Principles of Foundry Technology

Second Edition

P. L. JAIN
Pro/ruor rllld Head

Producliotl &/#",er;,., DtptJflmtll' Notiang/ lnJtitute 0/ Foundry and Forit Tttlrll()Io6Y

ROllchf

MIKIELVG S.\PI\.O
TEe! .: 1 '.\ L T. ~ ITlV'l

P.O

REFERE,'CE LIBRARY

Tata McGraw-HilI Publishing Compa.y LImited

NEWDBLHI

CONTENTS

Foreword Preface to the First Edition Preface to the Second Edition

1. INTRODUCTION TECHN OLOCY OF PAnER NMAK ING

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b

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2.1 2.2 2.3 2.4 2.5 2. 2.7

3.

Requirement 5 Pattern materials 5 Machines and tools for pattcrnmaking U Allowa nces and other technological considerations U Metal patterns 43 Life expectancy of patterns 44 Pattern storage and repair 45

TECHNOLOGY Of MOULDING AND COREMAKINC

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'09

3.1 MOUlding sands 46 3.2 Sand conditioning 68 3.3 Mould ing processes 73
3.1 Core sands and coremaking 77

3.5 Machine mouldi ng 81 3. 'Special' sand moulding processes 88

TECHroiOLOGY OF METAL MOULD CASTING PROC SSES

4.1 4.2 4.3 4.4 4.5 4. 4.7

Permanent mould casting J09 Pressure die casting J 11 Low pressure die casting J18 Squeeze casting 119 Centrifugal casting 1/9 Contin uous casting 111 Electra -slag casting 122

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CATING AND RISERINC OF CASTINGS

5.1 Gating system 123 5.2 Risering of castings 132 5.3 Casting design 138

TECHNOLOGY OF MELTING AND CASTING

6 1 Melting equipment for foundries 143 6.2 Refractories for melting units 171 6.3 Metallurgical characteristics of cast metals 175
7. DEFECTS IN CASTING AND QUALITY CONTROL

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7.1 Defects in castings 194 7.2 Inspection and testing of castings 199 7.3 Quality control in foundries 110
. FEITUNG AND HEAT TREATMENT OF CASTINGS

8.1 Feltling and repair of castings 211 8.2 Heat treatment of castings 211
9. MODERNISATION AND MECHANISATION OF FOUNDRIES 238

9.1 9.2 9.3 9.4

Need for modernisation and mechanisation 238 Arcas of mechanisation 139 Pollution control in foundries 247 Plant layout for foundries 152
257 264

Suggesud Reading Index

INDEX
Acid dem and value, 52 Acid refra ctor ies, 173 Acu rad process, 114 Add itive s, 65 Adv anll ,e' of cuti n,s. 2 Aer atio n, 71 Afte r-bu rner , 252 Allo wan ces. patte rn, 24 cont ract ion, 24 dist ortio n, 28 draf t. 2. mac blni o 28 flpp io 27 Alum iniu m allo,.s, 189 Aoo eaJi ol. 227 rull, 227 bom o.en i"liO D,2 28 isot berm al,2 28 aoft ,231
Aoti O_k iD 232

Arc air proc eu, 216 Ato mic bydrocen welding, 219 Aus lemp erio l. 230
Band... , 16

Baio ltc, 225 Base silic a sand , cho ke of. 61 B.si~ rdrl ctor ies, 111 Bml ooit c,63 BiD ders ,6S Boa dioa <:'1),1, 63 C.rb on dios ide mou ldio l. 89 Carb on equi vale nt, 201 Cast ing de.i ,n, J 38 141 Cut in, desi ,D, com pute r aide d, tole ranc es. 140 Ca, dlll CeDl1'if",a' u.tl n 119 Cera mic mouldioa:. 10) Cba mot lc, 62 ChapelS, 81 Che mica l t"ti n 201 Chil ls,13 7 Chil l test, 207 Chr omi t. sand , ~2 Cl., .. 47. 61

