International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), INTERNATIONAL JOURNAL OFFebruary (2013) IAEME

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UNDERSTANDING THE MELT FLOW BEHAVIOUR OF ZA ALLOYS PROCESSED THROUGH CENTRIFUGAL CASTING
Jyothi P.N1, A. Shailesh Rao1, M.C. Jagath2, K. Channakeshavalu3
1

K.S. School of Engineering and Management, Department of Mechanical Engineering Bangalore-062, Karnataka, India
2

Bangalore Institute of Technology, Department of Industrial Engineering and Management, Bangalore-004, Karnataka, India
3

East West Institute of Technology, Principal and Director, Bangalore-091 Karnataka, India

ABSTRACT: Centrifugal casting is a process of producing casting by causing molten metal to solidify in rotating moulds. The study of melt flow in centrifugal casting is much more important as it determines the quality and properties of the final product. Understanding the flow of liquid metals in centrifugal casting is much more complex as there is a drop in temperature during the flow of molten metal. In the present work, ZA alloys (i.e. ZA 8, ZA 12, and ZA 27) with 6mm cast tube are prepared at 400,600 and 800 rotational speed of the mould. It was found that, for ZA8 and Z12 alloys, a uniform cast tube was observed for 600rpm, whereas for ZA 27 a uniform cast tube was not formed for various rotational speed of the mould due to the increased composition of aluminum. The observation made in the behaviour of molten metal during various rotational speeds of the moulds is explained. To know about mechanical properties of the alloys, the microstructure and hardness are discussed finally. KEYWORDS: Centrifugal Casting, ZA alloys, Microstructure, Hardness.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

INTRODUCTION Centrifugal casting is a material processing technique in which the flow pattern of the molten metal during casting strongly affects the quality of the final product. Literature about fluid flow in centrifugal casting is very sparse. Theoretically, it should be possible to produce a true cylinder even when the mould is rotated at low speeds. But practically, the molten metal has to be accelerated to a certain speed to form a uniform hollow cylinder. Depending upon the conditions of the molten metal, there must be an optimum spinning speed, at which, the molten metal will be picked up to form a true cylinder. Jaluria [1] discussed the importance of fluid flow in material processing. He points out several aspects of fluid flow which changes the properties in various processing techniques. Most of the studies of liquid metal behavior are done on continuous casting, where cold modeling experiments were compared with the final castings [2-6]. Janco [7] indicates several important parameters involved during the centrifugal casting process. He explains the design of gating, importance of rotational speed, mold dimensions, etc. But he has not done much to explain the importance of molten metal behavior during the process. Ping [8] has reported that no systematic investigation of microstructure evolution in centrifugal casting has been done, although this information is important to know the mechanical properties of the material. Chang [9] studied the influence of process parameters on the microstructure formation in vertical centrifugal casting, but not the effect of liquid metal during casting. From the experiments, Shailesh [10] explained the optimum rotational speed for centrifugal casting of aluminum silicon alloys, for a given diameter of the mould. Below, this speed, Couette, Taylor and Ekmann flows are seen in the final cast tube. The mechanical properties are evaluated to substantiate optimum rotational speed of the mould. Even though some attempts are tried to understand the nature of melt flow in aluminum silicon alloys [11], the comparison of various composition of alloy, in understanding the fluid behavior is not understood. To understand the nature of melt flow, Zinc based aluminum alloys commonly referred as ZA alloys are taken for our investigation as it is now increasing in various commercial usages. Moreover, they have better sliding, wear resistance, machinability and excellent corrosion resistance in various environments [12-15]. In the present work, an effort has been made to develop ZA alloys (i.e. ZA8, ZA12, and ZA27) through centrifugal casting process, at various rotational speeds (i.e.400, 600 and 800 rpm) of the mould. The cast tube of a true cylinder had a dimension of 80x120mm and 6mm thick. It is explained from the literature, that addition of aluminum into molten zinc alloy improves the fluidity and cast ability under continuous casting [13]. In the case of centrifugal casting, it is understood that with the increase in the Aluminum content from 12% to 27% in zinc based alloy, fluidity decreases and do not form a true uniform cylinder under the various rotational speed of the mould. The behaviour of the liquid metal for all the cast tube is explained in this paper. The microstructure and micro hardness of the cast tube is found out and explained finally. 2. EXPERIMENTAL DETAILS The experimental alloys were prepared as per ASTM B86-11 Standard for ZincAluminum (ZA) Alloy Foundry, by liquid metallurgy route. The alloy was melted and 200OC as super heat was maintained as teeming temperature for all the cast tubes. Horizontal type
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

centrifugal casting machine as shown in Fig [1] is employed to cast ZA alloys samples in this investigation. It is driven by a 2 HP DC motor for varying speed from 20 to 2000rpm.

