Principles of Foundry Technology

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

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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

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TECHN OLOCY OF PAnER NMAK ING

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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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

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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

CATING AND RISERINC OF CASTINGS

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

'09

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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

9.1 9.2 9.3 9.4

238

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

Suggesud Reading Index

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257 264

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