NON-FERROUS FOUNDRYMAN'S HANDBOOK

By E. GANAO

1 TABLES AND GENERAL DATA SI UNITS AND THEIR RELATION TO OTHER UNITS SI, METRIC, NON-SI AND NON-METRIC CONVERSIONS CONVERSION TABLE OF STRESS VALUES AREAS AND VOLUMES OF CIRCLES, SPHERES, CYLINDERS ETC THE PHYSICAL PROPERTIES OF METALS THE PHYSICAL PROPERTIES OF METALS (CONTINUED) DENSITIES OF CASTING ALLOYS APPROXIMATE BULK DENSITIES OF COMMON MATERIALS PATTERNMAKERS CONTRACTION ALLOWANCES VOLUME SHRINKAGE OF PRINCIPAL CASTING ALLOYS COMPARISON OF SIEVE SIZES CALCULATION OF AVERAGE GRAIN SIZE CALCULATION OF AFS GRAIN FINENESS NUMBER RECOMMENDED STANDARD COLOURS FOR PATTERNS DUST CONTROL IN FOUNDRIES BUOYANCY FORCES ON CORES CORE PRINT SUPPORT OPENING FORCES ON MOULDS DIMENSIONAL TOLERANCES AND CONSISTENCY ACHIEVED IN CASTINGS 2 ALUMINIUM CASTING ALLOYS INTRODUCTION CASTING ALLOYS CASTING PROCESSES THE EFFECT OF ALLOYING ELEMENTS HEAT TREATMENT OF ALUMINIUM ALLOYS 3 MELTING ALUMINIUM ALLOYS INTRODUCTION RAW MATERIALS MELTING FURNACES CORUNDUM GROWTH CHOICE OF MELTING UNIT CONTENTS 4 FLUXES APPLICATION OF COVERAL POWDER FLUXES GRANULAR COVERAL FLUXES 5 INSURAL REFRACTORY FOR LADLES AND METAL TRANSPORT LADLE LINERS 6 TREATMENT OF ALUMINIUM ALLOY MELTS HYDROGEN GAS PICK-UP IN ALUMINIUM MELTS DEGASSING ALUMINIUM ALLOYS GRAIN REFINEMENT OF ALUMINIUM ALLOYS MODIFICATION OF ALUMINIUM ALLOYS SODIUM MODIFICATION STRONTIUM MODIFICATION PERMANENT MODIFICATION SAND, GRAVITY DIE AND LOW PRESSURE DIECASTING MEDIUM SILICON ALLOYS, 4 7% SI EUTECTIC SILICON ALLOYS, 12% SI TREATMENT OF HYPEREUTECTIC AL SI ALLOYS (OVER 16% SI) MELTING AND TREATMENT OF ALUMINIUM MAGNESIUM ALLOYS ( 4 10% MG) SPECIAL REQUIREMENTS FOR GRAVITY DIECASTING TREATMENT OF ALLOYS FOR PRESSURE DIECASTING 7 RUNNING, GATING AND FEEDING ALUMINIUM CASTINGS GATING WITHOUT FILTERS GATING WITH FILTERS FEEDING MECHANISMS IN AL ALLOY AND OTHER NON- FERROUS CASTINGS SIMULATION MODELLING 8 FILTRATION OF ALUMINIUM ALLOY CASTINGS SIVEX FC FILTERS USE OF FILTERS IN CONVENTIONAL RUNNING SYSTEMS DIRECT POURING OF ALUMINIUM ALLOY CASTINGS KALPUR COMBINED SLEEVE AND SIVEX FC FILTER FOR ALUMINIUM CASTINGS DIRECT POURING INTO METAL DIES 9 PRESSURE DIECASTING OF ALUMINIUM ALLOYS DIE DESIGN PROCESS CONTROL MODIFICATION OF THE DIECASTING PROCESS APPLICATIONS OF DIECASTINGS THE DIECASTING FOUNDRY DIE COATING 10 LOW PRESSURE AND GRAVITY DIECASTING LOW PRESSURE DIECASTING