Fig. 1 Centrifugal Casting Machine Set up For determining the microstructure, the samples were cut from the casting and were characterized using optical microscope. The samples were polished metallographically and etched suitably prior to their micro structural examination. Microstructures at the three regions (inner, middle and outer surface of the specimen) were examined to know changes in the mechanical properties along the radial direction of the cast tube. Finally, the Micro hardness for the samples at three regions were determined and explained. 3. RESULTS AND DISCUSSIONS 3.1 APPEARANCE OF THE CAST TUBE The ZA8 alloy heated in a furnace to form 6 mm thick cast tube is poured into rotating mould. An irregular pattern of the casting is formed at 400 rpm as shown in Fig. [2, a]. The molten metal, which is poured, leads to its stickiness at particular locations on the inner surface of the mould due to the lifting of the melt. Some quantity of molten metal is also found to move in the axial direction and a lump of mass settles in on one side at low rotational speed of the mould. Similar observations are also found in ZA12 alloy as seen from figure. With ZA27 alloy, an irregular pattern is seen in the final casting as observed from the figure. This is possibly due to the quick lifting of the liquid metal and hence limiting its axial movements. Further increase in the rotational speed of the mould to 600 rpm, a uniformly thick full cylinder is observed at 600 rpm with ZA8 and ZA12 alloy. This is possibly due to the molten metal getting along the circumference of the inner mould and thus avoiding other types of flows (Couette, Taylor Ekmann flows). The driving force which is acting on the molten metal should be sufficient, so that it is carried along the inner surface of the mould before it gets solidified. In case of ZA 27, the mould enables the rapid movement of the liquid metal in circumferential direction resulting in the formation of non-uniform thickness of the casting Fig [2, b]. Further increase in rotational speed to 800 rpm, enables the molten metal of all the alloys to move along the inner surface of the mould due to larger driving force. Only small amount of metal succeeds in moving along the axis getting solidified during its motion. Finally the casting which is formed has a varying thickness on its side Fig [2, c].
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From the above, it is understood that a uniform cast tube is formed at a rotational speed of 600rpm for ZA8 and ZA12 alloy for a given dimension of mould. Moreover, uniform cylinder is not formed in ZA27 alloy for different rotational speeds of the mould. Viscosity of the melt finds a major role in the formation of uniformly thick cylinder castings. A full cylinder is formed with irregular patterns inside the cast tube when rotated at speed of 400rpm. Since the viscosity and the driving force of the melt is low, it moves axially and obtains a lift from the inner walls of the mould during teeming process. The melt consumes more time for completing solidification which leads to formation of lumps in the final casting. Further with gradual increase in the magnitude of viscosity, the melt moves easily along the circumference of the mould and impression of the bands is formed in the final casting. The solidification rate and driving force of the melt finds more dependent on the viscosity and rotational speed of the mould. The melt must rotate at larger rotational speed after pouring, since it has low viscosity during teeming process. A uniform full cylinder is observed, when the mould is rotated at a speed of 600 rpm. Further increase in the rotational speed to 800rpm, the driving force plays a predominant role; it guides the molten metal to move along the circumference rather than moving along the axis. Finally, an irregular cast tube is formed. 3.2 MICROSTRUCTURES OF THE CAST TUBE The results of metallographic investigations of ZA alloys during centrifugal casting process are presented in Figure [3-5]. The microstructure of ZA8 alloy for various rotational speed of the mould is shown in Fig. [3].The structure is typically dendritic at the inner, middle and outer surface of the cast tube. Dendrites formed here are of complex shape and the growth of dendrite is moved from outer to inner surface of the mould. Here the liquid metal finds difficult to move along the circumference of the mould during teeming. It probably oscillates along the axis and when it becomes viscous, it moves along the circumference of the mould. This could be imagined and observed from the final cast tube. The process here has a lower solidification rate of the liquid metal in cast tube and finally improper structures are seen in the cast tube. Transformation of the dendritic structure into a fine structure is seen, when the rotational speed of the mould is increased to 600rpm.The solidification rate here is comparatively more since the liquid metal moved along the axis and simultaneously rises along the circumference of the mould forming a good cast tube. Increase in rotational speed to 800rpm, the liquid metal moves along the circumference of the mould after teeming into it. The driving force is too high, so that the melt has limited axial movement. Since the lump of melt is accumulated in one portion of mould, the solidification is low and hence dendrite structure is formed at the middle and inner surface of the mould. Due to sudden quenching of melt into mould during pouring, fine structures are seen at the outer surface of the mould. Similar observations are also seen for ZA12 alloy Fig [4]. Here the solidification of melt begins with the formation of aluminum rich dendrites. Further increase in aluminum for ZA27 alloy, a poor microstructure is observed in all the cast tube. For 400rpm, the liquid metal moves along the axial hitting the other side of the mould. It reverses back and tries to oscillate along the axis of the mould. Meanwhile the melt becomes viscous and then moves along the circumference of the mould. Increase in rotational speed to 600 and 800rpm, the melt moves along the circumference of the mould. This is due to high centrifugal force and viscosity. The microstructure shown in the Fig [5] revealed the above explanation. A rich primary aluminum is seen for the cast tube rotated at 400rpm. Since the aluminum restricts
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

fluidity, a coarse grain structure is seen in the metal rotated at higher rotational speed of the mould. L R

(A) 400 RPM Fig 2: ZA8, ZA12 and ZA27 alloys (L

(B) 600 RPM

(C) 800 RPM

R) for Various Rotational Speeds (6mm Thick)

