Kuliah 7 Penuangan Logam Cair

Penuangan logam cair
Penuangan
logam
terutama
untuk
cair
dari
tungku
tungku
dengan
kapasitas yang besar tidak langsung

dimasukkan ke dalam cetakan, tetapi
biasanya dituangkan terlebih dahulu ke
dalam
ladle
(tapping
process)
dan
kemudian dituangkan ke dalam cetakan

(pouring process). Hasil dari cetakan
tersebut disebut ingot.
kusharjanto, metalurgi-unjani
Metode penuangan logam cair ke cetakan ing

1. Direct teeming
2. Tundishing
3. Uphill/trumpet
teeming
kusharjanto,
metalurgi-unjani
Penuangan logam
cair
1. Direct
teeming
Logam
cair
dituangkan
ke
dalam cetakan dan langsung
mengenai dasar cetakan. Cara
ini
merupakan
cara
yang
termudah
tetapi
terjadi
percikan logam cair yang dapat
menyebabkan
cacat
pada
permukaan
ingot.
Dihindari
dengan memasang pelat yang
terbuat dari
baja dibagian
dasar cetakan yang nantinya
akan ikut menjadi cair.
2. Tundishing
Kotak tundish diletakkan di antara ladle
dan cetakan, ini dapat mengurangi
kecepatan
jatuh
logam
cair
dan
menghindari percikan.
Tundish-nya bisa dibuat satu atau lebih
sehingga efisien.
3. Uphill/trumpet
teeming
Logam
cair
dituangkan
melalui
saluran
berbentuk trompet yang berada ditengahtengah dua cetakan ingot, dimana logam cair
masuk ke dalam cetakan ingot dari bawah.
Kerugian
cara
ini
adalah
terbawanya
lining/bata tahan api akibat terkikis oleh aliran
logam cair.
Bentuk-bentuk cetakan ingot
Jenis baja ingot:

1. Killed steel
2. Rimming steel
3. Balanced or semi-killed
steel
10
Terjadinya perbedaan baja ingot disebabkan

karena pada saat proses pemurnian logam cair
mengandung karbon dan besi oksida yang tidak
larut.
Selain
selama
proses
peleburan/pencairan
logam, harus dilakukan pengontrolan komposisi

paduan, perlu pula diperhatikan timbulnya gasgas yang dapat terjebak pada saat pembekuan
dalam cetakan atau pengotor-pengotor yang
belum terikat sempurna menjadi slag/terak.
Untuk
menghilangkannya
ditambahkan
deoksidan/deoxidizer seperti silikon, aluminum

atau mangan.
11
Penampang ingot akibat proses

pembekuan
Proses pemanasan ingot

pada 1200 C, t= 4-8 jam
12
Skematik pengolahan ingot
13
14
15
Introduksi
Untuk
mendisain
dan
membuat
komponen yang bermanfaat, seorang
rekayasawan harus mengerti berbagai
sifat material dan dapat memilih dengan
benar material untuk aplikasi yang tepat
(the right material for
the
right
application).
application
Tetapi kadang-kadang kita tidak dapat
memilih material yang tepat atau yang
optimum, sehingga produk menjadi tidak
kompatibel dan masyarakat menjadi
16
Sifat-sifat material merupakan fungsi dari:

Struktur atom
Ikatan
Struktur kristal
Ketidaksempurnaan
Jika
variasi
diketahui,
struktur
maka
tersebut
sifat-sifat
material
dapat ditentukan.
Kita
dapat
membuat
sifat-sifat
material sesuai dengan kebutuhan.

