MSE 440/540: Processing of Metallic Materials

Instructors: Yuntian Zhu/Suveen Mathaudhu

Office: 308 RBII Ph: 513-0559 ytzhu@ncsu.edu

Lecture 6: Casting IV
Casting alloys

Department of Materials Science and Engineering

NC State University

Melt Fluid Properties

1. Viscosity Above Tm, most metals behave in a Newtonian manner (viscosity independent of shear strain rate), but behavior can change with alloy composition and phases present; presence of a solid phase induces non-Newtonian flow between TL and TS 2. Surface Effects Problematic when melt flows through small channels or into corners; modification of oxides changes this. 3. Fluidity the ability of a metal to fill a mold; property of both the metal and mold - Fluidity increases with increasing superheat; lowers viscosity and delays solidification - Increases with mold temperature; delays solidification - Depends on type of solidification: dendrites get in the way - Surface tension and oxide films have an effect - Mold material heat extraction and wetting phenomena
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Casting Alloys: Basics

- Except for metal made by powder metallurgy or electrolytic methods all alloys are cast as ingots or castings. - Ingots (~85% of alloys) are worked into final form - Castings are used as-cast - See Table 7.1 in Schey for relative production of cast alloys. - Ferrous alloys are the most common casting alloys

Department of Materials Science and Engineering

NC State University

Casting Alloys: Steel Casting

-Contains < 2% C -Advantages over wrought steel products: - Isotropic properties - Advantages over other cast alloys: - Excellent mechanical properties; heat treatable - Weldable - Disadvantages: - Large solidification shrinkage large risers needed - Good toughness means risers, gates must be sawed off castings, not just broken off as in cast iron.
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Casting Alloys: Fe-Fe3C Phase Diagram

- Steels have high melting point, and above 0.15%C and long freezing range - Homework: Answer why does larger shrinkage occur for cast steels than for cast iron?

Department of Materials Science and Engineering

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Casting Alloys: Cast Irons

-Contains > 2% C -Advantages - Engineering properties: Strength and hardness, machinability, wear resistance, abrasion resistance, corrosion resistance - Foundry properties: good fluidity, low solidification shrinkage, ease of production

Department of Materials Science and Engineering

NC State University

Casting Alloys: Chemical Composition Effects

- The approximate range in carbon and silicon contents of ferrous alloys - Carbon Equivalent

Si% + P% C .E .(%) = C% + 3
- Carbide (Fe3C) stablizers are Cr, Mn and S

Department of Materials Science and Engineering

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Casting Alloys: Gray Iron

- Formed at high C.E. (>4) - Gray iron is cast iron which solidifies according to the eutectic Fe-graphite, thereby containing graphite flakes. - The graphite counters solidification shrinkage - The graphite reduces tensile properties (<1% EL) - Low cost makes it preferred where properties arent critical
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Casting Alloys: White Cast Iron

- More rapid solidification and lower C content (C.E. <3%) and Si content - All C is in the form of Fe3C - Very brittle but hard; excellent wear resistance - Used for thin section products - Virtually unmachinable

Department of Materials Science and Engineering

NC State University

Casting Alloys: Malleable Cast Irons

- Made by heat treatment of white cast iron structures (10-30 hrs at 850-1000C followed by a slow cooling to 700C) - Decomposes Fe3C to Fe + C - Consists of C aggregates (temper nodules) in ferrite matrix - Strength and ductility similar to steel, but with lower melting point and better castability - Only thin sections possible - Machinable due to the graphite - Good for electronic components
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Casting Alloys: Nodular/Ductile Iron

- Graphite is made globular during solidification - small amount of Mg (0.1%) or Ce (0.2-0.4%) is added to Fe-C - Instead of graphite flake, spheroidal graphite grows - Combines good castability and machinability of gray iron with ductility and toughness of steel - Can be alloyed or hear treated - Ductile iron is seeing increasing use compared to gray iron
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Casting Alloys: Aluminum Castings

- Advantages - Wide range of mechanical properties - Relatively corrosion resistant - Electrical conductivity - Ease of Machining - Castable low melting point (660 C) - Lower density (2.7 g/cc) - Limitations - Cost per lb > cast iron, steel - lack of abrasion and wear resistance - Low strength compared to ferrous alloys

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Casting Alloys: Al-Si Alloys

- Advantages
- High fluidity (based on Al-Si eutectic) - Excellent feeding - Limitations - Binary AlSi Not heat treatable, (but ~0.35 Mg alloys Mg2Si precipitate to form - Two Alloys - 12% Si used for die casting (low Tm) - 5.3% Si contains dentrites of pure Al in Al+Si eutectic, 0.025% Na refines eutectic

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Casting Alloys: Magnesium Alloys

- Advantages
- Lightweight (1.7 g/cc) - Castable (low melting point 649 C) - Limitations - Very reactive, special precautions must be taken (melting under flux)

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Casting Alloys: Copper Alloys

- The earliest metallic alloys
made by man from molten metal - High Tm (1083 C) makes steel dies impossible - Major Alloys: - Pure copper - Cu-Zn: brass - Cu-Sn: bronze - Cu-Pb: valves - Cu-Be: gears and aerospace, precipitation hardenable
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Casting Alloys: Other Alloys

- Tin-based: bearings - Lead-based: battery grids, bearings - Zinc-based: die castings, automotive components, trim - Nickel and cobaltbased: superalloys, turbine blades

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