Theory
Casting is a solidification process, which means the solidification phenomenon controls most of the properties of the casting. Moreover, most of the casting defects occur during solidification, such as gas porosity and solidification shrinkage.
Solidification occurs in two steps: nucleation and crystal growth. In the nucleation stage solid particles form within the liquid. When these particles form their internal energy is lower than the surrounded liquid, which creates an energy interface between the two. The formation of the surface at this interface requires energy, so as nucleation occurs the material actually undercools, that is it cools below its freezing temperature, because of the extra energy required to form the interface surfaces. It then recalescences, or heats back up to its freezing temperature, for the crystal growth stage. Note that nucleation occurs on a pre-existing solid surface, because not as much energy is required for a partial interface surface, as is for a complete spherical interface surface. This can be advantageous because fine-grained castings possess better properties than coarse-grained castings. A fine grain structure can be induced by grain refinement or inoculation, which is the process of adding impurities to induce nucleation.
All of the nucleations represent a crystal, which grows as the heat of fusion is extracted from the liquid until there is no liquid left. The direction, rate, and type of growth can be controlled to maximize the properties of the casting. Directional solidification is when the material solidifies at one end and proceeds to solidify to the other end; this is the most ideal type of grain growth because it allows liquid material to compensate for shrinkage.
Read more about this topic: Casting (metalworking)
Famous quotes containing the word theory:
“A theory if you hold it hard enough
And long enough gets rated as a creed....”
—Robert Frost (1874–1963)
“Everything to which we concede existence is a posit from the standpoint of a description of the theory-building process, and simultaneously real from the standpoint of the theory that is being built. Nor let us look down on the standpoint of the theory as make-believe; for we can never do better than occupy the standpoint of some theory or other, the best we can muster at the time.”
—Willard Van Orman Quine (b. 1908)
“Many people have an oversimplified picture of bonding that could be called the “epoxy” theory of relationships...if you don’t get properly “glued” to your babies at exactly the right time, which only occurs very soon after birth, then you will have missed your chance.”
—Pamela Patrick Novotny (20th century)