Foundry Processes: Their Chemistry and Physics

526 Pages·1988·11.028 MB·English

by  S. Katz, B. L. Tiwari (auth.), Seymour Katz, Craig F. Landefeld (eds.)

FOUNDRY PROCESSES
Their Chemistry and Physics
General Motors Research Laboratories Symposia Series
1986 Seymour Katz, Craig F. Landefeld, eds., Foundry processes: Their chemistry and
physics, Plenum Press, New York, 1988.
1985 J. A. Bennett, M. E. Botkin, eds., The optimum shape: Automated structural design,
Plenum Press, New York, 1986.
1984 L. Evans, R. C. Schwing, eds., Human behavior and traffic safety, Plenum Press,
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1983 M. S. Pickett, J. W. Boyse, eds., Solid modeling by computers: From theory to
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1980 D. C. Siegla, G. W. Smith, eds., Particulate carbon: Formation during combustion,
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FOUNDRY PROCESSES
Their Chemistry and Physics
-
Edited by
Seymour Katz and Craig F. Landefeld
General Motors Research Laboratories
Warren, Michigan
PLENUM PRESS. NEW YORK - LONDON. 1988
Library of Congress Cataloging in Publication Data
International Symposium on Foundry Processes, their Chemistry and Physics (1986:
Warren, Mich.)
Foundry processes, their chemistry and physics.
(General Motors Research Laboratories symposia series)
"Proceedings of an International Symposium on Foundry Processes, their Chem
istry and Physics, sponsored by General Motors Reserach Laboratories, held
September 21-23,1986, in Warren, Michigan." - Verso t.p.
Includes bibliographical references and index.
1. Founding-Congresses. I. Katz, Seymour. II. Landefeld, Craig F. III. Title. IV.
Series.
TS228.99.16 1986 671.2 88-5806
ISBN-13 :978-1-4612-8292-1 e-ISBN-13 :978-1-4613-1013-6
DOl: 10.1007/978-1-4613-1013-6
Proceedings of an International Symposium on Foundry Processes:
Their Chemistry and Physics, sponsored by General Motors Research Laboratories,
held September 21-23,1986, in Warren, Michigan
© 1988 Plenum Press, New York
Softcover reprint of the hardcover 1st edition 1988
A Division of Plenum Publishing Corporation
233 Spring Street, New York, N.Y. 10013
All rights reserved
No part of this book may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, microfilming,
recording, or otherwise, without written permission from the Publisher
v
FOREWORD
For a number of years it has been a General Motors Research Laboratories
custom to hold a symposium on a subject which is new and emerging, and to invite
the best people in the world in that subject to come together to talk to each other.
Initially, I had some difficulty in regarding foundry processes as a new and
emerging subject. Copper alloys have been in foundry practice for about six
thousand years. Foundrymen working with those alloys have been recognized, as
such, for nearly all that time. Iron has a much shorter history, probably only three
or four thousand years.
So what's new?
What is new is that a subject which has always been so complex and so difficult
that it could only be a craft skill, with bits and pieces of knowledge and bits and
pieces of insight, has begun to yield to new abilities to solve very complex problems.
We do this now because we can handle great amounts of data by computational
means, using new and more complicated theoretical treatments than we could deal
with before. In fact, we have a new technology with which we can attack these
terribly difficult problems. Thus, foundry processing is becoming a new subject
because new things can be done with it.
This symposium provided an opportunity to exchange views on the new aspects
and on old aspects of the subject. We are delighted to have been able to provide
this opportunity, and are proud to present these Proceedings as a record of the
interesting and enlightening exchanges that occurred here.
Dr. Robert A. Frosch
Vice President
General Motors Research Laboratories
vii
PREFACE
These Proceedings are a compilation of papers and discussions presented at the
International Symposium, Foundry Processes: Their Chemistry and Physics, held
September 21-23, 1986 in Warren, Michigan. This Symposium was the thirty-first
in a series sponsored by the General Motors Research Laboratories (GMR) for the
purpose of exploring subjects important to the automotive industry and to the
technical community at large.
These symposia have generally dealt with new and emerging areas of technol
ogy. This symposium, however, examines a subject with ancient beginnings from
the perspective of modern science and engineering.
This change in focus has become necessary as the demand has escalated for
castings with more accurate dimensions, lighter weight, higher strength, fewer
defects, and lower cost. To meet these demands, improvement of foundry processing
is increasing and relevant technology is being developed which can quicken this pace.
To achieve these goals, this symposium brought together an international group
of experts on foundry science and allied areas to discuss new ideas and insights
for foundry processing. To allow full discussion in the available time, the subjects
considered were confined to liquid metal processing from melting to casting. This
area was chosen because considerable relevant science and technology is emerging
that promises to have major impact on product quality and cost. The symposium
did not consider melt solidification, a subject that falls within the subject scope
but is so broad that it could not be adequately treated as a portion of this two-day
program.
The symposium covered three major subject areas: (1) production of liquid
metals, (2) composition control, which includes alloy addition, tramp element
removal and continuous chemical analysis, and (3) sources and control of casting
defects, focusing primarily on gas porosity and non-metallic inclusions. To provide
cohesiveness to the range of subjects discussed, the first paper is a critical overview