Cl.y conl enl dete rmin alio n, 49 Coa l dUlt, 5' Cold ben; process, 98 Colo ur s.cbeme, patt erns . 36 Com para tive sieve dcsi ,Dat ions ,.so Com pute r-aid ed cast in, desiJD, 141 Con tinu ous cast io" 121 Conveyers, apro D,24 4 belt, 243 bucket, 243 flich t,24 4 rnon o-ra il,24 4 over head , 245 pall et,24 S plat e band , 246 roller, 2 Cop per allo)'l. 189 Core s, 78 bliaD ced, 79 cove r, 79 W,I D., 79 kiu, 79 rarn -up, 79 .ioa. 80 Cor e blow er, 87 Core ball, 32 Cor e dryi na, SO Cored struc ture , 177 Core prloll" 29 Cor e sand l, 77 Cr}' Itall lruc ture , 222 Cup ola runaace, 148 cbaraea. I SO coke leu, 159 difld ed blut , 160 elIkiODC)'. ISS cmiuiona, 241 bot blut , 1S7 oper atio n, 148 DSJlCn-enricbed blut , "9 .ate r-co oled , 1SI CJcfooe, ~

cold cracks, 199 cold shut, 199 dirt, 196 drop, 196 fin, 195 ps holes, rH bot tears, 199 metal pcmetration, 196 misrun,l99 'pin holes, J96 porosity, 196 scabs, 197 shrinkage cavity, 196 shift, )94 slal bole, 196 swell, 195 warped ca"int:, 195 Dendritic structure, 178 Depsainl, 179 Design considerations, 139 Dn.trio, 65 Die cutiol, 109 ac:urad proceSl, 114 dies,loo. III cold cbambers, 113 loose oeck, 114 hot chamber, 112 low prcuure, 118 machines, I1I multiphasc injection, 113 Dimensional iospection, 200 DireC'lional solidification, 133 Drawback, 39 Dust and fume control, 249 Dye penetrant inspection, 205 Economic considerations, 141 Eddy current IUI, 206 Etl'ectivc clay, 49 Elecukal (onduclivity Icst, 205 Electric rurnace, 161 basic alal process, 164 direct arc, 161 indirect arc, 169 induction, 169 steel meltinl practice, 1604 E1ectrO<kp(J$ition,IO Electrosl., Quinl, III Elevator, buclr:lIt, 243 EmistioDl in meltinl, 241 Equilibrium diqram, 179 EquilibriuQI moisture cooleDl, 6 Etcbinl reqentl, 209 Elb)'1 .ilicate, 103

Epolt)' resin alien, :uo EpolY resin pattern', 11 Eltothcrmic material., 136 Expanded polystyrene, 13 ferrosilicon process, 91 Feltlinl,212 fibre satUratiOn point, 6 Fibret1s material., 66 Fillets, pattern, 36 Filtcr, dust control, 250 Flow weldiDS, 220 Fluid ~nd mouldin" 92 Fracturqlest,208 Full mOl.lld caslinl, 105 Funn sand process, 99 Furnaces, melting. 143 air rUrnaces, 146 crucible type, 143 cupola, 148 e1eclric, 161 rOlO1'1, 146 Gates, 127 botlom,l29 finger, 127 born, 129 parlinll.127 pencil. 127 shrink bob, 127 skim bob, 127 skimming, 127 lop, 127 wedge, 127 whirlpool, 128 Gating ratio, 130 Gatins system, 123 Grain shape, sand, 47 Grain size. sand, 43 Gravity die casling, 109 Hand tools, mouldintl, ',6 Hand tools, panernmnkinll, 21 Hardenins. 228 Heal treatmeot, 222 problemS, 232 High pressure moulding. 86 High silica sand, 60 Hiah temperature testing, sand, 58 Homolenisation, 228, 236 Hol bolt mould in" 98 Hol spots, 138 Hydroblast, 214 Impact tcst, 203

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Indu

163

Inert P' arc weldifll, 21S Invcstmenl castinl, 101 Iron , 179 acicular. 186 ductile, 185 grey, ISO, 234 hip duty, 184 malleable, IS4, 235 special. 186 production, 184 J oi nter, wood, 17 Jolt Jqueeze moulding machine, S2 Life expectancy of patterns, 44 Linseed oil,66 Loose pieces, 34 UlW mellinl point alloy patterns, 10 Machine moulding, 81 Machines for metal paUernmakinl, 23 Machines for wood patternmakinl, J4 Ma8net!c particle inspection, 20S Magnetic separalor, 71 Malleable iron, 184, 235 Martempering,230 Match plate patterns, 39 Material handlin8. 242 Mechanical colleclor. 2S1 Mechanicalleslinl,201 Mechanisation, foundry, 238 Metc..t process, 10, 104 Mercury patterns, 10 Metallic coatings, patterns, 10 Metal patterns, 10,43 Metal sprayine, 221 Melalluraical characterisliCl J7S Microscopic uaminations, 209 Mlllins machine, pattern, 19 Minimum casling thickness, 140 Modernisation, fouodr)', 238 MOisture content, sand, SI Moiiture determinalion, sand, SI Molasses, 66 Mouldabilily tesling 239 Mould hardness, S3 Mnuldm, processts, 73 bench,7J dressinl.67 dry land, 75 cement, 92 ceramic, 10) cold box, 98 false check, 7)

