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METAL CASTING(INDUCTION FURNACE)

By

Dr. Rajesh Ranganathan

C.Manivannan

C.I.T

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TRANFORMER

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TRANSFORMER

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Induction furnace

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Coreless type induction furnace Channel type induction furnace

Type of Induction furnaces

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Coreless type induction furnace

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Coreless type induction furnace

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meniscus

melt flow

crucible

induction coil

magnetic yoke

melt

Steel-construction

concrete-ring

Coreless type induction furnace

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Coreless type induction furnace

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Coreless type induction furnace

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Coreless type induction furnace

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Channel type induction furnace

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Channel type induction furnace

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MELT FLOW MODEL IN A

SINGLE LOOP CHANNEL FURNACE

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Channel type induction furnace

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Channel type induction furnace

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Advantages of Induction Furnace It has no electrodes and electric arcs which allow productions of

steel & alloys low in carbon and occluded gases without any

quality problem.

Low melting losses & alloying elements.

High power efficiency, therefore, cost-effective.

Precise control of the operating parameters.

Induction furnaces

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Advantages of Induction Furnace It has no electrodes and electric arcs which allow productions of

steel & alloys low in carbon and occluded gases without any

quality problem.

Low melting losses & alloying elements.

High power efficiency, therefore, cost-effective.

Precise control of the operating parameters.

Disadvantages of Induction Furnace

Refining in Induction Furnace is not as intensive or effective as inElectric Arc Furnace (EAF).

Life of Refractory lining is low as compared to EAF.

Removal of S & P is limited, so selection of charges with less

impurity is required.

Induction furnaces

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METAL CASTING(CASTING DEFECTS )

By

Dr. Rajesh Ranganathan

C.Manivannan

C.I.T

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Defects caused by

A. Defects caused by Patterns and molding box equipment.1. Mismatch ormold shift

2. Variation in wall thickness of the casting

3. Fins, fash and strain

4.

Crush

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Defects caused by

A. Defects caused by Patterns and molding box equipment.1. Mismatch ormold shift

2. Variation in wall thickness of the casting

3. Fins, fash and strain

4.

CrushB. Defects due to Impropermolding and core-making

materials.

1.Blow holes.

2.Drop.

3.Scab.4.Pin holes

5.Metal penetration and rough surfaces

6.Hot tears

C. Defects due to Improper sand mixing and distribution.

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BLOW HOLES

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D.D

efects caused byM

olding, corem

aking, gating etc.

1. Hot tears

2. Shift

3. Fins and fash

4. crush

5. cold laps6. slag holes

7. shrinkage defects

Defects caused by

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HOT TEARS

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HOT TEARS

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HOT TEARS

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COLDSHUT

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D.

D

efects caused byM

olding, corem

aking, gating etc.

1. Hot tears

2. Shift

3. Fins and fash

4. crush

5. cold laps6. slag holes

7. shrinkage defects

E.Defects due to Impropermolding drying and core baking.

F.Defects occurring While pouring and closing the molds.

1. shift and mismatch

2.Misrun

3. cold laps

4. crush

5. run out

Defects caused by

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MISRUN

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MISRUN

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MISRUN

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MISRUN

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MISRUN

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G.Defects caused by Molten metal.1.Misrun

2. Cold shuts

3. Excessive penetration

4.

Tin and lead sweat5. Hot tears

Defects caused by

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Tin and lead sweat

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G.Defects caused by Molten metal.1.Misrun

2. Cold shuts

3. Excessive penetration

4. Tin and lead sweat

5. Hot tears

6. Sand cuts and washes

7. Fusion

8.Gas porosity, gas holes, sponginess

9. Shot metal10. Rattails and buckles

11. Swells

Defects caused by

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H.Defects occurring during fettling etc.I. Defects due to faulty heat treatment.

J. Defects due to cast metal.

K. War page

Defects caused by

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GAS POROSITY

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SLAG