Machine Castings of Ferrous Alloys

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Machine Castings of Ferrous Alloys

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ABSTRACT This is the first semi-annual report describing research conducted at the University of Illinois at Urbana-Champaign as part of a joint university-industry research program on machine casting of ferrous alloys. It covers a period of six months starting October 1 1975. At the time of initiation of this work the overall program had already been ni effect for 33 months. During the six months covered by this report work was performed on the following subjects.

A variety of casting systems were designed, constructed and operated. These included transparent, low and high temperature continuous slurry producers and a laboratory casting machine. Work was carried out to determine the effect of cast (Rheocast) structure on homogenization heat treatment response and mechanical properties of high temperature alloys. An economic analysis of the new machine casting process was initiated.

TABLE OF CONTENTS
ABSTRACT . 1
I. INTRODUCTION.3
II. PROCESS VARIABLES IN THE CASTING SYSTEM . 6 1.
Process Variables in the Continuous Slurry Producer. . 6 (a)
Shear Rate.6 (b)
Average Cooling Rate During Primary Solidifica¬ tion ..6 (c)
Volume Fraction Solid . 7 2.
Process Variables in the Casting Machine . . . 8
III. DESIGN, CONSTRUCTION AND OPERATION OF VARIOUS CASTING SYSTEMS . 9 1.
Transparent Model Continuous Slurry Producer . 9 2.
Low Temperature Alloy Continuous Slurry Producer ... 12 3.
High Temperature Alloy Continuous Slurry Producer . . 13 4. Laboratory Casting Machine . 15
IV. STRUCTURE, SEGREGATION, HOMOGENIZATION HEAT TREATMENT, AND MECHANICAL PROPERTIES OF RHEOCAST ALLOYS . 18 1.
Effect of Process Variables on Structure . 18 2.
Segregation, Homogenization Heat Treatment and Mechanical Properties.22 V.
ECONOMIC STUDIES . 26 1.
Identification of Parts.27 2.
Cost Breakdown - New Machine Casting Process . 29
VI. CONCLUSIONS.35
REFERENCES.37
APPENDIX.39
TABLES.42