Castings John Campbell OBE FREng Professor of Casting Technology pdf

[...]... succeeded in escaping the attention of most of the casting community for the last several thousand years A discussion of the techniques t o avoid entrainment during the production of cast material is an engineering problem too large to be covered in this book It has to await the arrival of a second volume planned for this series Castings I1- Practice listing my ten rules for good castings Chapter 2 ~~ Entrainment... the skin of the casting However, of course, the surface oxide is immediately and continuously re-forming, as though capable of infinite expansion This is a natural and protective mode of advancement of the liquid metal front It is to be encouraged by good design of filling systems As a fine point of logic, it is to be noted that the tearing and sliding process is driven by the friction of the casting. .. steel parts of the high pressure die casting machines and the die itself from rapid attack by zinc From the point of view of the casting quality, the film-formation problem does give some problems, assisting in the occlusion of air and films during the extreme surface turbulence of filling Nevertheless, these problems generally remain tolerable because the melting and casting temperatures of zinc pressure... n, 5 6 Castings water vapour, causing the concentration of gas in solution to rise to nearer 10 ml.kg-I This spells disaster for most normal castings Such metal has been preferred, however, for the production of many non-critical parts, where the precipitation of hydrogen pores can compensate to some extent for the shrinkage on freezing, and thus avoid the problem and expense of the addition of feeders... towards equilibrium within times of the order of one minute (This same reasoning explains the increase in rate of vacuum degassing by the action of bubbling nitrogen through the melt.) This is the order of time in which many castings are cast and solidified We have to conclude, therefore, that reactions of the melt with its environment continue to be important at all stages of its progress from furnace... common source of porosity in castings (socalled ‘shrinkage’, and so-called ‘gas’ precipitating from solution are only additive effects that may or may not contribute additional growth) The creation of this source of porosity has now been regularly observed in the study of mould filling using X-ray radiography It explains how this rather random distribution of porosity typical in many castings has confounded... defects Small bubbles of air entrapped between films (Figure 2.4b) are often the source of microporosity observed in castings Round micropores would be expected to decorate a bifilm, the bifilm itself often being not visible on a polished microsection Samuel and Samuel (1993) report reduced pressure test samples of aluminium alloy in which bubbles in the middle of the reduced pressure test casting are clearly... the surface of the liquid The presence of a solid film on the surface will hold the surface stationary, and because of the effect of viscosity, this stationary zone will extend for some distance into the bulk liquid The thickness of the The melt boundary layer is reduced if the bulk of the liquid is violently stirred However, within the stagnant liquid of the boundary layer the movement of solutes can... solutes can occur only by the slow process of diffusion, Le the migration of populations of atoms by the process of each atom carrying out one random atomic jump at a time Another region where diffusion is important is in the partially solidified zone of a solidifying casting, where the bulk flow of the liquid is normally a slow drift In the solid state, of course, diffusion is the only mechanism by... the formation of oxide films from the decomposition of moisture, and the formation of graphitic films from the decomposition of hydrocarbons, both result in the increase of hydrogen in the metal The comparative rates of diffusion of hydrogen and other elements in solution in various metals are shown in Figures 1.6 to 1.8 These reactions will be dealt with in detail later In the case of liquid copper . class="bi x0 y0 w0 h0" alt="" Castings Castings John Campbell OBE FREng Professor of Casting Technology, University of Birmingham, UK UTTERWORTH. understanding of this most complex of forming operations, the casting process. It is hoped thereby to improve the professionalism and status of casting technology,