Chapter10_cast

Chapter10_cast - Chapter 10 Manufacturing Processes Casting...

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Chapter 10 Manufacturing Processes asting Casting
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Overview of Manufacturing Processes • Definition: manufacturing, in its broadest sense, is the process of converting raw materials into product – Design of the product – Selection of the raw material – The sequence of processes through which the product will be manufactured Typical manufacturing methods include – Casting – Forming and shaping – Machining – Joining – Finishing Inspection, assembly if required, and testing typically follow
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Reading Material for Casting • AERO3700 course pack – p. 8 – 16 general knowledge – p. 16 – 25 . 221- 58 p. 221 258
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ommonly Used Casting Commonly Used Casting Techniques • Sand casting – p. 225 vestment casting 236 • Investment casting – p. 236 • Die casting – p. 242 • Directional solidification and single crystal casting – p. 248 • There is a good summary of these and ther techniques on p. 222 o e ec ques o p
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Casting • Casting is the process of pouring a liquid or viscous material into a mold where it cools and solidifies asting can be used to produce ingots p 18 (master Casting can be used to produce ingots p.18 (master alloy) for subsequent processing or near-to-shape parts xpendable molds are used in sand casting and Expendable molds are used in sand casting and investment casting • Permanent molds are used in die casting • Casting is used to produce complex shapes that cannot be made easily; e.g., those with internal cavities or hollows • Casting can reduce manufacturing complexity by reducing or eliminating steps such as weld and achining machining • Casting is also used for materials that are otherwise difficult to process
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Castings for Aero Applications – omplex shapes complex shapes Large, complex thin-walled ngine parts such as diffuser engine parts such as diffuser housings and combustors Investment casting up to 1.5 m dia. and 0.6 m long Gas turbine engine blades and nozzle guide vanes – Vacuum cast nickel-based superalloys (reduce machining) – Complex coring technology for internal cooling – Directional solidification and single crystal
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Casting used to eliminating welding
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icrostructural Difference in Microstructural Difference in Cast and Wrought Alloys See dendrites
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Typical Concerns with Castings onuniformity of properties Nonuniformity of properties – Porosities may exist due to gases evolved during solidification – Segregation refers to the concentration of alloying elements at specific regions due to the crystallization of ne phase with the subsequent concentration of other one phase with the subsequent concentration of other elements in the remaining liquid (macro and micro) – shrinkage during cooling which can lead to cavities and
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Chapter10_cast - Chapter 10 Manufacturing Processes Casting...

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