1. Tính chảy loãng của kim loại là gì?

Người ta dùng dụng cụ j để đo tính chảy loãng của

kim loại.
The molten metal flow characteristics are often described by the term fluidity, a measure
of the capability of a metal to flow into and fill the mold before freezing. Fluidity is the
inverse of viscosity (Section 3.4); as viscosity increases, fluidity decreases.
Standard testing methods are available to assess fluidity, including the spiral mold test
shown in Figure 10.3, in which fluidity is indicated by the length of the solidified metal
in the spiral channel. A longer cast spiral means greater fluidity of the molten metal.

FIGURE: Spiral mold test for fluidity, in which fluidity is measured as the length of the
spiral channel that is filled by the molten metal prior to solidification.
2.Vẽ đường nguội của quá trình đông đặc của hợp kim? Vẽ hình và trình bày về cấu trúc
hạt vật đúc của hợp kim? Tốc độ làm nguội (làm nguội nhanh và làm nguội chậm) ảnh
hưởng ntn tới cấu trúc trên
The cooling curve:
Characteristic grain structure in an alloy casting:

Region III

Region I
Region II

As soon as molten metal is poured into the mold, due to contact with the cooler mold
walls, the molten metal layer in contact with the mold surface cools rapidly and
immediately crystallizes into a thin metal layer. The mold walls themselves act as
heterogeneous nucleation sites, accelerating nucleation and crystallization rates. The
thickness of this layer gradually increases as solidification proceeds, forming a metal
shell surrounding the inner molten metal. This layer has a fine-grained structure, with
randomly oriented grains and is very thin (Region I).
The next region has a structure of elongated, columnar crystals oriented perpendicular to
the mold walls. The higher the cooling rate, the easier it is for the directional growth of
these crystals, which may meet at the center to form a columnar grain structure. This
structure is dense but anisotropic, and is prone to cracking under deformation (Region II).
The innermost region consists of polyhedral grains. At this stage, the mold wall has
heated up, crystallization occurs with a lower degree of supercooling, and heat dissipation
is nearly uniform in all directions. As a result, crystals grow uniformly in all directions,
forming a coarse, equiaxed grain structure (Region III).
Cooling speed effects to it microstructure:
Rapid cooling: Region II develops.
Slow cooling: Region III develops.
3.

In Figure b, the shrinkage cavity is formed in the triangular area because this section has
the least contact with the surrounding mold sand. During metal solidification and the
resulting contraction, this area cools more slowly than others, leading to delayed
solidification and happened shrinkage right at this location. Consequently, shrinkage
cavities are most likely to form here.
When a metal core is used to aid cooling, as shown in Figure b, the following occurs:
 For the internal chills, Internal chills are small metal parts placed inside the
cavity before pouring so that the molten metal will solidify first around these parts.
The internal chill should have a chemical composition similar to the metal being
poured, most readily achieved by making the chill out of the same metal as the
casting itself.
For the external chills, External chills are metal inserts in the walls of the mold cavity
that can remove heat from the molten metal more rapidly than the surrounding sand in
order to promote solidification. They are often used effectively in sections of the casting
that are difficult to feed with liquid metal, thus encouraging rapid freezing in these
sections while the connection to liquid metal is still open.
4. Trình bày vẽ hình minh họa các thành phần cơ bản của vật đúc
Present and illustrate the basic components of a cast product.
5. Do excercise
Dạng 1:

Example 1: One cubic meter of a certain eutectic alloy is heated in a crucible from room
temperature to 100°C above its melting point for casting. The alloy’s density 7.5 g/cm 3,
melting point 800°C, specific heat 0.33 J/g°C in the solid state and 0.29 J/g°C in the
liquid state; and heat of fusion 160 J/g. How much heat energy must be added to
accomplish the heating, assuming no losses?
Assume ambient temperature in the foundry =25°C and that the density of the liquid and
solid states of the metal are the same.
m3 = 106 cm3
H = (7.5)(106) {0.33(800 – 25) + 160 + 0.29(100)} = 3335(106) J
Example 2:
A disk 40 cm in diameter and 5 cm thick is cast of pure aluminum in an open mold
casting operation. Aluminum melts at 6600C, but the pouring temperature will be 8000C.
The amount of aluminum heated will be 5% more than what is needed to fill the mold
cavity. Compute the amount of heat that must be added to the metal to heat it to the
pouring temperature, starting from a room temperature of 250C. The Hf heat of fusion of
aluminum = 389.3 J/g. Specific heat = 0.88 J/g°C; ρ density = 2.7 g/cm3. Assume the
specific heat has the same value for solid and molten aluminum.
Volume V = πD2 h/4= π(40)2 (5)/4 = 6283.2 cm3
Volume of aluminum to be heated = 6283.2(1.05) = 6597.3 cm3
From Table 4.1 and 4.2, density ρ = 2.70 g/cm 3 and specific heat C = 0.21 Cal/g-°C =
0.88 J/g-°C
Heat required = 2.70(6597.3){0.88(660-25) + 389.3 + 0.88(800-660)} = 17,812.71{558.8
+ 389.3 + 123.2} = 19,082,756 J
Dạng 2: Tính toán quá trình rót
Example 1: The flow rate of liquid metal into the downsprue of a mold = 0.8 L/sec. The
cross-sectional area at the top of the sprue = 750 mm2, and its length = 175 mm. What
area should be used at the base of the sprue to avoid aspiration of the molten metal?

