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Processing Metals (Ch. 6)

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Expendable Mold Casting

Molds made out of plaster, sand, ceramics that are combined with binders.
The mold is broken up to remove the part.

Non-Expendable Mold Casting

Mold is designed to be used repeatedly

Expendable Mold: Sand Casting

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Floor and Pit casting = sand casting of large components (on the floor)
or very large parts using a pit as the drag

Loam molding = for HUGE castings.

50% clay, 50% sand is smoothed over
substrate made of bricks, wood whatever
to make contour, sheet metal sweeps used

Shell Molding = Sand glued with a resin: phenol formaldehydes, urea

formaldehydes, polyesters etc sand can be reclaimed
(good surface finish, can be automated, expensive)

CO2 process (works with sands containing 3-5% sodium silicate)

Plaster Molds No ferrous alloys Ag, Au, Mg, Cu, Al etc allowed
Unicast Plaster is poured over pattern and partially cured,
pattern removed and mold is fired in furnace
Osborn-Shaw process aggregate, hydrolyzed ethyl silicate, alcohol
poured over pattern, slurry hardens to rubbery state, and lit on fire
causing volatiles to burn off leaving ceramic with microcracks, crating
pourous mold

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Investment Casting

Permanent Mold Casting

Figure 6.2

Cast parts

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Continuous Casting

Working Process

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Hot Rolling of Steel

Cold Rolling of Metal Sheet

Figure 6.8

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Effects of Plastic Deformation

Extrusion
Die

Container

Metal

Direct
Extrusion
Container
Metal

indirect
Extrusion

Figure 6.9

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Extrusion details

Forging
Direct
Forging

Metal
Indirect
Forging

Dies

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Drawing
Figure 5.13

Wire or rod
Carbide nib

Figure 6.14

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Mechanical Properties

Strong
Weak
Tough
Brittle
Hard
Soft

Tensile test

Load Cell

Extensometer

Specimen

Figure 6.18

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Modulus of Elasticity

Yield Strength

Stress vs Strain

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Examples Stress vs Strain

Figure 6.14
Stress-strain curves of different metals

True Stress True Strain

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Yield Strength

Figure 6.23

Shear Stress

Poisons Ratio

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Percent elongation

Ductility

Percent Reduction in Area

Hardness and Hardness Testing

Rockwell hardness Figure 6.27

tester

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Hardness Tests

Table 6.2

Rockwell Details
Scale

Indenter

Major Load
F1
N

120oDiamond cone

490.5

100

Sheet steel ; shallow case hardened

1/16" steel ball

882.9

130

Copper, Aluminium alloys, Low Carbon Steel

120oDiamond

1373.4

100

Most Widely Used -Hardened Steels, Cast irons etc

120oDiamond cone

882.9

100

Thin but hard steels, Ductile Iron (Pearlitic

cone

Applications

1/8" steel ball

882.9

130

Cast Iron, Aluminium, Bearings alloys

1/16" steel ball

490.5

130

Annealed copper alloys , Soft thin metals

1/16" steel ball

1373.4

130

Phosphor bronze, beryllium copper, malleable irons, Lead etc

1/8" steel ball

490.5

130

Soft Metals Plastics etc

1/8" steel ball

1373.4

130

Soft bearing metals, Plastics, soft materials.

1/4" steel ball

490.5

130

Soft bearing metals, Plastics, soft materials.

1/4" steel ball

882.9

130

Soft bearing metals, Plastics, soft materials.

1/4" steel ball

1373.4

130

Soft bearing metals, Plastics, soft materials.

1/2" steel ball

490.5

130

Soft bearing metals, Plastics, soft materials.

1/2" steel ball

882.9

130

Soft bearing metals, Plastics, soft materials.

1/2" steel ball

1373.4

130

Soft bearing metals, Plastics, soft materials.

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Plastic Deformation in Single Crystals

Slip bands

Figure 6.28
Zinc single crystal

Slip Mechanism

Wall of high dislocation density

Figure 5.33
Figure 5.32

Dislocation cell structure in lightly

deformed Aluminum

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Slip in Crystals

Close packed
plane

Figure 5.34

Non-close-packed
plane

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Critical Resolved Shear Stress

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Schmids Law

Normal to
Slip plane

A1=Area of
Slip plane

F
A0

Slip
direction

Fr
A1

Example: Calculate on BCC Irons 112 111 slip system with 11.7 MPa
applied in the [001] direction.

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[001]

[112]
a

tan

2
35.26
2

[001]

[111]

tan

57.4

Twinning

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Twinning

Hall Petch Equation

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Effects of Grain Boundaries on Strength

Figure 6.40
Stress-strain curve of single
and polycrystalline copper

Figure 6.40
Slip bands in polycrystalline
aluminum grains

Figure 6.40
Dislocations piled up
against grain boundaries
in stainless steel

Effect of Cold Work on Tensile Strength

1018-Cold Rolled
1018-Annealed

Stress-Strain curves of 1018 steel

Figure 5.45

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Recovery

Cold worked (lots of

dislocations)

Recovered (dislocations
moved to low-energy configuration)

T < Tcrystallization

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Recrystallization
85% cold rolled

Stress relieved 302C 1 hr

Annealed 316C 1 hr

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Temperature and Time

Mechanism of Superplasticity

Grains before and after deformation

25