.What is directional solidification? Explain at least two methods how the damages due to
shrinkages are minimized.[05]
In order to minimize the damaging effects of shrinkage, it is desirable for the regions of the
casting most distant from the liquid metal supply to freeze first and for solidification to progress
from these remote regions toward the riser(s). In this way, molten metal will continually be
available from the risers to prevent shrinkage voids during freezing. The term directional
solidification is used to describe this aspect of the freezing process and the methods by which
it is controlled. The desired directional solidification is achieved by observing Chvorinov’s rule
in the design of the casting itself, its orientation within the mold, and the design of the riser
system that feeds it. For example, by locating sections of the casting with lower V/A ratios
away from the riser, freezingwilloccurfirstintheseregionsandthesupplyofliquidmetalfor the rest
of the casting will remain open until these bulkier sections solidify.
Another way to encourage directional solidification is to use chills—internal or external heat
sinks that cause rapid freezing in certain regions of the casting. Internal chills are small metal
parts placed inside the cavity before pouring so that the molten metal will solidify first around
these parts. The internal chill should have a chemical composition similar to the metal being
poured, most readily achieved by making the chill out of the same metal as the casting itself.
External chills are metal inserts in the walls of the mold cavity that can remove heat from the
molten metal more rapidly than the surrounding sand in order to promote solidification. They
are often used effectively in sections of the casting that are difficult to feed with liquid metal,
thus encouraging rapid freezing in these sections while the connection to liquid metal is still
open. Figure 10.9 illustrates a possible application of external chills and the likely result in the
casting if the chill were not used. As important as it is to initiate freezing in the appropriate
regions of the cavity, it is also important to avoid premature solidification in sections of the
mold nearest the riser. Of particular concern is the passageway between the riser and the main
cavity. This connection must be designed in such a way that it does not freeze before the
casting, which would isolate the casting from the molten metal in the riser. Although it is
generally desirable to minimize the volume in the connection (to reduce wasted metal), the
cross-sectional area must be sufficient to delay the onset of freezing. This goal is usually aided
by making the passageway short in length, so that it absorbs heat from the molten metal in the
riser and the casting.
4.a) A side cylindrical riser is to be used for a sand-casting mold. For a given cylinder volume,
determine the diameter-to-length ratio that will maximize the time to solidify.[03]
b) The cylindrical mould have diameter-to-height ratio as 1.0. Considering total time of
solidification as 2.0 min and mould constant as 1956000 sec/m2, Determine dimensions of the
mould. [02]
5a). Determine the dimension of the optimum cylindrical riser attached to the side of the steel
plate casting having dimensions 25cm x 12.5cm x 5 cm. The volume shrinkage of steel during
solidification is 3% and the volume of riser is 3 times that of dictated by the shrinkage
consideration alone.[03]
5b) Differentiate between pressurized and non-pressurized gating system.[02]
6.a)What are the objective of gating design? [2]
To fill the mould cavity rapidly without braking the flow of liquid metal and without using
very high pouring temperature.
To avoid corrosion of cores and mould cavity.
To stop scum, slag, dross and eroded sand particles from entering the mould cavity.
To minimize turbulence and dross formation
To prevent aspiration ( Entering of the gases from baking of organic compounds present in
the mould into to molten metal stream) of air or mould gases in the liquid metal stream.
To obtain favorable temperature gradient to promote directional solidification
6 b) The down sprue leading into the runner of a certain mold has a length = 175 mm. The
cross-sectional area at the base of the sprue is 400 mm2. The mold cavity has a volume =
0.001 m3. Determine
(i) the velocity of the molten metal flowing through the base of the down sprue,
(ii) the volume rate of flow, [3]
Solution: (i) Velocity v = (2 x 9815 x 175)0.5 = (3,435,096)0.5 = 1853 mm/s
(ii) Volume flow rate Q = vA = 1853 x 400 = 741,200 mm3/s
