ITP Metal Casting: Implementation of Metal Casting Best Practices
IMP Metal Casting
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Transcript of IMP Metal Casting
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METALFABRICATION
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METAL FABRICATION
How do we fabricate metals? Blacksmith hammer !for"ed#
Cast molte$ metal i$to mold
Formi$" O%eratio$s
Ro&"h stock formed to '$al sha%e
Hot worki$" (s) Cold worki$" Deformation temperature
high enough for
recrystallization
Large deformations
Deformation below
recrystallization
temperature
Strain hardening occurs
Small deformations
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METAL FABRICATION METHO*+ !I#
FORMI!
roll
Ao
Adroll
Rolling "#ot or $old Roll
"I&beams' rails' sheet ( pla
Ao Ad
force
die
blan)
force
Forging "#ammering* Stamping%
"wrenches' cran)shafts%
often at
ele+, T
-dapted fro
Fig, ..,/'
Callister &
Rethwisch 8
ram billet
container
container
forcedie holder
die
Ao
e0trusion
10trusion
"rods' tubing%
ductile metals' e,g, $u' -l "hot%
tensileforce
Ao
Addie
die
Drawing
"rods' wire' tubing%
die must be well lubricated ( clean
$-S2I! MIS$1LL-1O3S
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Forgingis mecha$icall,worki$" or deformi$" a
si$"le %iece of a $ormall,hot metal- this ma, beaccom%lished b, thea%%licatio$ of s&ccessi(eblows or b, co$ti$&o&s
s.&ee/i$")
For"i$"s are classi'eeither closed or o%e$
For closed die0 a fobro&"ht to bear o$more die hal(es hthe '$ished sha%ethat the metal is d
i$ the ca(it, betwthem
For o%e$ die0 two ha(i$" sim%le "eosha%es !e)")0 %ara
semicirc&lar# are
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Rolli$"0 the most widel, &seddeformatio$ %rocess0 co$sists of
%assi$" a %iece of metal betwee$two rolls- a red&ctio$ i$ thick$essres<s from com%ressi(e stressese2erted b, the rolls) Cold rolli$" ma,be &sed i$ the %rod&ctio$ of sheet0
stri%0 a$d foil with hi"h .&alit,s&rface '$ish
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For e2tr&sio$0 a bar of metal isforced thro&"h a die ori'ce b, acom%ressi(e force that is a%%lied to
a ram- the e2tr&ded %iece thatemer"es has the desired sha%e a$da red&ced crosssectio$al area)E2tr&sio$ %rod&cts i$cl&de rods a$dt&bi$" that ha(e rather com%licated
crosssectio$al "eometries- seamlesst&bi$" ma, also be e2tr&ded)
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*rawi$" is the %&lli$" of a metal%iece thro&"h a die ha(i$" a ta%ered
bore b, mea$s of a te$sile force thatis a%%lied o$ the e2it side) Ared&ctio$ i$ cross sectio$ res<s0with a corres%o$di$" i$crease i$le$"th) The total drawi$" o%eratio$
ma, co$sist of a $&mber of dies i$ aseries se.&e$ce) Rod0 wire0 a$dt&bi$" %rod&cts are commo$l,fabricated i$ this wa,)
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METAL FABRICATION METHO*+ !II#
FORMI! $-S2I!
$asting& mold is filled with molten metal
metal melted in furnace' perhaps alloyingelements added' then castin a mold
common and ine0pensi+e
gi+es good production of shapes
wea)er products' internal defects
good option for brittle materials
MIS$1LL-1O3S
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METAL FABRICATION METHO*+ !III#
Sand $asting "large parts' e,g,' auto engine bloc)s%
4hat material will withstand T5.677and is ine0pensi+e and easy to mold
-nswer: sand;;;
2o create mold' pac) sand around fo"pattern% of desired shape
Sand Sand
molten metal
FORMI! $-S2I! MIS$1LL-1O3S
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METAL FABRICATION METHO*+ !I3#
Stage I< Mold formed by pouring
plaster of paris around wa0 pattern,
=laster allowed to harden, Stage II< 4a0 is melted and thenpoured from mold
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METAL FABRICATION METHO*+ !3#
$ontinuous $asting
&& simple shapes "e,g,' rectangular slabs'
cylinders%
molten
solidified
FORMI! $-S2I! MIS$1LL-1O3S
Die $asting
&& high +olume
&& for alloys ha+ing low melting temperatures
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METAL FABRICATIONMETHO*+ !3I#
MIS$1LL-1O3S$-S2I!
=owder Metallurgy "metals w?low ductilities%
pressure
heat
point contactat low T
densificationby diffusion athigher T
areacontact
densify
4elding "when fabrication of one large
part is impractical%
#eat&affected zone:
"region in which the microstructure has been
changed%,
-dapted f
..,@' Call
Rethwisch
"Fig, ..,@
Castings
Handbook
4alton an
Opar "1d,
piece . piece B
fused base meta
filler metal "melted%base metal "melted
unaffectedunaffected
heat&affected z
FORMI!