618-3021/01 – Theory of foundry processes (TSP)

Gurantor departmentDepartment of Metallurgy and FoundryCredits6
Subject guarantordoc. Ing. Jiří Hampl, Ph.D.Subject version guarantordoc. Ing. Jiří Hampl, Ph.D.
Study levelundergraduate or graduateRequirementCompulsory
Year1Semesterwinter
Study languageCzech
Year of introduction2014/2015Year of cancellation
Intended for the facultiesFMTIntended for study typesFollow-up Master
Instruction secured by
LoginNameTuitorTeacher giving lectures
ELB77 prof. Ing. Tomáš Elbel, CSc.
HAM33 doc. Ing. Jiří Hampl, Ph.D.
LIC03 doc. Ing. Petr Lichý, Ph.D.
Extent of instruction for forms of study
Form of studyWay of compl.Extent
Full-time Credit and Examination 3+2
Combined Credit and Examination 16+0

Subject aims expressed by acquired skills and competences

Acquired knowledge - The student will be able to characterize the processes occurring during the solidification and cooling of molten metal - The student will be able to formulate the basic physic-chemical processes in the interaction of metals with the form Acquired skills - The student will be able to apply theoretical knowledge to design manufacturing technology and construction of castings - The student will be able to apply knowledge of the physic-chemical processes for the verification procedures of casting production

Teaching methods

Lectures
Individual consultations
Tutorials

Summary

The course focuses on the theoretical knowledge and practical knowledge of the theory of foundry processes occurring during casting, crystallization and solidification of molten metal in the mold. Emphasis is placed on knowledge of the physical laws that explain the hydraulic conditions during melt flow and volume changes during solidification and physic-chemical nature of the interactions of metal material forms.

Compulsory literature:

[1]GOODRICH,M.G. Iron Castings Enginering Handbook.Illinois:American Foundry Society, 2006.ISBN 0-87433-260-5. [2]FRUEHAN,R. et al.: The Making, Shaping and Treating of Steel. Pittsburgh: 1998. ISBN 0-930767-02-0. [3]Allibert, M. et. al. Slag atlas. Düsseldorf, 1995. ISBN 3-514-00457-9.

Recommended literature:

[1] CAMPBELL, J. Castings practice: the 10 rules of castings. Oxford: Elsevier Butterworth-Heinemann, 2007. ISBN 07-506-4791-4. [2]FRUEHAN, R. Casting volume: Ladle operations. Pittsburgh: AISE Steel Foundation, 2003. ISBN 0-930767-04-7

Way of continuous check of knowledge in the course of semester

Elaboration of semestral projects and completion of the interim tests

E-learning

http://www.fmmi.vsb.cz/cs/urceno-pro/studenty/podklady-ke-studiu/studijni-opory

Další požadavky na studenta

Elaboration of semestral projects and completion of the interim tests

Prerequisities

Subject has no prerequisities.

Co-requisities

Subject has no co-requisities.

Subject syllabus:

1. Properties of liquid metals, the theory of internal structure melts, the types of solutions. Viscosity, surface tension metals and alloys, non-metallic inclusions. 2. Metal crystallization, nucleation and crystal growth, homogeneous and heterogeneous crystallization, segregation and segregations. Thermal and gravitational convection. 3. Volumetric shrinkage metals. Morphology and solidification zone of melts, melt filtration in dendritic skeleton, two-phase zone, the kinetics of shrinkage. 4. Solidification of metals, solidification kinetics, shrinkage of metals in liquid state. Thermal and thermal node axis. Transformation shrink stress, cracking. 5. Directionally solidified casting, casting module. Boss, function, module riser, riser sizing, pressure ratios and scope riser. 6. Physical fundamentals of fluid flow. Hydraulic conditions during casting. Gating system, the flow of metal in the gating system. 7. Pressure in the mold. Dimensioning and optimization of gating systems. Types gating. Filtration of metals in the gating system. 8. Gases in the casting form. Reoxidation processes in metal form. Endogenous and exogenous bubbles. Condensing zone of the water in the sand form. 9. Properties of metals in the solidus temperature. Heat, phase and shrink tension. The emergence of tensions and cracks in the casting, measurement and removal of residual stresses. Collapse castings. 10. Definition of basic physical quantities in thermal heat transfer between the casting and the mold. Coefficient of thermal expansion. 11. Gravity casting in vacuum and pressurized atmosphere. Centrifugal casting. Moulding under pressure. Low-pressure casting. Casting with crystallization under pressure and in semi-solid state. 13. Solidification of castings in metal molds. Heat mode of the metal mold. 12. The use of acoustic emission in the study of related disorders. 14. Modeling of thermal processes during solidification of castings.

Conditions for subject completion

Combined form (validity from: 2014/2015 Winter semester)
Task nameType of taskMax. number of points
(act. for subtasks)
Min. number of points
Exercises evaluation and Examination Credit and Examination 100 (100) 51
        Exercises evaluation Credit 30  15
        Examination Examination 70  21
Mandatory attendence parzicipation:

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Occurrence in study plans

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2018/2019 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies P Czech Ostrava 1 Compulsory study plan
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2017/2018 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies K Czech Ostrava 1 Compulsory study plan
2017/2018 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials K Czech Ostrava 1 Compulsory study plan
2016/2017 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies P Czech Ostrava 1 Compulsory study plan
2016/2017 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials P Czech Ostrava 1 Compulsory study plan
2016/2017 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies K Czech Ostrava 1 Compulsory study plan
2016/2017 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials K Czech Ostrava 1 Compulsory study plan
2015/2016 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies P Czech Ostrava 1 Compulsory study plan
2015/2016 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies K Czech Ostrava 1 Compulsory study plan
2015/2016 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials P Czech Ostrava 1 Compulsory study plan
2015/2016 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials K Czech Ostrava 1 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies P Czech Ostrava 1 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials P Czech Ostrava 1 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T038) Modern Metallurgical Technologies K Czech Ostrava 1 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T039) Thermal Engineering and Ceramic Materials K Czech Ostrava 1 Compulsory study plan

Occurrence in special blocks

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