Chapter 1
Fundamentals of Metal Casting
Solidification of Pure Metals
Figure 10.1 (a) Temperature as a function of time for the solidification of pure metals. Note
that the freezing takes place at a constant temperature. (b) Density as a function of time
Cast Structures of Solidified Metals
Figure 10.3 Development of a
preferred texture at a cool mold
wall. Note that only favorably
oriented grains grow away from
Figure 10.2 Schematic illustration of three the surface of the mold
cast structures of metals solidified in a square
mold: (a) pure metals; (b) solid-solution
alloys; and (c) structure obtained by using
nucleating agents. Source: After G. W. Form,
J. F. Wallace, J. L. Walker, and A. Cibula
Alloy Solidification
Figure 10.4 Schematic illustration of alloy solidification and temperature distribution
in the solidifying metal. Note the formation of dendrites in the mushy zone.
Solidification of Iron and Carbon Steels
Figure 10.5 (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting.
Note that after 11 minutes of cooling, dendrites reach each other, but the casting is still mushy
throughout. It takes about two hours for this casting to solidify completely. (b) Solidification of
carbon steels in sand and chill (metal) molds. Note the difference in solidification patterns as
the carbon content increases. Source: After H. F. Bishop and W. S. Pellini
Basic Types of Cast Structures
Figure 10.6 Schematic illustration of three basic types of cast structures: (a) columnar
dendritic; (b) equizxed dendritic; and (c) equiaxed nondendritic. Source: Courtesy of D. Apelian
Cast Structures
Figure 10.7 Schematic illustration of cast structures in (a) plane front, single
phase, and (b) plane front, two phase. Source: Courtesy of D. Apelian
Fluid Flow and Solidification Time
p v2
Bernoulli’s theorem h constant
g 2g
Mass continuity Q A1v1 A2v2
A1 h
Sprue design 2
A2 h1
vD
Reynolds number Re
Volume n
Chvorinov’s Rule Solidification time = C
Surface Area
Casting Design and Fluidity Test
Figure 10.9 A test method for
Figure 10.8 Schematic illustration of a typical fluidity using a spiral mold. The
riser-gated casting. Risers serve as reservoirs, fluidity index is the length of the
supplying molten metal to the casting as it solidified metal in the spiral
shrinks during solidification. passage. The greater the length
of the solidified metal, the greater
is its fluidity.
Temperature Distribution during Metal Solidification
Figure 10.10 Temperature
distribution at the interface
of the mold wall and the
liquid metal during the
solidification of metals in
casting
Solidified Skin on a Steel Casting
Figure 10.11 Solidified skin on a steel casting. The remaining molten metal is poured out
at the times indicated in the figure. Hollow ornamental and decorative objects are made by
a process called slush casting, which is based on this principle. Source: After H. F. Taylor,
J. Wulff, and M. C. Flemings
Solidification Contraction or Expansion
Hot Tears in Castings
Figure 10.12 Examples of hot tears in castings. These defects occur because the
casting cannot shrink freely during cooling, owing to constraints in various portions
of the molds and cores. Exothermic (heat-producing) compounds may be used (as
exothermic padding) to control cooling at critical sections to avoid hot tearing
Common Casting Defects
Figure 10.13 Examples of common defects in castings. These defects can be
minimized or eliminated by proper design and preparation of molds and control of
pouring procedures. Source: After J. Datsko.
Types of Internal and External Chills used in Casting
Figure 10.14 Various types of (a) internal and (b) external chills (dark areas at
corners) used in castings to eliminate porosity caused by shrinkage. Chills are
placed in regions where there is a larger volume of metal, as shown in (c).
Solubility of Hydrogen in Aluminum
Figure 10.15 Solubility of
hydrogen in aluminum. Note the
sharp decrease in solubility as
the molten metal begins to
solidify.
Casting of an Aluminum Piston
Figure 10.16 Aluminum piston for an Figure 10.17 Simulation of mold filling
internal combustion engine: (a) as- and solidification. (a) 3.7 seconds after
cast and (b) after machining. start of pour. Note that the mushy zone
has been established before the mold is
filled completely. (b) Using a vent in the
mold for removal of entrapped air, 5
seconds after pour.
