CONCLUSION AND RECOMMENDATION

Foundry process is one of the sand casting process. We can use various metals such as
Aluminium and cast iron in this process. Our group choose to use Aluminium as our metal to be
melted and shaped in foundry process.
We can shape metal by melting them into a liquid, pouring the molten metal into a mold
that we had provided. As it cools, we removed the mold material after the metal has solidified.
Our group used polystyrene to create the mold. So, our shaped metal has some defects such as
the surface of the metal is rough and not smooth.

There are some ways and recommendations to reduce the defects in foundry process.

1. Smoothen the surface of the mold.

By using sand paper, smooth the surface of the polystyrene used as mold. By this, we will
able to obtain a smooth surface of our product.

2. Avoid bubble in the molten metal.

We should pour the molten metal into the mold slowly and carefully to avoid bubbles or
air trapped in the molten. If there are bubbles in the molten metal, our final product will have
holes and it is considered as defects due to porosity.

3. Ramming a mold.
Few inches of sand over the pattern should be carefully rammed and tightly packed. Soft
spots, packets should be rammed properly. The mold should be rammed layer by layer. Besides,
ramming should be done as close to vertical surfaces of pattern.

4. Moulding sand preparation and moisture content determination.

Water should be added sufficiently into the sand to bring the moisture content to within
desired limits and uniform distribution of water all over the sand so that all the part of the sand
received the same moisture properly. Do not let the sand dry out or else the sand will be fragile.
Use sand riddle to cover the first layer just the pattern only and ensure there is no lumps. If the
sand is too wet, it will become squishy and cannot be packed properly.