ME355

Winter 2015

Hw#3

Due: Friday, Jan. 30, 2015

Questions:
Q1: Identify the nondestructive techniques that are capable of detecting internal flaws and those that only
detect external flaws (refer to the Surface and Tribology Chapter).
Q2: Which of the nondestructive inspection techniques are suitable for nonmetallic materials? Why?
Q3: Describe the drawbacks to having a riser that is (a) too large, or (b) too small.
Q4: List and briefly explain the three mechanisms by which metals shrink during casting.
Q5: What are the benefits and drawbacks to having a pouring temperature that is much higher than the
metals melting temperature? What are the advantages and disadvantages in having the pouring
temperature remain close to the melting temperature?
Q6: Watch the movies on sand casting, lost foam and lost wax casting processes, and the permanent mold
processing using graphite casting mode (linked in the lecture notes, also listed below). Identify two
advantages of the expandable mold expandable pattern casting (comparing to the expandable mold
permanent pattern casting process), and two advantages of the permanent mold casting (comparing to
the expandable mold casting process).
Sand casting: http://www.youtube.com/watch?v=IrcNSgLZuFs
Lost foam: http://www.youtube.com/watch?v=QQSI6VYhcqw
Lost wax: http://www.youtube.com/watch?v=WXFRRg8YMT0
Permanent mold: http://www.youtube.com/watch?v=xL8ZCp93ulU

Problems:
P1: Using the phase diagram on next page, estimate the following quantities for a 58% Cu-42% Ni alloy:
(1) liquidus temperature,
(2) solidus temperature,
(3) percentage of nickel in the liquid at 2280 F,
(4) percentage of nickel in the solild at 2280 F,
(5) the major phases at 2280 F, and
(6) the ratio of solid to liquid at 2280 F.

P2: A round casting is 0.3 m in diameter and 0.5 m in length. Another casting of the same metal is elliptical
in cross section, with a major-to-minor axis ratio of 3, and has the same length and cross sectional area
as the round casting. Both pieces are cast under the same conditions. What is the difference in the
solidification times of the two castings? Use n=1.5.
P3: A cylinder with a height-to-diameter ratio of unity solidifies in 10 minutes in a sand casting operation.
What is the solidification time if the cylinder height is doubled? What is the time if the diameter is
doubled? Use n=1.5.
P4: Pure aluminum is being poured into a sand mold. The metal level in the pouring basin is 10 in. above
the metal level in the mold, and the runner is circular with a 0.4 in. diameter. What is the velocity and
rate of the flow of the metal into the mold? Is the flow turbulent or laminar? Use viscosity of 0.004 Ns/m2.

Answer key:
P1: 1) 2350 F, 2)~ 2200 F, 3) 33%, 4) 50%, (5) solid and liquid, 6) solid:liquid = 9:8
P2: tround/tellipse = 1.356
P3: a) t~13min, b) t~18min
P4: Q = 11.0 in3/s

Fig. 5.3. Phase diagram of a nickel-copper system obtained through low-rate solidification.