17
Struktur Logam
Setiap
logam
ataupun non logam
merupakan
unsur
kimia.
Pada
temperatur
kamar
umumnya
berbentuk padatan
(Au, Fe dan Pb).
Beberapa berbentuk
gas (O dan N).
Sedikit
berbentuk
cairan (Br dan Hg).
Karakteristik
unsur
18
Struktur atom
Struktur
atom
adalah
kumpulan atom yang terdiri
dari beberapa unsur kimia.
Bentuk umum untuk logam
dan
non-logam
adalah
senyawa dan larutan padat.
Senyawa:
material
yang
terdiri dari dua atau lebih
unsur yang secara kimiawi
dapat terbentuk.
Dalam
bentuk
yang
sederhana terbentuk dari
dua unsur.
19
Relationship between:
Atoms
Molecules
Minerals
Rocks
Landforms
20
Karakteristik
senyawa
yang terbentuk akan
berbeda
dari
unsurunsur pembentuknya.
Contoh pada air (H2O)
Air terbuat dari H dan
O,
dimana
keduanya
adalah gas.
H dan O adalah gas
yang berbahaya (mudah
terbakar dan beracun)
tetapi ketika bergabung
menjadi
air
sifatnya
berubah/berbeda
dari
asalnya.
21
Ketika dua material bergabung

dan membentuk larutan, salah
satu akan menjadi diktator
dan
lainnya
akan
tunduk.
Diktator akan menguasai dan
melarutkannya.
Diktator material dalam larutan
biasanya adalah cairan. Material
yang terlarut bisa cair atau
padat. Contoh sederhana adalah
air garam atau air gula.
Setelah gula terlarut dalam air,
akan sulit untuk mengetahui
perbedaan air gula dan air biasa.
Air adalah diktator, secara total
menguasai gula. kusharjanto, metalurgi-unjani
22
Diktator material =
SOLVENT
Material
terlarut
=
Pada
logam
berlaku
SOLUTE
padat
(solid solution).
larutan
Dengan demikian solvent dan

solute
keduanya
adalah
padatan.
Pelarutan
terjadi
pada
temperatur tinggi, di mana
kedua padatan berubah menjadi
cair.
Untuk
baja,
pada
temperatur tinggi, besi (Fe)
dapat melarutkan banyak unsurunsur khususnya karbon. Fe
menjadi diktator.kusharjanto,
Sejumlah
kecil
metalurgi-unjani
23
Struktur partikel atom mirip dengan sistim tata surya

Secara umum struktur atom terdiri dari inti atau nucleus
(proton dan neutron) yang dikelilingi oleh elektron.
Proton = partikel bermuatan positif
Neutron = netral
Elektron = bermuatan negatif
Jumlah proton = jumlah elektron
Setiap kulit pada orbit elektron mengandung sejumlah
elektron, misalnya pada kulit pertama (terdekat dengan inti)
= 2 elektron, kedua = 8 elektron, ketiga = 18 elektron,
keempat = 32 elektron
24
Jika kulit terluar telah terpenuhi jumlah

elektronnya, maka unsur akan menjadi
stabil dan tidak akan bereaksi dengan
unsur lain membentuk senyawa atau
molekul. Contoh: gas inert argon dan
helium
digunakan
sebagai
gas
pelindung dalam proses pengelasan,
karena tidak bereaksi dengan logam
untuk membentuk senyawa intermetalik
yang tidak diinginkan.
Jika kulit terluar belum terpenuhi
jumlah elektronnya, maka akan
berikatan dengan unsur lain untuk
membentuk senyawa atau molekul.
25
Salah satu dasar untuk mengklasifikasi material

adalah ikatan kimia.
Dua jenis ikatan kimia:
1.Ikatan kuat (primary bonding): melibatkan
pembagian elektron (ikatan ion, kovalen dan
logam).
2.Ikatan
sekunder
(secondary
bonding):
melibatkan tarik menarik atom-atom yang
relatif lemah dan tidak ada pembagian atau
pertukaran elektron (ikatan van der waals).
26
27
Sifat-sifat Tabel Periodik
28
Sifat-sifat yang dimiliki oleh tabel periodik:

(dari kanan ke kiri)
1.Kekuatan
menurun)
logam
meningkat
(non-metalik
2.Radius atom meningkat

