FOUNDRY

-involves casting molten

metal into a mould.

Non-ferrous ferrous

- Copper based alloys - Iron Casting

casting - Steel Casting
 are solid metal objects
produced by filling the void
within a mold with liquid
steel.
Copper Age
(7700-3300)

Bronze Age
(3300-1200)
 Copper Age
(7700-3300)

Bronze Age
(3300-1200)

Iron Age
(1200 B.C. onwards)
 Copper Age
(7700-3300)

Industrial Age
Bronze Age
(18th century
(3300-1200)
onwards)

Iron Age
(1200 B.C. onwards)
-PATTERN MAKING is the science
of an original pattern or form
which will be used to make a
mold.
-Usually made up of wood, metal
or plastics.
- MOLD is the primary piece of
equipment
MOULDING MACHINES
-This is the process of segregation and
preparation of alloys and scrap prior to the
melting process.
Raw Materials
Housekeeping
-Support cost-consciousness in your employee
Low Cost
-Try to keep raw materials dry and, if possible,
"warm inside, particularly scrap.
Melting
The opportunities for energy savings in melting are in:
- Preheating of the charge
- Proper selection and adjustments of gas (oil) burners
- Furnace insulation and maintenance
- Monitoring and control
- Proper choice of electric melting technology
Electric furnaces
Electric arc melting
Electrical induction furnaces
Melting
The opportunities for energy savings in melting are in:
- Molten Metal Holding
- Cupola melting
Mould Making
- Drying of mould coating
- Lost foam casting
- Housekeeping
Do not let equipment run when it is not needed.
Apply preventive maintenance.
Ensure regular calibration of the controls.
Monitor sand composition.
Control spillage of shell sand.
Control spillage of sand.
Pouring
- Ladles
- Filters
- Use of ultrasound
- Housekeeping
When preheating the ladle, place an insulating
blanket on top of it (e.g., using Fiberfrax
ceramic fibre).
Analyse the metal transfer and pouring operation
with an eye for unnecessary delays, which
contribute to the heat loss.
Cleaning and Finishing
- Electrohydraulic cleaning
- Mechanical grit blasting
- Housekeeping
Apply preventive maintenance to the casting
cleaning equipment and tools.