Outer

Middle

Inner

Fig 3: Microstructure of ZA8 alloy for 400rpm, 600rpm and 800 rpm (Top to bottom) with Magnification of 400
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

Outer

Middle

Inner

Fig 4: Microstructure of ZA12 alloy for 400rpm, 600rpm and 800rpm (Top to bottom) with Magnification of 400m

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

Outer

Middle

Inner

Fig 5: Microstructure of ZA27 alloy for 400rpm, 600rpm and 800rpm (Top to bottom) with Magnification of 400m. MICRO HARDNESS OF THE CAST TUBE Micro Hardness measurements of the test sample are made on Vickers Hardness tester of Model MMT-X7A with applied load of 1 kg, according to the standard testing protocols. The hardness is carried out on a piece cut radially about 10mm square. Since the sample is thin, the curvature is marginal and it is easily pressed flat. Averages of three readings are taken as the hardness value for a given specimen. The hardness values on the outer, middle and inner surface of the samples as a function of rotational speed is shown in Fig. [6]. Hardness of centrifugally cast specimen depends on flowability and melt filling Behaviour, which can be known by flow length and wall thickness. In the present work hardness of ZA8, ZA12, and ZA27 centrifugally cast tube at different rotational speeds is found out. It is found that at 400 rpm and 800 rpm, hardness is not uniform across the cross section of the cast tube. But at 600rpm uniform hardness at all the three layers is recorded, as the flow of melt in the rotating mould is uniform. Moreover, at lower rotational speed of the mould, there will be no uniformity of melt over the inner surface of the mould. Due to this, the solidification rate of the cast tube is less and hence lower hardness values are observed in the final cast tube. In the case of higher rotational speed, the mould itself lifts the liquid metal over its inner surface making limited movement in axial
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

direction. Again, here, lower hardness values are found out due to lower solidification rate of the cast tube. For ZA27 alloy for three rotational speeds of the mould, hardness is varying across the section of the cast tube, as the flow of melt in to the mould is not uniform. This is due to increase of Al content in the melt; which reduces fluidity of the molten metal forming irregular cast tube.

(a)

(b)

(c)
Fig 6: Vickers Hardness Value versus Rotational speed of the mould for (a) ZA 8 alloy (b) ZA 12 alloy and (c) ZA 27 alloy
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 1, January - February (2013) IAEME

CONCLUSION ZA alloys are cast centrifugally with varying rotational speed of the mould. The following are the conclusions remarks from the experiments. 1) A uniform cast tube was formed for ZA8, ZA12 alloy due to lower content of aluminum in the metal. When the aluminum content is increased, say ZA27 alloy a uniform cast tube was not formed. All the cast tube formed must be substantial with mechanical properties. A fine microstructure was formed for uniform cast tube (i.e. both ZA8, ZA12 alloy). With aluminum rich ZA27 alloy, a coarse grain structure was formed. Hardness test for all the cast tube showed an increased value for uniform cylinder. The hardness value is varied across the section for ZA27 alloy.

2)

3)

ACKNOWLEDGEMENT The authors acknowledge Management, Principal, Staff and Non-teaching Staff of K.S.School of Engineering and Management, and NITTE Meenakshi Institute of technology, Bangalore for their kind support for this project. REFERENCES [1] [2] [3] [4] ogesh Jaluria, J. Fluid Engineering, 123, pp.173-210 (2001). Z Zipnicki Dynamical Solidification of metal filling a Cooled cylindrical channel,Int. Comm. Heat and Mass Transfer, Vol 27, No5, pp. 689,(2000). Wei Shyy, Multi Scale computational heat transfer with moving solidification Boundaries, Int. Journal of Heat and Fluid Flow, Vol 23, pp.278.( 2002). S M H Mirbagheri, H Esmaeileian, S Serajzadeh, Simulation of melt flow in coated mould cavity in the casting process, Journal of Material Processing Technology, Vol 143, pp.493,( 2003). Tatakani H, EBSD characterization and modeling of columnar dendrite grains growing in the presence of fluid flow, Acta Metallica, vol 48, pp.675,( 2000). S M H Mirbagheri, M Dadashzadeh, S Serajzadeh Modeling the effect of mould wall roughness on the melt Flow simulation in casting process,Applied Mathematical Modeling, Vol 28, pp.993,(2004). Nathan Janco, Centrifugal casting, Schaumburg,IL: Americal Foundrymens Society, (1988). Wu Shi Ping, LD Rong, GJ Jie, LC Yun, SY Qing, , Numerical simulation of microstructure evolution of Ti-6Al-4V alloy in vertical centrifugal casting, Material Science and Engineering A, vol 426, pp. 240,(2006). S R Chang, JM Kim, CP Hong,Numerical Simulation of microstructure evolution of Al alloys in centrifugal casting, ISIJ International, Vol 41, No 7, pp.738, (2001). Shailesh Rao A, P G Mukunda, Shrikantha S Rao,Influence of Optimal Speed for Sound Centrifugal Casting of Al-12Si Alloys, Journal of Materials. Vol 63, No.5, pp.25-29, (May 2011)

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