…Foundry Technology...

Course Contents
• Definition
• Sections in the foundry
• Advantages and limitations
• Terminologies in foundry
• Classification of molding/casting processes.
• Sand casting
• Special –sand casting techniques
• Permanent mold casting techniques
• Melting practice
• Gating systems and riser
• Solidification of metals/ alloys
• Al/Al alloys, cast iron and steel foundry
practice
• Casting defects…analysis and remedies
• Shakeout, cleaning, fettling, finishing heat
treatment and salvage of defective casting
 Manufacturing processes
• Rolling:
• Forging:
• Extrusion:
• Wire drawing:
• Machining:
• Welding:
• Powder metallurgy:
• Casting:
• Foundry or casting is the process of
producing metal/alloy component
parts of desired shapes by pouring
the molten metal/alloy into a
prepared mould (of that shape) and
then allowing the metal/alloy to cool
and solidify. The solidified piece of
metal/alloy is known as a
CASTING.
 Sections in the Foundry

Pattern Core Mould

sand

Mould Mould
tools box Sands
Pouring Binder
Furnace Ladle Mould
(Molten Additive
metal Fuel Casting
Moisture
Fettling
(Cleaning
Raw
Inspection
materials Salvaging Dispatch
and testing

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 TYPES OF FOUNDRIES

FERROUS LIGHT NON-FERROUS

HEAVY NON-FERROUS
METALS
Cast Iron
Bronze Aluminium

Malleable Iron
Brass Magnesium

S.G. Iron
Copper

Steel
Zinc

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 • Advantages:
• Freedom of design(shape, size and quantity)
• One piece
• Very heavy and bulky parts
• Metals difficult to machine like cast iron
• Applications:
• Automobile
• Machine beds
• Aircraft industry
• Pipes
• Railway, agriculture, construction etc
Steps involved in making a casting:
1. Make the pattern out of Wood , Metal or Plastic.
2. Prepare the necessary sand mixtures for mould and core
making.
3. Prepare the Mould and necessary Cores.
4. Melt the metal/alloy to be cast.
5. Pour the molten metal/alloy into mould and remove the
casting from the mould after the metal solidifies.
6. Clean and finish the casting.
7. Test and inspect the casting.
8. Remove the defects, if any.
9. Relieve the casting stresses by Heat Treatment.
10.Again inspect the casting.
11.The casting is ready for shipping.
 Terminologies used in foundry
Flask: A metal or wood frame, without fixed top or
bottom, in which the mold is formed. Depending upon
the position of the flask in the molding structure, it is
referred to by various names such as drag - lower
molding flask, cope - upper molding flask, cheek -
intermediate molding flask used in three piece
molding.
2. Pattern: It is the replica of the final object to be made.
The mold cavity is made with the help of pattern.
3. Parting line: This is the dividing line between the two
molding flasks that makes up the mold.
Core: A separate part of the mold, made of sand
and generally baked, which is used to create
openings and various shaped cavities in the
castings.
5. Pouring basin: A small funnel shaped cavity at
the top of the mold into which the molten metal
is poured.
6. Sprue: The passage through which the molten
metal, from the pouring basin, reaches the mold
cavity. In many cases it controls the flow of
metal into the mold.
7. Runner: The channel through which the molten
metal is carried from the sprue to the gate.
Gate: A channel through which the molten
metal enters the mold cavity.
9. Chaplets: Chaplets are used to support the
cores inside the mold cavity to take care of its
own weight and overcome the
metallostatic force.
10. Riser: A column of molten metal placed in
the mold to feed the castings as it shrinks and
solidifies. Also known as feed head.
11. Vent: Small opening in the mold to facilitate
escape of air and gases.
 Pattern making

 Pattern is a replica of the Casting

 Material of pattern depends on possibility
of repeat order & surface finish
 Core boxes additional tooling
 Material for Pattern & core boxes
 Materials for Patterns
g Wood
g Metal
g Alloys
g Thermocol
g Plastic
g Resin
g Acrylic sheets
g Ply wood
g Plaster of Paris
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Selection of material used for pattern making

1)Quantity
2)Quality
3)Intricacy
4)Degree of accuracy
5)Possibility of Design Changes
6)Molding method
7)Possibility of repeat orders

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Steps in Molding a Bushing

16
 First it is necessary to make
a pattern
The pattern is the form
embedded in the sand or any
other suitable material to
make a mould

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 Classification of the Moulding Process

Sand Casting

Green Sand Moulding Loam Moulding

Dry Sand Moulding Shell Moulding

Carbon di-oxide Moulding Pit & Floor Moulding

Cement Bonded Sand Full Mould Process

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 Classification of the Moulding Process

