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- Solidification / Liquid stateprocess
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Concepts of solidification
Nucleation Homogeneous and heterogeneous
Inoculation
Cast structure Continuous casting process
Glass manufacture by float glass (Pilkington)
Slip casting of ceramics
Composites casting
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Solidification process of transformation of a liquid to a
solid
The basis of casting technology and other process including
welding, surface alloying, crystal growth, ingot production,
materials purification and refining
In solidification, a solid phase is nucleated and grows with a
crystalline structure.
If solid crystalline phase is not nucleated, a glassy
structures are formed.
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Table 8.1 Major Types of Phase Transformations
Type of Transformation Example
1. Vapor liquid Condensation of moisture
2. Vapor solid Formation of frost on a window
3. Liquid crystal Formation of ice on a lake
4. Crystal 1 crystal 2
(a) Precipitation Formulation of Fe3C on cooling austenite
(b) Allotropic -Fe-Fe at 910 C
(c) RecrystallizationCold-worked Cu new grains at high
temperatures
From J.D. Verhoeven, Fundamentals of Physical Metallurgy, Wiley, 1974
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Table 8.2 Degree of Complexity Involved in Phase Transformations
(a) Structure change
(b) Structure change + composition change
(c) Structure change + strain formation
(d) Structure change + strain formation + composition change
From J.D. Verhoeven, Fundamentals of Physical Metallurgy, Wiley, 1974
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Cooling Rate >104 -107oC/s
Rapidly cool or quench to produce amorphous or glassy
structure (metallic glass)
By processes such as: Atomization, melt spinning, roller-
quenching or plasma spray or laser or electron beam
surface treatment
melt solidifies without any chem changes.
Crystalline or amorphous (improved mech. properties)
Microsegregation-free structures
Using powder metallurgy to process the materials.
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Conventional casting process produces 2types of structures
Equiaxed smaller grains and higher strengh
Columnar longer, lower strength.
Introduce an inoculating agent
Also refer as grain refinement process
Introducing smaller particle (1-5 micron) intosolid solution.
Increase the degree of nucleation in the solidsolution and grain growth via heterogeneousnucleation
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Typical inoculants for various casting alloys
Metal Inoculant
Cast iron FeSi, SiCa, graphite
Mg alloys Zr, C
Cu alloys Fe, Co, Zr
AlSi alloys P, Ti, B
Pb alloys As, Te
Zn alloys TiTi alloys AlTi intermetallics