of foundry liquid metal processing.
In preparing for the symposium, the organizers were confronted with the
enviable situation of having a larger number of potential speakers than could
normally be accommodated in the two-day symposium. In order to include as many
Vlll PREFACE
of these valuable contributions as possible, four speakers presented shorter papers.
These were Professors Fray (Paper 7a), Fruehan (Paper 8a), Loper (Paper lla) and
Wieser (Paper 16a). Professors D. R. Gaskell (Purdue University) and K. S. Goto
provided prepared discussions of Papers 3, 7, and 7a.
Many people contributed to the planning and implementation of this sympo
sium. Professors R. J. Fruehan (Carnegie Mellon University) and J. Szekely (Mas
sachusetts Institute of Technology), served as consultants for the symposium, and
were instrumental in developing the program.
A debt of gratitude is due our able Session Chairmen, Professors A. McLean
(University of Toronto), K. W. Lange (University of Aachen), D. G. C. Robertson
(University of Missouri-Rolla) and K. S. Goto (Tokyo Institute of Technology).
S. A. Worth (GMR Technical Information Department), the third member of
the GMR triumvirate, took meticulous care of all the physical arrangements for the
symposium as well as publication of these Proceedings. The creative artwork for
the symposium was provided by R. Berube and S. E. McWilliams (GMR Technical
Information Department), and secretarial support by F. A. Kukula and M. D.
Aschmetat.
Thanks are due to those who worked behind the scenes to provide the
participants with the setting that facilitated active and enlightening discussion.
These GMR staff members include: J. J. Bommarito, K. Ernst, K. D. Gardels, C.
Herhager, G. A. Kruger, J. Lane, D. T. Maher, W. L. Serveney, S. R. Tiderington,
M. R. Tomlin and G. H. Tucker.
Finally, special thanks are due to members of GMR management, J. D. Caplan,
C. S. Tuesday, G. H. Robinson, and L. R. Buzan, for providing guidance and
support.
Seymour Katz
Craig F. Landefeld
Metallurgy Department
General Motors Research Laboratories
ix
CONTENTS
SESSION I: FUNDAMENTALS
Chairman: A. McLean, University of Toronto
Paper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 1
A Critical Overview of Liquids Metal Processing in the Foundry
S. Katz, B. Tiwari, General Motors Research Laboratories
Paper 2 ............................................. 53
Physicochemical Phenomena of Mechanisms and Rates of Reactions in Melting,
Refining, and Casting of Foundry Irons
E. T. Turkdogan, United States Steel Research Laboratories
Paper 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 101
The Capacities and Refining Capabilities of Metallurgical Slags
I. D. Sommerville, University of Toronto
Paper 4 ............................................ 135
Partition of Alloying Elements in Freezing Cast Irons and its Effect on Graphitiza
tion and Nitrogen Blow Hole Formation
A. Kagawa, T. Okamoto, Osaka University
SESSION 2: PRODUCTION OF LIQUID METALS
Chairman: K. W. Lange, Technische Hochschule-Aachen
Paper 5 ............................ . . ..... 163
Chemical Processes and Heat Loss in Cupolas
C. F. Landefeld, General Motors Research Laboratories
x CONTENTS
Paper 6 ............................................ 193
The Modelling of Fluid Flow Phenomena in Foundry Operations
J. Szekely, Massachusetts Institute of Technology
Paper 7 ............................................ 219
Electrochemical Sensing of Carbon, Oxygen, and Silicon in Iron Melts
A. R. Romero, K. Ichihara, H.-J. Engell, D. Janke, Max-Planck-Institut
fur Eisenforschung
Paper 7a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Possible Uses of Sensors in the Aluminum Foundry Industry
D. J. Fray, University of Cambridge
Paper 8 ............................................ 261
Fluid Flow and Mass Transfer in Gas Stirred Ladles
S. Asai, I. Muchi, Nagoya University; M. Kawachi, Aichi Steel
Paper 8a .......................... . . .......... 293
Two Phase Mass Transfer in Gas Stirred Ladles
R. J. Fruehan, S-H Kim, Carnegie-Mellon University
SESSION 3: PURIFICATION OF LIQUID METALS
Chairman: D. G. C. Robertson, University of Missouri-Rolla
Paper 9 ................................. . . .. 303
The Principles of Gas and Powder Injection for Iron Refining
G. A. Irons, McMaster University
Paper 10 ........................................... 333
Physico-chemical Aspects of Ladle Desulfurization of Iron and Steel
H. Gaye, C. Gatellier, P. V. Riboud, IRSID
Paper 11 ........................................... 357
Thermodynamic Aspects of Removing Impurity Elements from
Carbon-Saturated Iron
N. Sano, University of Tokyo
Paper 11a .......................................... 375
The Effect of Bismuth in Gray Cast Iron and the Chemistry of its
Neutralization with Rare Earth Metals
C. R. Loper, Jr., University of Wisconsin-Madison
Paper 12 ........................................... 393
Chemical Inpurities in Aluminum
J. H. L. vanLinden, R. E. Miller, R. Bachowski, Alcoa Laboratories
PREFACE xi
SESSION 4: CASTING DEFECTS
Chairman: K. S. Goto, Tokyo Institute of Technology
Paper 13 ........................................... 411
The Thermodynamics and Kinetics of Gas Dissolution and Evolution from Iron
Alloys
R. J. Fruehan, Carnegie-Mellon University
Paper 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Formation of Porosity During Solidification of Cast Metals
R. D. Pehlke, University of Michigan
Paper 15 ........................................... 447
On the Detection, Behavior and Control of Inclusions in Liquid Metals
R. 1. L. Guthrie, McGill University
Paper 16 ............... . . ..................... 467
Metal Refining by Filtration
D. Apelian, K. K. Choi, Drexel University
Paper 16a ................... . . ................... 495
Filtration of Irons and Steels
P. F. Wieser, Case Western Reserve University
Symposium Participants . 513
Subject Index . . . . . . . . 521