Permanent Mould Casting Plaster Mould Casting

Die Casting Investment Casting

Centrifugal Casting Air Set Moulding

Special Processes

Graphite Moulds Ceramic Moulds

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 Sand Casting
Green Sand Mixtures consist of

 Silica or other sand

 Binder in the form of bentonite clay
 Water
 Special additives for specific properties
 Properties Required in the Sand
• Green Strength:
• Dry Strength:
• Hot Strength:
• Refractoriness
• Permeability
• Flowability
• Grain size
• Collapsibility
Properties Required in the Sand
Green Strength:
The strength of the sand in the moist condition required for
compacting and handling.
Dry Strength:
The strength required by the sand to withstand the erosion and the
metallostatic pressure of the molten metal
Hot Strength:
The elevated temperature properties, i.e. above 1000C to prevent
mould enlargement and sand erosion.

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Properties Required in the Sand (Contd.)
Refractoriness:
The property of the sand to withstand the molten metal
temperature without softening or fusing.
Permeability:
The ability of the moulding sand to allow free passage of evolved
gases due to interaction of the molten metal and the moisture in
the sand.
Flowability:
The ability of the sand to flow under the load during the process of
moulding.

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Properties Required in the Sand
(Contd.)
Grain Size:
Finer sands with high refractoriness produce
smooth casting surfaces.
Collapsibility:
Heated sand becomes hard so it requires
collapsibility to allow the casting to cool without
cracking

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These Properties of the Sand are
Dependent on the Following:

A. Size, shape and size distribution of the grains

B. Chemical composition of the sand (purity)
C. Refractoriness and thermal stability

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 Sand Grain Shapes

(a) Rounded sand grains (b) Angular sand grains

(c) Compounded sand grains (d) Subangular sand grains

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SILICA SAND

 Most used in the foundry industry

 Should contain minimum 99.8%Silica
balance – oxides
 Excess oxides lower the fusion point

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CLAY
 Used in quantities from 2 to 50 %
 Contribute to the bonding of the sand
 They are natural deposits called:
• Bentonites (Montmorillonites)
• Fireclays ( Kaolinites)
• Special clays ( Halloysite, illite)
 Bentonites and fireclays are mainly used.
 Clays Impart base exchange, swelling index
and shrinkage characteristics
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WATER
 Used between 1.5 to 8 %
 Activates Clay
 Develops plasticity
 Develops strength
 Temper water: Limiting amount of water
adsorbed by the clay
 The adsorbed water develops the
strength in the moulding sand
 Excess water is free water: lubricates,

reduces strength and contributes to rejections

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SPECIAL ADDITIVES
To enhance one or more properties
• Cereals
• Pitch
• Coal Dust
• Wood Flour
• Silica Flour
• Iron Oxide

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 SPECIAL ADDITIVES (contd)

Cereals
Finely ground corn flour or gelatinised and
ground starch
Added from 0.25 to 2.0 %

Pitch (A Petrolem Product)

Imparts hot strength
Improves surface finish
Added upto about 2%
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Coal Dust
Finer than the base sand
Improves surface finish
Eases cleaning of the castings
Added from 2.0 to 8.0 %

Wood Flour
Improves thermal stability
Controls sand expansion
Added upto about 2%
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Silica Flour
Added to improve hot strength
Finer than 200 mesh
Improves surface finish
Added upto 35 %

Iron Oxide
Added to improve hot strength
Added upto about 1%

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TESTING OF PREPARED SANDS
Prepared sands are tested for
a. Moisture
b. Green Compression Strength (G.C.S.)
c. Green Shear Strength (G.S.S.)
d. Green Tensile Strength
e. Dry Compression Strength(D.C.S.)
f. Dry Shear Strength(D.S.S.)
g. Dry Tensile Strength

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h. Permeability
i. Mould Hardness
j. AFS Clay
k. Grain Fineness
l. Compactability

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Back to 19 No
Melting Furnaces
Types of Furnaces used for Melting

Furnaces are classified on the basis of

Fuels used-

Types of Fuels for Melting

 Electricity
 Fuels –Coke, Gas, Oil
 Types of Furnaces

Fuel Fired Electricity

[Coke, Gas, Oil]

Types
Types

Hearth Crucible Induction

Crucible Shaft Hearth

Direct Arc Resistor rod

Crucible Cupola Reverberatory

Indirect Arc Resis, Electricity

Cored Ind. Furnace Non-Cored Ind.

Furnace

Normal Medium High

Frequency Frequency Frequency