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MEC 322 > Casting > Flashcards

Casting Flashcards

slay the midterm pt. 2

1
Q

what shape can be casted?

A

ANY SHAPE!

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2
Q

what are the capabilities/advantages of Casting?

A
  1. complexity (any shape)
  2. net shape (single step process)
  3. size
  4. material
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3
Q

What are the 2 types of casts

A
  1. expandable mold (can not be reused)
  2. permanent mold (can be reused)
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4
Q

Disadvantages of casting

A
  • mechanical properties
  • poor dimensional accuracy and finish (sand casting)
  • shrinkage, porosity, cracks
  • permanent mold is expensive
  • microstructures hard to control
  • not uniform
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5
Q

What are the 6 basic requirements for casting process?

A
  1. mold cavity
  2. melting process
  3. pouring technique
  4. solidification process
  5. mold removal
  6. cleaning, finishing, inspection operations
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6
Q

What are the two halves of a mold?

A
  1. Cope = upper half
  2. Drag = lower half
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7
Q

What does a riser do?

A

holds extra material and solidifies last, minimizes shrinkage and creates pressure

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8
Q

what does the down sprue and pouring cup do?

A

minimizes turbulence (trapped air molecules) and controls flow rate

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9
Q

Purpose of a draft angle

A

allows the material to be removed from the casting

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10
Q

pouring temperature has to be … (for pure metals)

A

much higher than melting point, so it doesn’t solidify fast

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11
Q

Local solidification time (for pure metals)

A

freezing begins to freezing finishes (all at melting point)

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12
Q

Total solidification time (for pure metals)

A

pouring temperature to freezing temperature finishes

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13
Q

Relation ship between melting points and freeze speed

A

high melting point freezes first, low melting point freezes last

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14
Q

Do alloys and metals freeze the same?

A

No, for alloys its a freezing range not point

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15
Q

What happens in alloy segregation

A
  • chill zone, material freezes fast (edges)
  • columnar zone, dendrites, has metal with high melting point
  • equiaxed zone, center then has very no high melting point metals
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16
Q

what is used to minimize alloy segregation?

A

cooling rate and nucleating agents, mechanical means; vibration, electromagnetic stirring
(macro easier to minimize than micro)

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17
Q

is it better to have a high or slow cooling rate?

A

high cooling rate is better because it has a shorter solidification time

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18
Q

what does a slow cooling rate cause?

A

coarse dendritic structures (large spacing between dendrite arms)

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19
Q

What does a high cooling rate cause?

A
  1. small dendrites
  2. large equiaxed zone
  3. small grain size result in
    - strength and ductility increase
    - micro-porosity decreases (shrinkage voids)
    - decrease crack on casting
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20
Q

Solidification time, Chorinov’s Rule

A

TST = Cm(V/A)^n

v= Volume
A= surface area
n=2
Cm= mold constant

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21
Q

Fluidity (fill mold before freezing) is affected by the following 4.

A
  1. viscosity
  2. surface tension (high tension low f)
  3. inclusion (insoluble)
  4. freezing range (long range, low f)
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22
Q

How to make sure riser is last to solidify

A

(V/A)Riser > (V/A)Casting

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23
Q

at what stage does shrinkage happen?

A

In all stages! when pouring, freezing, and cooling

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24
Q

What is shrinkage allowance?

A

when making the pattern a little bigger to make the mold bigger.

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25
Q

what is solidification toward in directional solidification?

A

the riser

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26
Q

What can external chills do?

A

induce chilling effect creating directional solidification!

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27
Q

velocity of liquid equation

A

v= sqrt[2gh]

28
Q

what is volumetric flow rate (Q)

A

Q = vA
velocity*area

29
Q

what is time required to fill a mold

A

T = Mold cavity volume/ volumetric flow rate
T = V/Q

30
Q

What is aspiration in casting?

A

as metal goes down sprue and velocity increases, unwanted air goes into the mold

31
Q

to determine the minimal cross sectional area of the taper at any point what equation is used?

A

A1/A2 = sqrt[h2/h1]
(assuming pressure on top and bottom are equal)

32
Q

what is gates in casting?

A

the passages where the molten material goes into a mold

33
Q

how should a gate be designed?

A
  • for large parts, multiple gates
  • should feed into thick sections of casting
  • fillets for where gate and casting meet (less turbulence)
  • gate closest to sprue should be far enough to remove
  • minimum gate length should be 3 to 5 times the gate diameter, depending on metal being casted
34
Q

What are the different types of expandable molds?

A
  1. sand molds
  2. shell molds
  3. vacuum molds
  4. plaster molds
  5. investment molds
35
Q

What are the different reusable molds?

