LECTURE 5
Pouring the Molten Metal
For this step to be successful, metal must flow into all
regions of the mold, most importantly the main cavity,
before solidifying.
Factors that determine success are;
▪ Pouring temperature
▪ Pouring rate
▪ Turbulence
ENGINEERING ANALYSIS OF POURING
Bernoulli’s theorem governs the flow of molten metal through the gating
system and into the mould cavity.
Continuity Equation
Another important consideration during pouring is that the
volume flow rate remains constant during pouring
Therefore, the time required to fill the mould cavity of volume V
is;
Where TMF= mold filling time, s (sec);V= volume of mold cavity, cm3;
and Q = volume flow rate, cm3/s
Aspiration effect
The pressure anywhere in the
liquid metal stream does not fall
below the atmospheric pressure
otherwise the gases from baking
of organic compounds in the
mould will enter the molten
metal stream, producing porous
castings
Numerical
A mold sprue is 20 cm long, and the cross-sectional area at its
base is 2.5 cm2. The sprue feeds a horizontal runner leading into
a mold cavity whose volume is 1560 cm3.
Determine: (a) velocity of the molten metal at the base of the
sprue, (b) volume rate of flow, and (c) time required to fill the
mold.
Q) Molten metal flows into the down sprue of a mold at a rate of
1.1 L/s. The cross-sectional area at the top of the sprue is 800
mm2 and its length is 220 mm. What area should be at the base of
the sprue to avoid any aspiration of the molten metal?
Solution: Flow rate Q = 1.1 L/s = 1.1 106 mm3/s
Velocity v = (2 9810 220)0.5 = 2078 mm/s
Assuming volumetric continuity, area at base A = 1,100,000/2078 = 529 mm2
Ladles
Two common types of ladles to transfer molten metals to molds:
(a) crane ladle, and (b) two-man ladle
Solidification of Metals
Solidification of Metals
1. Transformation of molten metal into solid state
2. Solidification differs depending on whether the metal
is
▪ A pure element or
▪ An alloy
Cooling Curve for a Pure Metal
A pure metal
solidifies at a
constant temperature
equal to its freezing
point (same as
melting point)
Solidification of Pure Metals
1. Due to the chilling action of the mold wall, a thin skin
of solid metal is formed at the interface immediately
after pouring
2. Skin thickness increases to form a shell around the
molten metal as solidification progresses
3. Rate of freezing depends on heat transfer out of the
mold, as well as thermal properties of the metal
Solidification of Pure Metals
Characteristic grain structure
in a casting of a pure metal,
showing randomly oriented
grains of small size near the
mold wall, and large
columnar grains oriented
toward the center of the
casting
Most Alloys Solidify Over a Temperature Range
(a) Phase diagram for a copper-nickel alloy system and (b)
Cooling curve for a 50%Ni-50%Cu composition
Solidification of Alloys
Characteristic grain
structure in an alloy
casting, showing
segregation of alloying
components in center of
casting, resulting in the
condition ‘ingot
segregation’
Dendritic Growth
Several Zones of Cooling
SOLIDIFICATION TIME
Solidification time
▪ Total solidification time TTS = time required for casting
to solidify after pouring
▪ TTS depends on size and shape of casting by a
relationship known as Chvorinov's rule
n
V
TTS = Cm
A
where TTS = total solidification time, V = volume of the
casting; A = surface area of casting, n = exponent
with typical value = 2, and Cm is mold constant
Bennett University 19
Mold Constant in Chvorinov's Rule
1. Mold constant Cm depends on:
▪ Mold material
▪ Thermal properties of casting metal
▪ Pouring temperature relative to melting point
2. Value of Cm for a given casting operation can be
based on experimental data from previous
operations carried out using same mold material,
metal, and pouring temperature, even though the
shape of the part may be quite different
Significance of Chvorinov's Rule
1. A casting with a higher volume-to-surface area ratio
cools and solidifies more slowly than one with a lower
ratio
2. To feed molten metal to the main cavity, TTS for riser
must be greater than TTS for main casting
3. Since mold constants of riser and casting will be equal,
design the riser to have a larger volume-to-area ratio
so that the main casting solidifies first. This minimizes
the effects of shrinkage
