FERROUS FOUNDRYMAN'S HANDBOOK
CONTENTS CHAPTER 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 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 OPENING FORCES ON MOULDS DIMENSIONAL TOLERANCES AND CONSISTENCY ACHIEVED IN CASTINGS CHAPTER 2 TYPES OF CAST IRON INTRODUCTION PHYSICAL PROPERTIES OF CAST IRONS IRON CASTING PROCESSES CHAPTER 3 GREY CAST IRON SPECIFICATIONS RELATIONSHIP BETWEEN COMPOSITION, STRENGTH AND STRUCTURE OF GREY CAST IRON APPLICATIONS OF GREY IRON CASTINGS THE PRODUCTION OF GREY IRONS CHAPTER 4 MELTING CAST IRON CUPOLA MELTING ELECTRIC MELTING SHOP FLOOR CONTROL OF METAL COMPOSITION CHAPTER 5 INOCULATION OF GREY CAST IRON LADLE INOCULATION LATE STREAM INOCULATION MOULD INOCULATION CHAPTER 6 DUCTILE IRON PRODUCTION OF DUCTILE IRON MELTING DUCTILE IRON BASE CUPOLA MELTING AND DUPLEXING INDUCTION FURNACE MELTING USE OF THE TUNDISH COVER LADLE SANDWICH TREATMENT NODULANT PURE MAGNESIUM CONVERTER PROCESS CORED WIRE TREATMENT IN-THE-MOULD TREATMENT INHIBITING ELEMENTS INOCULATION AND FADING SPECIFICATIONS FOR DUCTILE CAST IRON HEAT TREATMENT OF DUCTILE IRON CASTING DUCTILE IRON COMPACTED GRAPHITE IRONS CHAPTER 7 MALLEABLE CAST IRON WHITEHEART MALLEABLE BLACKHEART MALLEABLE IRON CHAPTER 8 SPECIAL PURPOSE CAST IRONS HEAT RESISTING ALLOYS CORROSION RESISTANT CAST IRONS WEAR RESISTANT CAST IRONS CONTENTS CHAPTER 9 TYPES OF STEEL CASTINGS SPECIFICATIONS FOR STEEL CASTINGS TYPES OF STEEL CASTINGS CARBON STEELS LOW ALLOY AND MEDIUM ALLOY STEELS AUSTENITIC MANGANESE STEEL HIGH ALLOY STEELS DUPLEX STEELS PHYSICAL PROPERTIES OF STEELS SELECTION OF SUITABLE STEEL FOR CASTING CHAPTER 10 MELTING AND TREATMENT OF STEEL FOR CASTING ARC FURNACE MELTING AOD REFINING MELTING AND CASTING QUALITY CHAPTER 11 MOLTEN METAL HANDLING IRON FOUNDRIES METAL HANDLING SYSTEMS LADLE LINING KALTEK LADLE LINING SYSTEM FOR IRON FOUNDRIES KALTEK INSULATING LINING SYSTEM FOR AUTOMATIC POURING BOXES CASTING DEFECTS DUE TO POOR LADLE MAINTENANCE MOLTEN METAL HANDLING IN STEEL FOUNDRIES LADLE PRACTICE THE KALTEK LADLE LINING SYSTEM POURING TEMPERATURE FOR STEELS CHAPTER 12 SANDS AND GREEN SAND SILICA SAND MEASUREMENT OF SAND PROPERTIES NON-SILICA SANDS GREEN SAND PARTING AGENTS SPECIAL MOULDING MATERIALS, LUTRON GREEN SAND MOULDING MACHINES CHAPTER 13 RESIN BONDED SAND CHEMICAL BINDERS SELF-HARDENING PROCESS SAND RECLAMATION SELF-HARDENING RESIN BINDER SYSTEMS TRIGGERED HARDENING SYSTEMS HEAT TRIGGERED PROCESSES GAS TRIGGERED PROCESSES REVIEW OF RESIN COREMAKING PROCESSES CHAPTER 14 SODIUM SILICATE BONDED SAND CO2 SILICATE PROCESS (BASIC PROCESS) IMPROVEMENTS TO THE CO2 SILICATE PROCESS SELF-SETTING SODIUM SILICATE PROCESSES ADHESIVES AND SEALANTS CHAPTER 15 LOST FOAM CASTING PRINCIPLE OF THE PROCESS PATTERNMAKING ASSEMBLING CLUSTERS COATING THE PATTERNS INVESTING IN SAND THE MECHANISM OF CASTING INTO FOAM PATTERNS ADVANTAGES OF LOST FOAM CASTING