3.Potensial ionisasi menurun (energi yang
dibutuhkan untuk melepaskan elektron dati
atom)
4.Afinitas elektron menurun (energi yang
dilepaskan untuk memberikan elektron pada
atom)
5.Kelektronegatifan
menurun
elektron menarik
sebuah atom)
(kemampuan
29
Bonding
If atoms are large distance from each other, there is little

interaction.
As the distance between the atoms decreases, the energy
begins to decrease and the system becomes more stable.
Eventually, the atoms reach an optimal separation which
is the bottom of the energy curve. The separation is the
bond length. Bond energy is depth of well.
Atoms too close have repulsive energy.
Bonding occurs when two or more atoms come into close
proximity resulting in an attraction between atoms.
Bonding is attributed to interactions between the electrons.
unstable
System
Energy
Stable
Repulsive energy
Bond
Energy
Separated atoms
Distance between atoms
30
Ionic Bond
When elements donate or
receive an electrons in its outer
shell a charged particle or an
ION is formed.
If the element gives up an
electron, it is then left with at
net + 1 charge, and is called a
POSITIVE ION.
Charged particles are

attracted to each other.
31
Covalent Bonding
Occurs when valence

electrons are shared
Form between elements
that have too many or
require too many electrons
for Ionic Bond to form.
The nuclei is POSITIVE
(+), therefore, if electrons
(-) are shared by adjacent
nuclei, the result is a
VERY strong bond.
32
Metallic Bond
Metallic elements have only 1, 2, or 3 electrons in
their outer shell.
Since fewer electrons, bond is relative loose to the
nucleus.
When valence electrons approach adjacent atoms
orbit, electrons may be "forced out of natural orbit".
Results in positive ions being formed.
These floating electrons form a "cloud" of shared
valence electrons, and electron movement can occur
freely.
33
34
Van Der Waal Bond

Formed when an atom or
molecule
is
asymmetric,
creating a net polar moment
in the charges.
The bond is weak and is
found in neutral atoms such
as inert gases.
This type of bonding is of
little interest in metals.
More important in
polymers.
35
Sifat-sifat material
Ada 4 sifat material:
1.Sifat fisik (physical properties)
2.Sifat mekanik (mechanical properties)
3.Sifat kimia (chemical properties)
4.Sifat teknologi (technological properties)
36
Chemical and Physical

Properties
Chemical property the way a

substance reacts with others to form
new
substances
with
different
properties.
Involve the reactivity of elements or
compounds
Flammable
Able to rust or oxidize
Reactivity the ability of a

substance to combine chemically
with another substance.
37

Properties
Physical property a characteristic of a

substance that can be observed or
measured without changing the
composition of the substance.
Physical Properties
Shape, color, odor, texture
Melting point, boiling point, density,
strength, hardness, conductivity, etc.
38
Physical Properties
Melting point the temperature at which
a solid becomes a liquid
Boiling point - the temperature at which
a liquid becomes a gas (below the
surface)
Density is calculated by dividing the
objects mass by its volume. D = m/V
Properties help determine uses

Copper is used in electrical power lines,
telephone lines, and electrical motors
because of its good electrical conductivity.
Ethylene
glycol remains a liquid at
temperatures that would normally boil or
freeze in a car radiator. (Antifreeze)
39
Density of some items

Item
Chem Formula
Air
Gasoline
Water
Mixture
Mixture
H2O
Density
g/cm3
0.00129
1.9
1.00
Lead
Iron
Helium
Ice
Pb
Fe
He
H2O
11.3
7.86
0.00018
0.92
40

Changes
Materials that stay in the same state

under normal conditions
Surgical steel
Concrete
Glass
Materials that change and combine

Gasoline
Car batteries
Human metabolism (oxidation)
Digestion, kusharjanto,
etc. metalurgi-unjani
41

