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Lab # 6
In a casting process, the material is first heated to completely melt and then poured into a cavity of the mold. As soon as the molten metal is in the mold, it begins to cool. When the temperature drops below the freezing point (melting point) of the material, solidification starts. Solidification involves a change of phase of the material and differs depending on whether the material is a pure element or an alloy. A pure metal solidifies at a constant temperature, which is its melting point (freezing point). For alloys, the solidification occurs over a temperature range depending upon the composition. A typical cooling curve for Ni-Cu system is given in Figure 6.2.
As temperature drops, solidification begins at a temperature indicated by liquidus and is completed when the solidus is reached. It is also of interest to examine the metallic grain formation and growth during the solidification process. The metal which forms the initial skin has been rapidly cooled by extraction of heat through the mold wall. This causes the grains to be fine, equiaxed, and
1 January 9, 2010
Lab # 6
(a) (b) Figure 6.3. Characteristic grain structure of (a) a pure metal, and (b) an alloy.
Objective: 1. To identify the importance of phase diagram. 2. To illustrate the use of cooling curves to determine chemical compositions of alloys using a series of Sn-Pb solder alloys. 3. To calculate the amount of heat extracted from pure Sn during various stages of solidification.
2 January 9, 2010
Lab # 6
References: 1. M.P. Groover, Fundamentals of modern manufacturing, 3rd edition, (2007). 2. Metals Handbook, 9th edition, vol. 16, ASM International, Materials Park, Ohio, 1989. 3. www.wikipedia.org
3 January 9, 2010