Example 2: A mold has a downsprue of length = 6.0 in. The cross-sectional area at the
bottom of the sprue is 0.5 in 2. The sprue leads into a horizontal runner which feeds the
mold cavity, whose volume = 75 in3. Determine (a) velocity of the molten metal flowing
through the base of the downsprue, (b) volume rate of flow, and (c) time required to fill
the mold cavity.

Example 3: 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 to fill the mold.
Example 4: The volume flow rate of molten metal into the downsprue from the pouring
cup is 45 in3/sec. At the top where the pouring cup leads into the downsprue, the
crosssectional area = 1.0 in2. Determine what the area should be at the bottom of the
sprue if its length = 8.0 in. It is desired to maintain a constant flow rate, top and bottom,
in order to avoid aspiration of the liquid metal.

Example 5: Molten metal is poured into the pouring cup of a sand mold at a steady rate of
500 cm3/s. The molten metal overflows the pouring cup and flows into the downsprue.
The cross section of the sprue is round, with a diameter at the top = 3.4 cm. If the sprue is
22 cm long, determine the proper diameter at its base so as to maintain the same volume
flow rate.

Dạng 3: Solidification time

Example 1: When casting low carbon steel under certain mold conditions, the mold
constant in Chvorinov’s rule 4.0 min/cm2. Determine how long solidification will take
for a rectangular casting whose length 30 cm, width 15 cm, and thickness 20 mm.
Cm= 4 min/cm2
V= 30x15x2=900 cm3
A= 30x2x2 + 15x2x2 + 30x15x2=1080 cm2
n=2
Tts= 2.78 min
Example 2: A disk-shaped part is cast out of aluminum. Diameter of the disk 650 mm
and thickness 16 mm. If the mold constant 2.2 sec/mm2 in Chvorinov’s rule, how long
will it take the casting to solidify?
Cm=2.2 sec/mm2
V=πD2/4 x H = 5309291,6 mm3
A=πD2/4x2+πDx16=221650pi mm2
N=2
Tts= 127,9 sec
6. Vẽ sơ đồ trình bày quy trình đúc trong khuôn cát (Draw a diagram and present
the sand-casting process.)

Sand casting, also known as sand-mold casting, consists of pouring molten metal into a
sand mold, allowing the metal to solidify, and then breaking up the mold to remove the
casting. The casting must then be cleaned and inspected, and heat treatment is sometimes
required to improve metallurgical properties.
7. Phương pháp đúc trong khuôn kim loại (Metal Mold Casting Method)
a. Vẽ sơ đồ và trình bày nguyên lí? (Draw a diagram and explain the
principle)
 Mold preparation → Pour themolten material into the mold → Mold separation → Cast product