"onr, 7)
ps-setting resin, 100 &feen sand, 75 high, pressure, 86 hot box, 98 loam. 76 machine, 81 odd side, 14 plaster, 10) plate, 14 shell,93 staek,14 vacuum, 108 Moulding saod, 46 Moulding lools, 16 Mushy lone, 178 Muller, sand, 11 NlIIural mouldinl sands, 60 Nature of casl metal.$, 175 Neutral refractories. 17) Nondestructive tesling, 291 Non_ferrous alloys, c:astinl, JBB, 190, Normalising, 227 Nucleation,22S O liYine S3nd, 62 Padding, 136 Parting agents, 67 Patterns, 37 ,lllcd,37 loosc.31 m:ltch plale, 311 shell moulding, 93 Skeleton, 38 sweep, )8 Pallern cnnstruction, 40 Pallern layout, 41 PaUerns materials, 5 epoxy, Il metal,9 f'lastef, 10 plastic, 11 polye5ter resin, 12 polystyrene, IJ polyurethane, IJ waxes, 14 wood,6 Pattern milling machine, 19 Paltem plales, )9 Paltern ~torale and repair, 45 Percussion tesl 203 Permanent mould castilll, 109

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164 Indu

: Permeability test sand, j3 Planer, wood, 18 Plant layout, foundry, 2j2 Pollutan ts, 247 Pollution control, 247 Pouring basin, 124 Pressure test , 204 Quality control, foundry , 210 statistic al,210 Radiogr np hic inspection, castings, 204 Redudn g agents, 6j Ref,acto rics, 172 acid,l73 basic, 173 neutral, I73 selection, 174 Require ments, patterns , j Riddle, sand, 71 Risering , 132 Risetlcs . desi,n, 138 Riser location , 13j Rou&h ellStinl costs, 141 Runner, 126 Sand,46 ctassifieation. j9 cOre, 77 chamol te,62 chromit e,62 ,recn,7 2 dry, 72 ollyine, 62 spedal, 6 1 zircon, 61 Sand blastin" 214 Sand conditio ninl, 68 Sand preparatIOn, 69, 239 Sand rammcr , j5 land testing routine, S9 Sander, disc and bobbin, 20 Saws, wood, 16 Scrubbe r,2SI Seasoning, timber, '1 Selection of metal composition . 182 Shd:eout, sand, 240 Shaper, wood, 18 Shatter test, nnd, 57 Shell mouldin l, 93 pattern, 96 Shot bl"'iDI , 215

Silica sand grains, 48 Silicone rubber, 14 Slinger, sand, SS, 88 Sodium silicate, 66, 89 Soldering, 218 Solidification, castings, 175 So]utionise_quench:l,e trC3lment, 236 sponge iron, use, 160 Sprue, 125 Squeeze casting, 119 SlatiSlical quality control, 210 Sleel casting, 187 Stop-off, 39 Strength lest, sand, SS Suc" relieving, 231 Sulphur print test, 208 Super cootinS, 224 Synthetic sand, 64 Tempering. 229 Timber, types, 8 Tooll and instruments, patterns , 23 Tou8hncss of sand, 56 Transfo rmation , steel, 225 Transve rse sccdon, timber, 1 T-TT diagrams, 22S Tumbli n"21) Ultrason ic inspection, 206 Vacuum moulding proct, 108 Vibrator y shake-o ut, 241 Visual inspectio,}, 199 Weldins , 216 atomic hydrogen, 219 braze, 220 ftow, 220 inert gas metal arc. 218 metal arc, 216 oxyacetylenc,21 7 submerged IrC, 219 thermit, 219 Wood impregnates, 8 Wood laminates, 8 Wood joioter, 11 Wood planer, 18 Wood worlr.ing lathe, 15 X-ray test, 204 Zircon nnd, 61