GRAVITY DIECASTING DIE COATINGS FOR GRAVITY AND LOW PRESSURE DIECASTING 11 SAND CASTING PROCESSES GREEN SAND MOULDING MACHINES CORE ASSEMBLY SAND PROCESSES THE LOST FOAM PROCESS 12 SANDS AND SAND BONDING SYSTEMS PROPERTIES OF SILICA SAND FOR FOUNDRY USE TYPICAL SILICA FOUNDRY SAND PROPERTIES SAFE HANDLING OF SILICA SAND SEGREGATION OF SAND MEASUREMENT OF SAND PROPERTIES THERMAL CHARACTERISTICS OF SILICA SAND GREEN SAND ADDITIVES THE GREEN SAND SYSTEM GREEN SAND PROPERTIES CONTROL OF GREEN SAND SYSTEMS SAND TESTING CONTROL GRAPHS PARTING AGENTS SPECIAL MOULDING MATERIALS, LUTRON 13 RESIN BONDED SAND CHEMICALLY BONDED SAND SELF-HARDENING PROCESS (ALSO KNOWN AS SELF-SET, NO- BAKE OR COLD- SETTING PROCESS) TESTING CHEMICALLY BONDED, SELF-HARDENING SANDS MIXERS SAND QUALITY PATTERN EQUIPMENT CURING TEMPERATURE DESIGN OF MOULDS USING SELF-HARDENING SAND FOUNDRY LAYOUT SAND RECLAMATION TYPICAL USAGE OF SAND RECLAMATION FURANES PHENOLIC-ISOCYANATES (PHENOLIC-URETHANES) ALKALINE PHENOLIC RESIN, ESTER HARDENED HEAT TRIGGERED PROCESSES GAS TRIGGERED SYSTEMS THE SHELL OR CRONING PROCESS HOT-BOX PROCESS WARM-BOX PROCESS OIL SAND PHENOLIC-URETHANE-AMINE GASSED (COLD-BOX) PROCESS ECOLOTEC PROCESS (ALKALINE PHENOLIC RESIN GASSED WITH CO2) THE SO2 PROCESS SO2- CURED EPOXY RESIN ESTER-CURED ALKALINE PHENOLIC SYSTEM REVIEW OF RESIN CORE-MAKING PROCESSES 14 SODIUM SILICATE BONDED SAND SODIUM SILICATE CO2 SILICATE PROCESS ( BASIC PROCESS) GASSING CO2 CORES AND MOULDS IMPROVEMENTS TO THE CO2 SILICATE PROCESS THE CARSIL RANGE OF SILICATE BINDERS SOLOSIL SELF-SETTING SODIUM SILICATE PROCESSES ESTER SILICATE PROCESS ADHESIVES AND SEALANTS CORSEAL SEALANTS TAK SEALANT 15 MAGNESIUM CASTING CASTING ALLOYS THE MELTING, TREATMENT AND CASTING OF MAGNESIUM ALLOYS 16 COPPER AND COPPER ALLOY CASTINGS THE MAIN COPPER ALLOYS AND THEIR APPLICATIONS SPECIFICATIONS FOR COPPER-BASED ALLOYS COLOUR CODE FOR INGOTS MELTING COPPER AND COPPER-BASED ALLOYS MELTING AND TREATMENT OF HIGH CONDUCTIVITY COPPER COPPER-SILVER COPPER CADMIUM COPPER CHROMIUM COMMERCIAL COPPER MELTING AND TREATMENT OF BRASSES, COPPER ZINC ALLOYS MELTING BRONZES AND GUNMETALS MELTING ALUMINIUM BRONZE MELTING MANGANESE BRONZE MELTING HIGH LEAD BRONZE MELTING COPPER NICKEL ALLOYS FILTRATION OF COPPER-BASED ALLOYS 17 FEEDING SYSTEMS NATURAL FEEDERS AIDED FEEDERS FEEDING SYSTEMS THE CALCULATION OF FEEDER DIMENSIONS