PROCESSES
FOR
LIGHT METALS
PREPARED BY :SWAPNIL
NIGAM
SEMISOLID
PROCESSI
NG
SQUEEZE
CASTING
PROCES
SES
COSWOR
TH
PROCESS
ILP
CASTING
PROCESS
SEMI-SOLID PROCESSING
(SSP)
Initiated at MIT in 1971,
by Spencer & Flemings, during
their experiment with Sn-15%Pb alloy.
Thixotropic
behavior of a
system
Timedependent
thixotropic
behavior
Schematic of
Original THIXOMOLDING
machine
HDPC Machine
component
prepared by
thixomolding
BENEFITS of SSP
Energy requirements are less because complete
melting is not required. Energy needed to heat
aluminium alloys for casting is 35% greater than
that required to heat the same aluminium alloy
for the conditions needed for semisolid forming
Shrinkage and cracking within the mould are
reduced because the alloy is already partly
solidified when cast.
Lower operating and pouring temperatures lead to
an increase in the lives of metal dies.
Foundry cleanliness is easy to maintain, cycle
times are reduced and scrap is minimized.
Composite materials can be readily produced
Significantly lower capital investment & operating
costs.
SQUEEZE CASTING
Idea suggested by CHERNOV in 1878 to apply steam
pressure to molten metal while being solidified.
PRINCIPLE OF PROCESS High pressure solidification of
the system within a reusable die.
Squeeze casting process is a generic term to specify a
fabrication technique, which combines the permanent mold
casting with die forging, into a single operation, where
molten metal is solidified under high hydrostatic pressure.
It has become known as squeeze casting because the
casting is squeezed in a controlled fashion under high
pressure to complete the filling of the die
The process is now-a-days the most popular fabricaiton
route for MMC (Metal Matrix Composites) artifacts
Schematic of SQUEEZE
FORMING
MODES OF PROCESS
1. On basis of the way of pressure application,
Direct SC mode
Indirect SC mode
2. On basis of the timing of pressure application,
Before beginning of crystallization
After beginning of crystallization
BENEFITS of SC
Using this method it is possible to produce heat
treatable castings.
Yields a pore-free, fine-grained casting with
wrought product type mechanical properties &
casting has isotropic properties. The SN curves
obtained in fatigue tests also lie within the
scatter
band for wrought materials.
Offers high metal yield, minimum gas or
shrinkage, low porosity and an excellent surface
finish, combined with lower operating costs.
Possibility of using pre-forms (high-porosity
bodies made from specially selected materials).
DEMERITS of SC
High costs due to complex tooling & thus, high
production volumes.
No flexibility as tooling is dedicated to specific
components & increased process costs.
COSWORTH PROCESS
Process was developed in 1978 to meet the need for highly
specialized components for the Formula One racing car
engines manufactured by Cosworth Engineering, Ltd., in
England.
PRINCIPLE OF PROCESS Counter-gravity pumping of the
molten metal, into the mould through the base using
pressure assisted feeding.
Schematic
of
COSWORT
H
PROCESS
PROCESS CHARACTERISTICS:
Alloy range Al alloys.
Casting size = for Al-alloys (0.2-50 kg) , max. size
used is 915 x 610 mm.
Thin section capabilities 2.5 mm with overall size of
200mm.
Cast holes dia. of 6mm.
Surface finish = 3.5-6.3 microns.
LIMITATION: Is not suitable for a wide range of metals and
casting sizes.
ILP PROCESS
It is the Improved Low Pressure process of casting,
developed in Australia.
PRINCIPLE OF PROCESS utilizes transfer of molten metal
vertically through a riser tube into the bottom of the mould
cavity.
SPECIAL FEATURES :
The use of a combination of metal cores and
resin-bonded silica sand for the mould which
promotes rapid unidirectional solidification in
those regions of the casting where optimal
properties are required.
The mould can be inverted to facilitate this
controlled solidification, which may provide
dendrite arm spacings < 20 m adjacent to the metal
cores, and < 0.5% microshrinkage overall.
REFERENCES