Abstract
Porosity forms in castings by shrinkage resulting from density differences between liquid and solid, and by evolution of dissolved gases. These effects can manifest themselves independently, or they can develop porosity synergistically.
With emphasis on basic principles underlying mechanisms involved in generation of porosity during solidification, the roles of nucleation and growth processes are outlined. Examples of individual mechanisms are presented based on practical systems.
Modeling of porosity formation during solidification utilizing analyses of basic mechanisms is outlined. The use of modeling to predict distribution, amount and pore size is discussed. Examples of plate castings of Al-4.5% Cu and steel are compared with predictions from a numerical model.
Empirical rules utilized to assure sound castings have been developed. These rules are supported by fundamental considerations. Minimization of gas content and maximization of mold chilling capability to assure strong directional solidification are required to avoid porosity. Casting design which incorporates these considerations and meets productivity requirements is vital to a successful foundry operation.
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© 1988 Plenum Press, New York
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Pehlke, R.D. (1988). Formation of Porosity During Solidification of Cast Metals. In: Katz, S., Landefeld, C.F. (eds) Foundry Processes. Springer, Boston, MA. https://doi.org/10.1007/978-1-4613-1013-6_17
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DOI: https://doi.org/10.1007/978-1-4613-1013-6_17
Publisher Name: Springer, Boston, MA
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