Peed Cast Metal in Sand Molds Using Your Own Backyard Foundry! Pee ett Procite acme PeenaPn eer enced reer eee rere ret annie pare ree eerie ea eset rena ane e see nnE MNT TET pene erent ser Rated Petar nen retro Pere eee sone Sees ee ec ene eee arenas Paveeren eran emernnt Leeann reenmeer nest een eaten rer) ae en ets Pee coe tee os Caer ty emir’ isnot in reporting the eres eres eae the reader how it is coe eg that shows YOU how cenMetaleasting: A Sand Casting Manual for the Small Foundry Vol. 1 By Stephen D. Chastain Ca 0 By Sepe D.Che ISBN 0-9702203.2-4 “The Sal Fundy Stes y Seen Chain ‘Volumen Making Cupola Fuases rhe Sl ony ‘ola Mel Casing & Sand Casing ara Va Stevechaainaomai com org tn alight atin in be roe. nome in Sy a a ak resin Kenseth aes tice aps gets i oe ‘TaBLe oF Contents VoLuMe I Purpose & Introduction 5 Health and Safety 7 1. THE SAND CASTING PROCESS 9 ‘The sand casting process 9 Basic Foundry Equipment 10 1 FOUNDRY PROJECTS: a Make a Match Plate Vibrator 2 Mold Making » Making Wooden Flasks 40 ‘Making Flask Hardware a ‘Making an Aluminum Flask s4 Rammer 37 Hardware Patents 9 IIL, MELTING EQUIPMENT 6 CCrucibles and Ladles ot Fumaces for the Small Foundry 70 Beginner's Charcoal Furnace 15 Stepping upto a Gas Fired Furmace 4 Forming Shoet Metal for Furnaces 98 IV. TEMPERATURE MEASUREMENT ns Temperature Measurement 13 ‘Thermocouples naMaking a Thermocouple Thermometer Optical Pyrometers \V. FOUNDRY SANDS AND BINDERS Molding Sand Clays Mullers and Mi (Cement Binders Development of Oi! Bonded Sand Petro Bond Furan Binders VICOREMAKING Cores Core Binders Baking Cores Core Finishing Core Sigs Core Buoyancy Strainer Cores Core Coatings BIBLIOGRAPHY APPENDIX. SUPPLIERS. INDEX Continued In Volume tt u7 nat 126 126 145 148 150 133 154 158, 160 160 169 13 rr 183 185 19 193 196 197 202 208 PURPOSI The purpose of this book, volumes I and i, is to describe and demonstrate the basic sand casting process so it may be successfully applied to the small foundry. The book will cover green sand molding, skin dried and dry sand molds. Sands, core practice, mold washes and basic molding equipment are described, as well as the basic principles of gating and rserng, A brief introduction tothe ‘metallurgy of east iron, copper based alloys and aluminum ate presented. Construction of small furnaces and various pieces of small foundry equipment are include so that you can build your own equipment as your foundry grows. Temperature measurement, an introduction to pattem raking and typical automotive casting of the 1930's, complete the sand casting books, ‘This book is not intended to be an exhaustive study of foundry practice. It is deliberately focused on low-tech readily available binders such as clay, linseed oil and molasses, Man has cast metals for thousands of years before modem polymer binders, petro-bond, cast, Styrofoam pattems, and ai set sand were available. Your trandfather probably deove a car with an engine cast in a skin dried mold sprayed with molasses water and pasted up cores made of sand and linseed oil. They work as well today as they did then “Metal casting has been an art long before it was a science. In some areas the science has yet to catch up with the art. Basie theories are presented to help you design or troubleshoot your work as your casting projects become more complicated. As with all the books in the "Small Foundry Series,” math is included as a tool or to help explain an idea The math isnot difficult and may be done on $9.95 scientific calculator (read the instructions forthe calculator). Tables and graphs are provided where calculations are long and tedious.