Properties
Chemical changes are changes in

composition
42

Properties
Electrolysis the process by which

water can be broken down into
hydrogen and oxygen.
The atoms of oxygen and hydrogen are
not destroyed, but rearrange
themselves to form hydrogen and
oxygen gas. [See figure 2-22 in text.]
Burning of gasoline into C, CO2, & H2O
A change in odor or color is a good clue
that a substance is changing chemically
i.e. food burning, paint fading, etc.
43
Dimensional Change
The percent
shrinkage or
expansion of a
material
Usually expressed
as a percentage of
an original length
or volume
Examples?
Thermal change
Temperature
changes
tooth & material

changes are different
Results in leakage of
fluids between
restoration & tooth
Each material has a
different thermal
coefficient of
expansion
44
Thermal Conductivity
Materials have
different rates of
conducting heat
Metals have higher

value than plastics
or ceramics
Therefore, metals
would cause patient
to feel more
sensitivity
Enamel and dentin

are poor thermal
conductors
In deep
restorations, a
cement base will
be used as an
insulator
Gold causes the
most sensitivity
45
Galvanism and Corrosion
Galvanism
Generation of
electrical currents
in mouth
Results from
presence of
dissimilar metals in
mouth
Causes pain and
tastes metallic
Corrosion
Dissolution of
materials in mouth
Results from presence
of dissimilar metals
Roughness and
pitting
Tarnish
Surface reaction of
metals to components
in saliva or foods
46
Solubility and Sorption
Solubility
Susceptible to
being dissolved
Adsorption
Sorption
Adsorption plus
absorption
Natural process
where molecules of a
gas or liquid adhere
to the surface of a
solid
Absorption
Passage of a
substance into the
interior of another by
solution or
penetration
47
Mechanical Properties
Mechanical properties apply to the way materials
behave when external loads and forces are applied.
Sometimes the material stretches (when loaded in
tension), bulges (when loaded in compression), or twists
(when loaded in torsion).
Anytime a load is applied to a material it will undergo
some change in shape. This change is called
deformation.
Mechanical properties indicate the strength and
deformability (change in shape) of a material.
48
How a material deforms is useful in determining if it

is suitable for products and processing.
Example - if the material deforms easily it may not
have high enough strength but may process quite
easily.
It is important to find the proper characteristics of a
material to determine if it meets the requirements for
both the product and the processing.
Mechanical properties are usually determined by
carrying out tests based on standards that define the
procedure so comparisons can be made to the way a
certain material is expected to behave.
49
Material
Loading
We will look at material loading in

several ways including:
tension,
compression,
shear
torsion.
50
Stress
Stress or tensile strength refers to a
materials ability to resist being pulled apart .
Diagram shows a front view of a circular
member loaded in tension.
Stress is calculated by dividing the load (P)
by the cross sectional area (A)
Load ( P )
Stress ( S )
Area ( A)
P
S
A
51
Problem
If a 1/2 inch diameter steel rod is used to suspend a
5000 pound load. What is the tensile stress in the
rod ?
Solution:
A = x R
= 3.14 x (0.25 in)
= 3.14 x 0.0625 in
= 0.19625 in
S = 5000 lbs. / 0.1963 in
= 25, 458.25 lbs / in
= 25, 500 psi
52
Strain
Material will change in length as a load is applied.
This is called strain and is measured by comparing
the change in length to the original length.
This change can be expressed as either a percentage
or a ratio with implied units being inches/ inch or
mm/mm
l = Extended length (lf) Original Length (lo)
l
e
x100%
l0
53
Modulus of Elasticity
Modulus of Elasticity determines a materials stiffness.
Ratio of stress to strain within the elastic region.
Modulus of Elasticity (E) = Stress (S) / Strain (e)
E=S/e
As stiffness increases, slope of the line will become
steeper.
Material that stretches easily will have a "flatter"
slope.
Modulus of Elasticity is an important property in
determining how much deformation will occur under
load.
54
The diagram shown below illustrates the comparison of

