Solidification Processes

Starting material is heated

sufficiently to transform it into a
liquid or highly plastic state
Examples: metal casting, plastic
molding

Ancient Cast Structures

1000 years
4000 -5000 Years

4000 -5000 Years

Fundamental Factors
Solidification of the materials from the molten/liquid
state
Fluid flow of the material into the mold cavity
Heat transfer during solidification and cooling of the
materials in the mold
Influence of the type of mold materials

Solidification
Liquid

Liquid

Solid

snow-flakes-ice crystals

Dendrite grains in metal systems

science.nasa.gov

(IACS), EPFL

VariousStagesduringSolidificationofaCrystallineMaterial
(a)Smallcrystallitenuclei;
(b)(b)growthofcrystallites;

(c)solidificationcomplete;
(d)grainstructureas
itappearsunderamicroscope

grainboundary

Solidification
Nucleation
Growth
Nucleation
Formation of tiny stable solid particles from
liquid (50-60 atoms of ~ 1-2 nm dia.)
Undercooling provides energy for creation
of new S/L interface
Larger the extent of undercooling, greater
will be the number of nuclei formed

Types of nucleation
Two types of nucleation
Heterogeneous
Nuclei form on a solid surface (wall of the mold,
particulates in the liquid)

Homogeneous
Nuclei form on their own

Heterogeneous nucleation easier to occur

See where ice formation starts in the ice tray

Types of nucleation

Homogenous
Homogeneous

Heterogenous
Heterogeneous

Cooling curves
Pure Material
(T)

Pouring
Temperature
a
L
T

b
S

Freezing
Point

(t)

ab:Superheat;bc:Undercooling
CoolingRate:SlopeofTvs.t

Alloys

Cooling curve
T(C)

1500

L (liquid)

1400

s
u
d
i
u
q
li
L +lidus
so

1300

(TL)
C
(TS)

(FCC solid
solution)

1200
1100
1000
0

1600

20

40

60

80

t
100

A=PouringTemperature;B=Liquidustemperature(TL)
C=SolidusTemperature(TS)
BC=Bothsolidandliquidarepresent(Mushyzone)

Example: Cooling in a Cu-Ni Alloy

T(C) L (liquid)
1300
L: 35wt%Ni
: 46wt%Ni

+
L

A
32

35

B
C

46
43

24
1200

L: 35wt%Ni

L: 32wt%Ni

36

+
L

: 43wt%Ni

L: 24wt%Ni
: 36wt%Ni

(solid)

Consider

1100
20

Co = 35wt%Ni.

30

35
Co

40

50

wt% Ni

Cooling curve

Alloys

Cooling curves

Typical cooling curves for crystalline and amorphous solids.

In (ii) there was insufficient molten metal to provide latent heat
which would otherwise have caused a return to equilibrium as in
(ii)

Growth
Nuclei grow and then aggregate
Occurs as heat of fusion is extracted from
liquid
Direction and rate of growth can be
controlled by the manner of heat removal
Directional solidification
Movement of S/L interface opposite to the direction
of heat flow.
Modify heat flow direction

MetalSolidification

AlloySolidification

Inalloyswithlarge(TL TS),mushyzoneforms
throughoutcasting

Grainstructureduringsolidification

GrainStructureinaCasting

Cast Structure
Chilled
Zone

Columnar
Zone

Equiaxed
Zone

GrainStructureinaCasting

GrainStructureinaCasting

CastStructureinAluminum
Effectofmouldmaterials(coolingrate)

1cm

CastinSandMould

CastinwatercooledCumould

MetalCastingProcesses
-Expendable mold

Permanent mold

GreenSandMolding

GreenSandMolding

GreenSandMolding

Engine Block

Compressor Parts

ShellMolding
Step I:

Step IV:

Step II:

Step V:

Step III:

Step VI:

ExpandedPolystyreneProcess

SlipCasting

(i)
(ii)
(iii)
(iv)

Slipisfirstpouredintoanabsorbentmould
alayerofclayformsasthemouldsurfaceabsorbswater
whentheshellisofsuitablethicknessexcessslipispouredaway
theresultantcasting