Course detail

Fundamentals of Foundry Theory

FSI-POB Acad. year: 2026/2027 Summer semester

Learning outcomes of the course unit

Prerequisites

Students must have the knowledge of the thermodynamics and kinetics of phase transformations (diffusion, phase equilibrium diagrams, phase transformations and their effect on structure and properties). 

Planned learning activities and teaching methods

Assesment methods and criteria linked to learning outcomes

Language of instruction

Czech

Aims

Specification of controlled education, way of implementation and compensation for absences

The study programmes with the given course

Programme N-SLE-P: Foundry Technology, Master's
branch ---: no specialisation, 6 credits, compulsory

Type of course unit

 

Lecture

39 hours, optionally

Syllabus

1. Description of substances using physical quantities, thermophysical and thermodynamic properties of substances.


2. Surface tension of metals and alloys, measurement of surface tension.


3. Hydrostatics – wettability of liquids, penetration of melt into the form of buoyancy of liquids.


4. Hydrodynamics – ideal fluid, Bernoulli's equation, free stream, flow in the channels of the inlet system.


5. Hydrodynamics – binding liquid, viscosity, hydraulic losses, loss height, liquid, Bernoulli's equation, free flow, flow in the channels of the inlet system, laminar and turbulent flow, fluidity of metals and alloys.


6. Thermodynamics of solidification, three different regions with different grain structure in the macrostructure of the casting, an overview of the theories of their formation.


7. Methods of heat transfer, conduction, radiation and heat flow, heat transfer coefficients.


8. Nucleation stage of solidification, nucleation rate, model of homogeneous nucleation and heterogeneous nucleation on a plane substrate. Models of heterogeneous nucleation in refractories cavities.


9. Stage of crystal growth, heat transport at the phase interface and in the mold-casting system. Transport of mass at the phase interface, the emergence of segregation of elements during solidification.10. Constitutional supercooling, phase interface morphology.


11. Control of solidification of metals, dynamic methods, melt modification, control of crystallization in the stage of crystal growth, single crystals.


12. Crystallization of basic types of foundry alloys. Volume changes during the solidification of castings and their consequences, thermal nodes, concentrated and scattered deposits.


13. Formation of thermal and phase stresses in the casting. Consequences of tension in the cooling casting, formation of cracks, cracks and collapse of the casting, possibilities of reducing tension in the casting.

Laboratory exercise

14 hours, compulsory

Syllabus

1. Practical tests of running property (the Curry spiral, platelets of varying thicknesses), aluminium, cast iron
2. Thermophysical properties of the mould, establishing experimentally the heat accumulation coefficient of mould bf
3. Solidification of castings, experimental determination of the solidification constant
4. Experimental measurement of temperature fields in the casting and in the mould, condensation zone
5. Experimental measurement of temperature vs. time in the casting and in non-insulated, insulated and exothermal risers
6. Solidification vs. time in an experimental casting


7. Shrinkage of castings during cooling, measuring the shape and dimensions of castings using 3D scanning.

Exercise

12 hours, compulsory

Syllabus

1. Introduction to metal flow, theory of running property, basic tests of running property
2. Gating systems, their types, calculation of simple gating systems (underpressure, overpressure)
3. Introduction to the measurement of temperature fields, possibilities of measuring by thermocouples, optical pyrometers and thermocamera
4. Casting risering, calculation of modules, evaluation of experiments
5. PC simulation of solidification, prediction of shrinkage cavities, comparison of simulation and experiment
6. Stress and casting deformations, PC simulation of stress