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Solidification - E C Rollason

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Athlur Sai Kiran
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64 views

Solidification - E C Rollason

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Athlur Sai Kiran
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CHAPTER Lv SOLIDIFICATION OF METALS tals may be produced (a) condensation of “ANG (b) electrolytic deposition—copper, nickel ; (c) welding a pasty mass of metal and slag—wrought, iron ; : (d) compression and sintering of metal powders—tungsten lainp filament, Widia tools ; (ec) freezing of a liquid, which is by far the most common method of preparing metals used in engineering, either as castings with the desired shape or as ingots which are subjected to subsequent shaping processes, Solid me by @ variety of ways, including vapour—zi . Crystallisation of a Pure Metal When a pure molten metal solidifies, it does so like other elements at a fixed temperature, known as its freezing-point. If the tem- perature of the metal is observed at intervals and plotted against Stable 4 (dd 2 Metastable S Fe + CO to occur. ( Deep-seated blowholes are formed by the carbon monoxide at a uniform depth below the ) (6) Rimming Steel Ingot ( (a) 18.—Sulphur Prints of Killed Steel (a) and of (b). Fe. = CHEMICAL HETEROGENEITY—SEGREGATION 59 surface and piping ig equnteracted. The central core is zich in impurities uniformly distributed and it corrodes more r: dly ¢i an the pure rim, ‘This type of steel is called “effervescing ” or “rimming ”-steel ; a typical macro structure is shown in Figs. 17 5 ingot_ by carbon a ide (a non-oxidising gas) is not, oxidised and app very white, Such blowholes weld up more or less completely during subsequent hot rolling. Owing to the absence of piping, practically no material is discarded, Rimming steel can be readily identified by the characteristic segregated core. ‘The high reputation of this material for deep drawing and pressing is due to the ductile proper- ties of the skin which, in most operations, is the most highly stressed region. r YG Chemical Heterogencity Segregation’ MM ‘ 7 eet) Ex orth It is found that the composition of metal ingots is not uniform £ throughout and that the concentration 1 of impurities is greater in certain parts of the ingot than in others. This subject is particularly important in steel production owing to the large ingots used (up to 200 tons) and it has been studied by the Heterogeneity Committee of the Iron and Steel Institute, who have issued reports from 1926 onwards, . Molten. steel contains soluble impurities—sul hur, phosphorus— and soluble alloying elements together with insoluble impurities or slag particles in suspension. As will be seen in Chapter Vii crystals to separate contain less impurity than is indica -by the average composition of the alloy, and those elements which lowe: r the freezing-point, such as sulphur, phosphorus, carkon, 3 manganese and silicon, collect in the’last portions to solidify,Z This Separation of various substances into different places in the ingot is Catted segregation, and for killed steel and also other metals it i be classed as follows 2 / Interdendritic segregdtion, caused by the concentration of impurities between the arms of the dendrites. On annealing, elements, such as carbop; will diffuse and_become uniformly dis- tributed, but phosphorus and non-metallic inclusions will be only _ Slightly affected, Py alr 60 SOLIDIFICATION OF METALS S, ic Normal segregation is the concentration of sulphur, phosphorus and_carbon in the centre and upper portions of the ingot. Tt is largely assogiated with the pipe and is mainly romoved-wh is discarded” The direction Of Now of the metal during fecdiny shown by the V-form of this segregate (ig. 17). Inverse or A segregation is the concentration of fusibia t” elements near the oyter-sones of an ingot, and in extreme « inverse segrgntiog’ekixdation occurs on the surface of particularly those containing “lead _(tin_sweat).” In “Keilic : this type of segregation occurs Spout mates midway between the « 2 and the outside, in the form of an “ inverted V” (Fig. 17). Ingot corner segregation is the cntrapping of impurities at the juaction of two sets of crystals growing Trom the sides and bottom of the mould: Gravity segregation ocgurs when the primary crystals differ in density from the fiquid. Ms good example is the rising of the cuboids in tin-antimony alloys (p. 289). ee Seams—Rokes—Shells—Laps Although the ingots should be cast at as low a temperature as possible in order to get good properties, it is just as important that the metal should be sufficiently fluid to prevent semi-solid skins forming.on the surface _as the metal_level rises in the mould. Periodically the liquid metal bursts through the oxidised skin and covers it. When rolled a seam is formed, as shown in Fig. 17. Smaller defects starting from the surface, but due to similar causes, are called rokes (Fig. 17). A defect, somewhat similar to a roke, is caused by poor roll design or by rolling at too low a temperature. The metal spreads to an extent greater than the designed pass and form fins on opposite sides of the bar, which in subsequent passes are lapped over to give the lap illustrated in Fig. 17. - Splashes of oxidised metal on the surface of the mould, particu- larly near the bottom, appear as scales or shells on the ingot after it is stripped. Surface defects such as mentioned above tend to cause cracks during heat treatment and have a harmful effect on the fatigue and other properties of the material, They can be revealed by macro-examination, CHEMICAL MBTEROGENEITY—SEGREGATION 61 Sand Moulds Castings-are made both in permanent moulds (p. 291) and i moulds which necessitsdte the use of wooden or metal patt 1 except in the case of loam moulds of simple curved shapes, which only require templates in their construction. The essential properties of a moulding sand are re: ce to high temperatures, bond strength and permeability to gas The red sands, consisting of silica grains bonded together with natural clay, are used for non-ferrous and iron castings. or cast iron, coal dust is added to the sand or coated on the mould surface (i.e. blacking) in order to improve the surface finish of the casting hence the black colour of the sand. For the same purpose moulds * for casting aluminium are dressed with french chalk. Sand used in the steel foundry must be capable of resisting very high tem- peratures and Belgian yellow sand or a “compo” consisting of crushed silica bricks, old crucibles, china clay, etc., is used. “Green sand” moulds are made from sand which has been made sufficiently damp to hold together, while “ dry sand ” moulds are dried in stoves before casting. Cores, which have to be strong enough to be handled and yet easily removed from hollow parts of a casting, are frequently made from sea sand bonded with linseed oil and dried. The Lost Wax process of precision casting to within +- 0-002 in. has recently become more important for gas turbine blades and other intricate parts which would otherwise entail much expensive machining. It consists in making a wax pattern in a master mould. The moulding sand, made into the consistency of cream with ethyl silicate binder, is poured around the wax pattern, and vibrated. When the mould has set the wax is melted out and the jointless mould baked. nsand 8,

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