Abstract
Abstract : In the SD (diffusion solidification) casting process high carbon liquid iron is brought into contact with low carbon solid iron isothermally, and the liquid solidifies by rejecting carbon to the solid. The solidification mechanism is controlled by mass transfer rather than heat transfer as is the case in conventional castings. Advantages of the SD process over conventional casting processes and products result from (1) lower casting temperatures; (2) elimination of the need for a riser; (3) more rapid solidifcation; (4) plane- front as opposed to dentritic solidification; and (5) complete solidification under isothermal conditions. Diffusion solidification in the iron-carbon system can produce castings with greater than 99% of the theoretical density; solidification times typically range from a few seconds to several minutes, even for ingot sized castings; and tensile strengths as high as 185,000 psi with 15% reduction of area to break have been attained.
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