Use of a Metal-mould Process in the Development of Hemispherical Heavy-walled Castings

The exacting quality required of hemispherical heavy-walled steel castings, used in nuclear power applications, has been remarkably improved by the adoption of a newly developed metal-mould process. This technique is dependent on the use of a metal core. The optimum conditions for solidification were determined by the finite element analytical method. The appropriate wall-thickness of the chill elements was also investigated using data based on actual experience. The core was designed in such a manner that the surface carried a series of concave “dimples” in the manner of a golf-ball, the pattern being intended to prevent the formation of cracks, generated on the casting surface when in contact with a metal mould. Stresses caused by solidification shrinkage were reduced by splitting the core. In the event, the casting structure conformed well to the results of the solidification analysis. Radiographic examination revealed a high level of soundness, with no trace of internal defects. No anisotropy was detected in mechanical properties. It is shown that this process is being currently employed in the manufacture of actual products.