Metal mold casting is a term that refers to a production method for cast products by
pouring liquid metal into a metal mold. The cast product solidifies under the influence of
gravity without any external forces acting upon it. This method is very common today.
b. Phân loại (Classification)
 Centrifugal casting:
Refers to several casting methods in which the mold is rotated at high speed so that
centrifugal force distributes the molten metal to the outer regions of the die cavity The
group includes: true centrifugal casting, semicentrifugal casting, and centrifuge casting.
 High pressure die casting
Die casting is a permanent-mold casting process in which the molten metal is injected
into the mold cavity under high pressure
c. Ưu nhược điểm (Advantages and disadvantages)
Advantages:
 High accuracy and surface finish of the cast product. (Độ chính xác và độ bóng
bề mặt vật đúc cao)
 Low machining allowance and high productivity. (Lượng dư gia công thấp,
năng suất cao)
 Easy to mechanize and automate. (Dễ cơ khí hóa, tự động hóa)
 Enhanced mechanical strength of the cast product.( Nâng cao độ bền cơ học của
vật đúc)
 Increased durability of the cast product. (Nâng cao độ bền cơ học của vật đúc)
Disadvantages:
 Fabrication of metal molds. (Chế tạo khuôn kim loại)
  Difficult to cast highly complex shapes and expensive. (Khó đúc nhất phức tạp
và đắt tiền)
 The durability of metal molds is limited, especially when casting steel.( Độ bền
khuôn kim loại bị han chế, đặc biệt là khi đúc thép)
 Ineffective for small production runs.( Không hiệu quả khi sản xuất nhỏ)
 Prone to white cast iron formation when casting cast iron. (Dễ biến trắng khi
đúc gang)
 The cast product experiences high stress due to the strong contraction resistance
of the metal mold during cooling (Vật đúc có ứng suất lớn do khuôn kim loại
cản co mạnh những vật thành mỏng)
d. Ứng dụng (Applications)
Pressure die casting is commonly used to manufacture complex components such as fuel
pump housings, injection chamber covers, air valves, and brass instruments.
Đúc áp lực thường được dùng để chế tạo các chi tiết phức tạp như vỏ bơm xăng dầu, nắp
buồng ép, van dẫn khí, kèn đồng…
Centrifugal casting is used to produce axis-symmetric components such as cylinders,
discs, hollow pipes, bearings, sleeves, bushings, nozzles, pipelines, pulleys, and wheels.
Đúc li tâm được sử dụng để sản xuất các chi tiết đối xứng trục như xi lanh, đĩa, các ống
rỗng, ổ trục, ống bọc, bạc lót, vòi phun, đường ống, ròng rọc, bánh xe
e. Các khuyết tật của vật đúc (Casting defects)
Porosity: Formed due to air bubbles or trapped air in the cast product.
( Rỗ khí: Hình thành do bọt khí hoặc không khí bị mắc kẹt trong vật đúc.)
Shrinkage Cavities: Occur due to uneven shrinkage during solidification.
(Lõm co ngót: Xuất hiện do sự co rút không đồng đều khi đông đặc.)
Cracking: Caused by residual stresses generated during cooling and solidification.
(Nứt: Do ứng suất dư sinh ra trong quá trình nguội và co rút.)
Incomplete Filling: Occurs when the flow of liquid metal does not completely fill the
mold.
(Không đầy khuôn: Do dòng kim loại lỏng không điền đầy hoàn toàn vào khuôn.)
8. Phương pháp đúc trong khuôn mẫu chảy
a. Vẽ sơ đồ và trình bày nguyên lí
The principle of casting in a flowing mold is based on the use of a mold containing a
liquid material, typically molten metal, to shape the product. The process begins by
heating the metal to a liquid state and then pouring it into the mold. When the molten
metal is poured into the mold, it takes on the shape of the mold and, after a period of
cooling, solidifies to form the final product.
Nguyên lý đúc trong khuôn mẫu chảy dựa trên việc sử dụng khuôn chứa chất lỏng,
thường là kim loại nóng chảy, để tạo hình sản phẩm. Quá trình bắt đầu bằng việc làm
nóng kim loại đến trạng thái lỏng và sau đó đổ vào khuôn mẫu. Khi kim loại lỏng được
đổ vào khuôn, nó sẽ chiếm lấy hình dạng của khuôn và sau một thời gian làm nguội, nó
sẽ đông đặc lại, tạo thành sản phẩm cuối cùng.
b. Phân loại
c. Ưu nhược điểm
Ads:
 High surface quality (Chất lượng bề mặt cao)
 High dimensional accuracy (Độ chính xác về kích thước cao)
 Ability to produce complex shapes (Tạo ra được những hình dáng phức tạp)
 Suitable for casting thin-walled parts (Đúc được những vật đúc có thành
mỏng)
 No parting line (Không có mặt phân khuôn)
 Reduced thermal stress and machining time (Giảm ứng suất nhiệt và thời gian
gia công cơ khí)
Disads:
 High labor intensity (Cường độ lao động cao)
 High mold fabrication cost (Giá thành chế tạo khuôn cao)
 Long casting time (Thời gian đúc dài)
 Mold can only be used once (Khuôn chỉ đúc được 1 lần)
d. Ứng dụng (Application)
Used in the production of jewelry, automotive parts such as pistons, cylinders, gear
assemblies, valve assemblies, bearings, radiators, drive assemblies, and many other
components with high lubrication capability and wear resistance.
được sử dụng để sản xuất trong lĩnh vực kim hoàn, các bộ phận ô tô như piston, xi lanh,
cụm bánh răng, cụm van, vòng bi, bộ tản nhiệt, cụm truyền động và nhiều linh kiện khác
với khả năng bôi trơn và độ mài mòn cao.
e. Các khuyết tật
"Crazing" - subsurface cracking.
"Rạn chân chim" - nứt lõm
9. Shell molding
a. Schematic diagram

