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
%. TECHNOLOCY OF PAnERNMAKING
2.1
Requirement 5
2.2 Pattern materials 5
2.3 Machines and tools for pattcrnmaking U
2.4 Allowances and other technological considerations
2.5 Metal patterns 43
2 . Life expectancy of patterns 44
2.7 Pattern storage and repair 45
3. TECHNOLOGY Of MOULDING AND COREMAKINC
3.1
MOUlding sands 46
3.2 Sand conditioning 68
3.3 Moulding processes 73
3.1 Core sands and coremaking 77
3.5 Machine moulding 81
3 . 'Special' sand moulding processes 88

TECHroiOLOGY OF METAL MOULD CASTING PROCSSES
4.1 Permanent mould casting J09
4.2 Pressure die casting J 11
4.3 Low pressure die casting J 18
4.4 Squeeze casting 119
4.5 Centrifugal casting 1/9
4 . Continuous casting 111
4.7 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
U
,
'"
b
1
,
..
'09
, 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
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 Need for modernisation and mechanisation 238
9.2 Arcas of mechanisation 139
9.3 Pollution control in foundries 247
9.4 Plant layout for foundries 152
Suggesud Reading
Index

257
264
INDEX
Acid demand value, 52
Acid refractories, 173
Acurad process, 114
Additives, 65
Advanll,e' of cutin,s. 2
Aeration, 71
After-burner, 252
Allowances. pattern, 24
contraction, 24
distortion, 28
draft. 2.
macblnio 28
flppio 27
Aluminium allo,.s, 189
AooeaJiol. 227
rull,227
bomo.eni"liOD,228
isotbermal,228
aoft,231
AotiO_kiD 232
Arcair proceu, 216
Atomic bydrocen welding, 219
Auslemperiol. 230
Band ... , 16
Baioltc, 225
Base silica sand, choke of. 61
B s i ~ rdrlctories, 111
Bmlooitc,63
BiDders,6S
Boadioa <:'1),1, 63
C.rbon dioside mouldiol. 89
Carbon equivalent, 201
Casting de.i,n, J 38
Cutin, desi,D, computer aided, 141
Ca,dlll tolerances. 140
CeDl1'if",a' u.tln 119
Ceramic mouldioa:. 10)
Cbamotlc, 62
ChapelS, 81
Chemical t"tin 201
Chills,137
Chill test, 207
Chromit. sand, ~ 2
Cl.,.. 47. 61
Cl.y conlenl determinalion, 49
Coal dUlt, 5'
Cold ben; process, 98
Colour s.cbeme, patterns. 36
Comparative sieve dcsi,Dations,.so
Computer-aided castin, desiJD, 141
Continuous castio" 121
Conveyers,
aproD,244
belt, 243
bucket, 243
flicht,244
rnono-rail,244
overhead, 245
pallet,24S
plate band, 246
roller, 2
Copper allo)'l. 189
Cores, 78
bliaDced, 79
cover, 79
W,ID.,79
kiu, 79
rarn-up, 79
.ioa. 80
Core blower, 87
Core ball, 32
Core dryina, SO
Cored structure, 177
Core prloll" 29
Core sandl, 77
Cr}'Italllructure, 222
Cupola runaace, 148
cbaraea. I SO
cokeleu, 159
diflded blut, 160
elIkiODC)'. ISS
cmiuiona, 241
bot blut, 1S7
operation, 148
DSJlCn-enricbed blut, "9
.ater-cooled, 1 SI
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 ~ n 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
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)
Indu 163
"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
OliYine 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 ~ t o r l e and repair, 45
Percussion tesl 203
Permanent mould castilll, 109

'"
164 Indu
: Permeability test sand, j3
Planer, wood, 18
Plant layout, foundry, 2j2
Pollutants, 247
Pollution control, 247
Pouring basin, 124
Pressure test , 204
Quality control, foundry, 210
statistical,210
Radiogrnphic inspection, castings, 204
Redudng agents, 6j
Ref,actorics, 172
acid,l73
basic, 173
neutral,I73
selection, 174
Requirements, 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
chamolte,62
chromite,62
,recn,72
dry, 72
ollyine,62
spedal,61
zircon, 61
Sand blastin" 214
Sand conditioninl, 68
Sand preparatIOn, 69, 239
Sand rammcr, j5
land testing routine, S9
Sander, disc and bobbin, 20
Saws, wood, 16
Scrubber,2SI
Seasoning, timber, '1
Selection of metal composit ion. 182
Shd:eout, sand, 240
Shaper, wood, 18
Shatter test, nnd, 57
Shell mouldinl, 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
Transformation, steel, 225
Transverse sccdon, timber, 1
T-TT diagrams, 22S
Tumblin"21)
Ultrasonic inspection, 206
Vacuum moulding proct, 108
Vibratory shake-out, 241
Visual inspectio,}, 199
Weldins, 216
atomic hydrogen, 219
braze, 220
ftow, 220
inert gas metal arc. 218
metal arc, 216
oxyacetylenc,217
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