STEEL, MALLEABLE IRON, WHITE IRONS, LIGHT ALLOYS AND COPPER- BASED ALLOY CASTINGS GREY AND DUCTILE IRONS INTRODUCTION RANGE OF FEEDER PRODUCTS BREAKER CORES THE APPLICATION OF FEEDER SLEEVES WILLIAMS CORES FERRUX ANTI-PIPING COMPOUNDS FOR IRON AND STEEL CASTINGS METAL-PRODUCING TOP SURFACE COVERS FEEDOL ANTI-PIPING COMPOUNDS FOR ALL NON-FERROUS ALLOYS AIDS OT THE CALCULATION OF FEEDER REQUIREMENTS NOMOGRAMS FEEDERCALC CALCULATING FEEDER SIZES FOR ALUMINIUM ALLOY CASTINGS CHAPTER PREFIX SYMBOL PREFIX SYMBOL DECI D CENTI C MILLI M MICRO NANO N PICO P EXAMPLE: ONE MILLIONTH OF A METRE IS EXPRESSED AS ONE MICROMETRE, 1 M TABLES AND GENERAL DATA POWER: 1 KW = 3412 BTU/HR 1 HP (HORSEPOWER) = 0 745700 KW ENERGY, HEAT, WORK: 1 BTU = 1 05506 KJ 1 CAL = 4 1868 J 1 KWH = 3 6 MJ = 3412 BTU 1 THERM = 100 000 BTU = 105 506 MJ 1 KJ = 0 277778 W H SPECIFIC HEAT CAPACITY, HEAT TRANSFER: 1 CAL/G°C = 1 KCAL/KG°C = 4186 8 J/KG K 1 BTU/LB°F = 4186 8 J/KG K 1 BTU/H = 0 293071 W 1 PSI (LBF/IN2) = 7 KPA 1 N (NEWTON) = THE WEIGHT OF A SMALL APPLE! TEMPERATURE: °F = 1 8 °C + 0°C (CELSIUS) = 273 15 K (KELVIN) TABLES AND GENERAL DATA CONVERSION TABLE OF STRESS VALUES EQUIVALENT STRESSES AMERICAN BRITISH METRIC SI (LB/IN2) (TON/IN2) (KGF/MM2) (N/MM2) 100 CONVERSIONS 10 CYLINDER; RADIUS OF BASE R, HEIGHT H: AREA OF CURVED SURFACE = 2RH VOLUME = R2H CONE; RADIUS OF BASE R, HEIGHT H: VOLUME = 1?2 AREA OF BASE HEIGHT = 1?2R2H TRIANGLE; BASE B, HEIGHT H: AREA = 1?2BH TABLES AND GENERAL DATA VOLAT THALLIUM TL FOSECO NON-FERROUS FOUNDRYMAN’S HANDBOOK THE PHYSICAL PROPERTIES OF METALS (CONTINUED) ELEMENT THERMAL CONDUCTIVITY (W/M K) RESISTIVITY (OHM CM AT 20°C) VOL CHANGE ON MELTING (%) DENSITY (G/CM3) COEFF OF EXPANSION ( 10–6/K) BRINELL HARDNESS NO AL – BA – – BE – BI – AU – MG – MO – OS – PD – PT – AG SR – – S – TA 1 6 – W – U – ZN – TABLES AND GENERAL DATA OTHER ALLOYS ZINC BASE ALUMINIUM, CAST LEAD WROUGHT ALUMINIUM BRONZE ASHES MAGNESITE MERCURY 13 BRASS, ROLLED MONEL SWARF BABBIT METAL NICKEL, CAST NICKEL SILVER FIRECLAY BRONZE PHOSPHOR BRONZE PIG IRON, MEAN CAST IRON, SOLID PIG IRON AND SCRAP TURNINGS (CUPOLA CHARGE) CEMENT, LOOSE CHALK CHARCOAL, LUMP SILVER, CAST STEEL COAL DUST COKE TIN CONCRETE COPPER, CAST WATER, ICE CUPOLA SLAG LIQUID 0°C 100°C DOLOMITE OAK FIRE CLAY PINE FRENCH CHALK TEAK WROUGHT IRON GLASS GOLD, PURE 19 ZINC, CAST 22 CARAT 17 ROLLED GRAPHITE, POWDER SOLID