A
  1. permanent molds
  2. die casting
  3. centrifugal casting
36
Q

pros and cons of sand casting

A

pros
- many metals, sizes, shapes, cheap
- high temps
- high volume

cons
- poor finish & tolerance
- automation is not easy

37
Q

what are casting, sand properties

A
  • cohesiveness (retain shape after packing)
  • strength (maintain shape)
  • permeability (allow air to escape~ large grain size, bad surface finish)
  • refractoriness/ thermal stability (withstand high temps)
  • collapsibility (ease of reusing same sand)
  • reusability
38
Q

what is typical mix of sand binders

A

90% sand, 7% clay, 3% water
silica (siO2)

39
Q

The 3 types of sand molds

A
  1. green sand (sand, clay, water) - contains moisture
  2. dry sand (organic binders not clay) - baked to make stronger
  3. skin dried (drying mold cavity surface of a green) - 10 to 25 mm using torches or heat lamp
40
Q

what is the pattern

A

full sized model of part (enlarged for shrinkage and machining allowance)

41
Q

The 3 pattern materials

A
  1. wood (moisture, warps)
  2. metal (expensive , lasts)
  3. plastic (compromise)
42
Q

The 4 pattern types

(worst to best)

A
  1. solid pattern
  2. split pattern
  3. match plate pattern
  4. cope and drag pattern
43
Q

what holds a core in place

A

chaplets and they have a higher melting temp

44
Q

is sand casting net shape?

A

no its near net shape because it needs trimming and removal of core (if it has internal structure)

45
Q

the 2 different types of sand casting

A
  1. shell molding (only creating the shell of the moldings pattern,2 halves together, pouring molten, final product) - no porosity, better finish, too expensive
  2. Vacuum mold - takes time, better finish, expensive, no porosity bc no water is used
46
Q

Expanded Polystyrene Process

A

is when u use the polystyrene beads in a die, take out and coat it, then pour molten metal

vary good surface finish, cheap, high volume manufacturing the, porosity problems minimized

Cost of DIE used to make pattern is very expensive

47
Q

what is investment casting

A

when a pattern made of wax is coated with a refractory material to make mold, then wax is melted away before pouring molten metal

48
Q

what is the difference between Expanded Polystyrene Process (lost foam) and Investment casting

A

polystyrene is using beads (expanding polystyrene) and investment casting is using wax

49
Q

What type of finish does investment casting give

A
  • no porosity issues
  • VERY GOOD SURFACE FINISH
  • used for medical tools
  • very expensive
  • too many steps
50
Q

What’s the difference between plaster mold vs sand mold

A

plaster has better finish and accuracy but worst porosity and cant withstand high temps (only used for low melting point materials)

cant use wood patterns b/c too much moisture

51
Q

pros of ceramic finish?

A
  • good surface finish and porosity
  • can with stand high temp
52
Q

what do u base ur choice on when it comes to sand, plater or ceramic casting?

A

this is based on the melting point of the material

53
Q

what material do permanent molds use?

A

instead of sand the use a metal mold

54
Q

What happens when u use metal

A

gives u the wall situation with the chill zone

55
Q

processes of permanent mold casting

A
  1. basic permanent mold process
  2. die casting
  3. centrifugal casting
56
Q
  1. basic permanent mold process
A

use metal for 2 sections (easy open and close) mold must with stand the temp

57
Q
  1. Die casting
A

Appling high pressure, throughout processes till it solidifies
- hot chamber (continuous, high production rate, low melting point)
- cold chamber (no continuous source of molten material, low production rate but can be used for high melting point materials)

58
Q
  1. centrifugal casting
A

by rotating mold at high speed, uses centrifugal force to distribute molten material

59
Q

The 3 groups of inertial forces caused by rotation

A
  1. true centrifugal casting (radially symmetric inside is always circular, tubular)
  2. Semi centrifugal casting (radially symmetric, poor quality in center, density and quality increases in outer)
  3. centrifuge casting (non radial structures and smaller features)
60
Q

What are slush castings used for?

A

used for hollow structures because it doesn’t allow for everything to solidify

61
Q

The 4 extra General Defects

A
  1. Misrun
  2. Cold shut
  3. Cold Shot
  4. Shrinkage cavity
62
Q

General Defects: Misrun

A

casting that solidifies before completely filling mold cavity

63
Q

General Defects: cold shut

A

2 portions of metal flow togther but lack of fusion due to premature frezzing

64
Q

General Defects: cold shot

A

metal splatters during pouring and becomes trapped in casting

65
Q

General Defects: shrinkage cavity

A

depression in surface caused by solidification shrinkage that restricts amount of molten metal available in last region to freeze

66
Q

Foundry inspection methods

A
  1. any defects
  2. does it meet specification (required measurements)
  3. does it have the metallurgical/chemical/ physical properties
67
Q
A

MEC 322 (3 decks)

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