Principle of shell molding method:

Steps in shell-molding: (1) a match-plate or cope-and-drag metal pattern is heated and
placed over a box containing sand mixed with thermosetting resin; (2) box is inverted so
that sand and resin fall onto the hot pattern, causing a layer of the mixture to partially
cure on the surface to form a hard shell; (3) box is repositioned so that loose, uncured
particles drop away; (4) sand shell is heated in oven for several minutes to complete
curing; (5) shell mold is stripped from the pattern; (6) two halves of the shell mold are
assembled, supported by sand or metal shot in a box, and pouring is accomplished. The
finished casting with sprue removed is shown in (7).
b. Classified
Thin-shell molding methods are classified as follows:
 According to mold material:
Resin-coated sand: Use sand and phenolic resin, heat to create mold.
Ceramic: Used for high-temperature alloys.
 According to mold making method:
Melted plastic coating: Dip the model into sand and resin.
Ceramic molding: Dip the model into ceramic slurry, then dry and bake.
 According to mold hardness:
Hard mold: Withstand high pressure, use resin-coated sand.
Soft mold: Withstand less pressure, use sand and synthetic resin.
 According to product requirements:
Complex details, high precision.
Large details: Use ceramic mold or resin-coated sand.
c. Advantages and disadvantages
 Advantages

 Disadvantages
d. Application
Shell molding has many applications in areas requiring high precision and smooth surface
finish, such as:
1. Automotive industry: Manufacturing complex parts such as cylinder heads, gearboxes,
and engine parts that require high precision and heat resistance.
2. Aerospace industry: Manufacturing complex, lightweight, and durable components
such as turbine blades, engine covers, and aircraft parts.
e. Common defects of castings using the thin-shell mold casting
Common defects of castings using shell molding casting method include:
Pores: Occur when gas does not escape in time during the metal pouring process or when
the resin sand mixture is not sufficiently breathable, creating holes inside the casting.
Cracking: Occurs due to uneven expansion and contraction when the metal cools,
especially when the mold design is not reasonable, or the casting has uneven wall
thickness.
Dimensional deviation: May be due to the thin shell not being hard enough, leading to
deformation when pouring the metal or due to poor metal shrinkage control.
Surface defects: The surface may be rough, sandy, or uneven if the quality of the resin
sand mixture is unstable or the molding process does not ensure smoothness.
Material shortage (defect): Occurs if the amount of metal is not enough or due to
improper pouring technique, causing the metal to not fill the entire mold.
Deformation: Due to uneven temperature or insufficient mold hardness, the casting warps
after cooling.
10.
Wrong shape, size and weight
- Deficiency: Incomplete shape of the casting.
- Deviation: displacement between parts of the casting.
- Burr: excess metal. It is often formed at the parting surface, core pillow.
- Convex: Is the protruding part on the casting due to poor, uneven compaction of the
mold.
- Warp: Is the change in shape and size of the casting due to unreasonable structure of the
casting, not ensuring rigidity.
Surface defects
- Sand burn: the core mold material is burned under the effect of pouring temperature and
adheres to the surface of the casting
- Joint: Is a discontinuous phenomenon on the surface of a solid object due to the contact
of metal flows.
- Concave: Are holes of different shapes and sizes that reduce the wall thickness of the
casting.
- Crack: Due to internal stress, due to uneven shrinkage between different regions in the
casting both during crystallization and cooling.
Internal defects - Porosity:
- gas is dissolved in the liquid metal. When the metal solidifies, the gas does not
escape but remains inside the casting.

- Pores: small spaces in a casting that are not filled with metal, do not contain gas,
are of varying shapes and sizes, and are not as smooth as gas pores.