some selected metals
55
Up to this point we have considered only

tension.
Remember that normal stress is simply the
load divided by the cross sectional area when a
single axial load is applied.
We will now look at a few other types of
stresses and loading conditions including:
compression
bending
shear
torsion
56
Compression
The compressive strength of a material determines how much
it deforms under a compressive load.
Some materials such as concrete are strong in compression
but weak in tension.
Generally a material will respond in one of the three
following ways:
(A) Brittlekusharjanto,
Fracturemetalurgi-unjani
(B) Barreling
(C)
57 Buckling
Compression
For materials that are brittle only slight
deformation occurs prior to fracture.
With more ductile materials, failure may occur by
either barreling (when the length is less than twice
the diameter) or buckling (when the length is
greater 2.5 times the diameter).
Compressive stress can be determined by the load
divided by the cross sectional area.
58
Bending
When a member is subjected to bending, the outside
elements are placed in tension and the inside elements
are in compression.
At the center, stress is zero along the neutral axis.
The level of stress depends on the section geometry,
bending radius and loading, and the deflection depends
on the loading, section geometry and modulus of
elasticity.
59
Torsion
Torsion is stress created by twisting forces.
These forces have a moment or torque.
Example, torque is applied to a solid shaft to transmit torque
from the power source to the driven machine like a pulley, gear,
or flywheel.
Torque may also be applied by using a crank or lever (such as
a ratchet wrench driving a socket).
When torque is applied to a material, the material resists
being twisted, thus stresses are created - shear stresses.
Imagine a round bar being a column of washers. If the torque
is applied to one washer, it would slide or turn with respect to
the adjacent washer and create a shear force.
60
Torsion
Strength of a material in torsion is similar to tension in
concept, however rather than using force divided by area to
find stress, torsion is force multiplied by the distance from
the end of the lever/pulley to the center of the material being
acted upon.
61
Shear Stress
Shear describes the condition when parallel forces
(planes) act in opposing directions
Example - scissors cutting paper, or a hole punch
producing a hole.
Shear strength is also important in mechanical
fasteners, power transmission couplings, and many
manufacturing processes.
Shear stress is the applied force divided by the area
in shear.
62
Shear Stress
Practical applications of how shear stress occurs.
63

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Kuliah 7 Penuangan Logam Cair

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Penuangan logam cair

kapasitas yang besar tidak langsung

kemudian dituangkan ke dalam cetakan

Metode penuangan logam cair ke cetakan ing

Bentuk-bentuk cetakan ingot

Jenis baja ingot:

Terjadinya perbedaan baja ingot disebabkan

logam, harus dilakukan pengontrolan komposisi

deoksidan/deoxidizer seperti silikon, aluminum

Penampang ingot akibat proses

Proses pemanasan ingot

Skematik pengolahan ingot

Sifat-sifat material merupakan fungsi dari:

material sesuai dengan kebutuhan.

Ketika dua material bergabung

Dengan demikian solvent dan

Struktur partikel atom mirip dengan sistim tata surya

Jika kulit terluar telah terpenuhi jumlah

Salah satu dasar untuk mengklasifikasi material

Sifat-sifat Tabel Periodik

Sifat-sifat yang dimiliki oleh tabel periodik:

2.Radius atom meningkat

If atoms are large distance from each other, there is little

Distance between atoms

Charged particles are

Occurs when valence

Van Der Waal Bond

Chemical and Physical

Chemical property the way a

Reactivity the ability of a

Chemical and Physical

Physical property a characteristic of a

Properties help determine uses

Density of some items

Chemical and Physical

Materials that stay in the same state

Materials that change and combine

Chemical and Physical

Chemical changes are changes in

Chemical and Physical

Electrolysis the process by which

tooth & material

Metals have higher

Enamel and dentin

Galvanism and Corrosion

Solubility and Sorption

How a material deforms is useful in determining if it

We will look at material loading in

The diagram shown below illustrates the comparison of

Up to this point we have considered only

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