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    10 Rules For Casting

    Uploaded by

    Bijendra Prajapati
    The document outlines 10 rules for producing quality castings: 1. The melt must be properly prepared and treated prior to casting. 2. The liquid metal front should not move too quickly, generally between 0.4-0.6 m/s, to avoid damage. 3. The liquid metal front must continuously move and not stop to prevent thick oxide film formation. 4. No bubbles from the filling system should pass through the mold cavity to avoid defects. 5. No bubbles from outgassing cores should pass through the mold cavity. 6. Feeding design must be reliable to prevent shrinkage defects. 7. Thin and thick castings avoid conve

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    10 Rules For Casting

    Uploaded by

    Bijendra Prajapati
    240 views2 pages
    The document outlines 10 rules for producing quality castings: 1. The melt must be properly prepared and treated prior to casting. 2. The liquid metal front should not move too quickly, generally between 0.4-0.6 m/s, to avoid damage. 3. The liquid metal front must continuously move and not stop to prevent thick oxide film formation. 4. No bubbles from the filling system should pass through the mold cavity to avoid defects. 5. No bubbles from outgassing cores should pass through the mold cavity. 6. Feeding design must be reliable to prevent shrinkage defects. 7. Thin and thick castings avoid conve

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    10 Rules for Casting

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    The document outlines 10 rules for producing quality castings: 1. The melt must be properly prepared and treated prior to casting. 2. The liquid metal front should not move too quickly, generally between 0.4-0.6 m/s, to avoid damage. 3. The liquid metal front must continuously move and not stop to prevent thick oxide film formation. 4. No bubbles from the filling system should pass through the mold cavity to avoid defects. 5. No bubbles from outgassing cores should pass through the mold cavity. 6. Feeding design must be reliable to prevent shrinkage defects. 7. Thin and thick castings avoid conve

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    240 views2 pages

    10 Rules For Casting

    Uploaded by

    Bijendra Prajapati
    The document outlines 10 rules for producing quality castings: 1. The melt must be properly prepared and treated prior to casting. 2. The liquid metal front should not move too quickly, generally between 0.4-0.6 m/s, to avoid damage. 3. The liquid metal front must continuously move and not stop to prevent thick oxide film formation. 4. No bubbles from the filling system should pass through the mold cavity to avoid defects. 5. No bubbles from outgassing cores should pass through the mold cavity. 6. Feeding design must be reliable to prevent shrinkage defects. 7. Thin and thick castings avoid conve

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 2

    Rule 1: Good-Quality Melt

    Immediately prior to casting, the melt shall be prepared and treated, if necessary, using the best
    current practice.

    Rule 2: Liquid Front Damage
    This is the requirement that the liquid metal front (the meniscus) should not go too fast.
    Maximum meniscus velocity is in the range of 0.4 to 0.6 m/s (1.3 to 2.0 ft/s) for most liquid
    metals. This maximum velocity may be raised in constrained running systems or thin-section
    castings. This requirement also implies that the liquid metal must not be allowed to fall more
    than the critical height (which corresponds to the height of a sessile drop of the liquid metal).

    Rule 3: Liquid Front Stop
    This is the requirement that the liquid metal front should not go too slowly and, more exactly,
    should not stop at any point on the front. The advancing liquid metal meniscus must be kept
    alive (i.e., moving) and therefore free from thick oxide film that may be incorporated into the
    casting. This is achieved by designing the liquid front to progress only uphill in a continuous
    uninterrupted upward advance (in the case of gravity-poured casting processes, from the base of
    the sprue onward).

    Rule 4: Bubble Damage
    No bubbles of air entrained by the filling system should pass through the liquid metal in the mold
    cavity. This may be achieved by:
    _ Use of an offset step pouring basin design of sufficient size to facilitate detrainment of
    entrained air and oxides; preferred use of a stopper to aid the filling of the basin; the use of sprue
    and runner designed to fill in one pass; avoidance of the use of wells or other volume-increasing
    features of filling systems; possible use of ceramic foam filter close to sprue/runner junction;
    possible use of bubble traps
    _ No interruptions to pouring

    Rule 5: Core Blows
    _ No bubbles from the outgassing of cores should pass through the liquid metal in the mold
    cavity. Cores must be of sufficiently low gas content and/or adequately vented to prevent
    bubbles from core blows.
    _ No use of clay-based core or mold repair paste (unless demonstrated to be free from the risk of
    creating bubbles)

    Rule 6: Shrinkage Damage
    _ No feeding uphill because of unreliable pressure gradient and complications introduced by
    convection
    _ Demonstrate good feeding design following all seven feeding rules, by an approved computer
    solidification model and test castings
    _ Control of the level of flash at mold and core joints, the mold coat thickness, and the
    temperatures of metal and mold



    Rule 7: Convection Damage
    Assess the freezing time in relation to the time for convection to cause damage. Thin and thick-
    section castings automatically avoid convection problems. For intermediate sections, either
    reduce the problem by avoiding convective loops in the geometry of the casting and rigging, or
    eliminate convection by rollover after filling.

    Rule 8: Segregation
    Predict segregation to be within the specification limits or agree upon out-of-specification
    compositional regions with the customer. Avoid channel segregation formation if possible.

    Rule 9: Residual Stress
    No quenching of certain light-alloy castings into water following solution treatment. (Boiling
    water is also not permitted for these castings, but polymer quenching or forced-air quench may
    be acceptable if casting stress is shown to be negligible.)

    Rule 10: Location Points
    All castings are to be provided with agreed upon location points for dimensional reference and
    for pickup for machining.

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