DISADVANTAGES APPLICATIONS THE FUTURE CHAPTER 16 COATINGS FOR MOULDS AND CORES THE NEED FOR A COATING CHOICE OF COATING AND FORM OF SUPPLY COMPONENTS OF A COATING APPLICATION METHODS FOR COATINGS COATINGS FOR IRON AND STEEL FOUNDRIES COATINGS FOR HIGH PRODUCTION FOUNDRIES COATINGS FOR JOBBING MOULDS AND CORES SPIRIT BASED COATINGS THE TRIBONOL PROCESS MISCELLANEOUS COATINGS COATINGS FOR FOUNDRY TOOLS CHAPTER 17 FILTRATION AND THE RUNNING AND GATING OF IRON CASTINGS CONVENTIONAL RUNNING SYSTEMS WITHOUT FILTERS FILTRATION OF IRON CASTINGS SEDEX CERAMIC FOAM FILTERS CELLULAR CERAMIC FILTERS COMBINED FILTER, FEEDER AND POURING CUP, THE KALPUR DIRECT POURING SYSTEM CHAPTER 18 FILTRATION AND THE RUNNING AND GATING OF STEEL CASTINGS CONTROLLING THE FLOW OF METAL THE USE OF CERAMIC FOAM FILTERS INCLUSIONS IN STEEL CASTINGS STELEX ZR CERAMIC FOAM FILTERS KALPUR ST DIRECT POUR UNIT COST SAVINGS THROUGH THE USE OF STELEX AND KALPUR CHAPTER 19 FEEDING OF CASTINGS NATURAL FEEDERS AIDED FEEDERS – FEEDING SYSTEMS THE CALCULATION OF FEEDER DIMENSIONS DETERMINATION OF FEEDING REQUIREMENTS STEEL, MALLEABLE IRON, WHITE IRONS, LIGHT ALLOYS AND COPPER BASED ALLOY CASTINGS GREY AND DUCTILE IRONS FOSECO FEEDING SYSTEMS KALPUR FILTER FEEDER UNITS BREAKER CORES APPLICATION OF FEEDER SLEEVES FERRUX ANTI-PIPING COMPOUNDS FOR IRON AND STEEL CASTINGS AIDS TO THE CALCULATION OF FEEDER REQUIREMENTS FEEDERCALC CHAPTER 20 COMPUTER SIMULATION OF CASTING PROCESSES SOLIDIFICATION MODELLING MOULD FILLING SIMULATION THE SOLSTAR SOLIDIFICATION PROGRAM COST BENEFITS OF SOLIDIFICATION SIMULATION CONCLUSIONS CHAPTER TABLES AND GENERAL DATA SI UNITS AND THEIR RELATION TO OTHER UNITS THE INTERNATIONAL SYSTEM OF UNITS (SI SYSTEM) IS BASED ON SIX PRIMARY UNITS: QUANTITY UNIT SYMBOL LENGTH METRE M MASS KILOGRAM KG TIME SECOND S ELECTRIC CURRENT AMPERE A TEMPERATURE DEGREE KELVIN K LUMINOUS INTENSITY CANDELA CD MULTIPLES SI PREFIXES ARE USED TO INDICATE MULTIPLES AND SUBMULTIPLES SUCH AS PREFIX SYMBOL PREFIX SYMBOL DECI D CENTI C MILLI M MICRO µ NANO N PICO P EXAMPLE: ONE MILLIONTH OF A METRE IS EXPRESSED AS ONE MICROMETRE, 1 µM 1 PT (PINT) = 0 568261 L 1 US GAL = 3 78541 L = 0 832674 GAL (IMP) 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 CAL/CM S°C = 418 68 W/M K (THERMAL CONDUCTIVITY) 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 = 2?RH VOLUME = ?R2H CONE; RADIUS OF BASE R, HEIGHT H: VOLUME = 1/2 AREA OF BASE × HEIGHT = 1/2 ?R2H TRIANGLE; BASE B, HEIGHT H: AREA = 1/2BH TABLES AND GENERAL DATA VOLAT THALLIUM TL FOSECO FERROUS FOUNDRYMAN’S HANDBOOK THE PHYSICAL PROPERTIES OF METALS (CONTINUED) ELEMENT THERMAL RESISTIVITY VOL CHANGE DENSITY COEFF OF BRINELL CONDUCTIVITY (µOHM CM ON MELTING (G/CM3) EXPANSION HARDNESS (W/M K) AT 20°C) (%) (× 10–6/K) 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 10 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