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Foseco Ferrous Foundryman’s Handbook
Foseco Ferrous
Foundryman’s Handbook
Edited by
John R. Brown
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 01801-2041
A division of Reed Educational and Professional Publishing Ltd
A member of the Reed Elsevier plc group
First published 2000
© Foseco International Ltd 2000
All rights reserved. No part of this publication
may be reproduced in any material form (including
photocopying or storing in any medium by electronic
means and whether or not transiently or incidentally
to some other use of this publication) without the
written permission of the copyright holder except
in accordance with the provisions of the Copyright,
Designs and Patents Act 1988 or under the terms of a
licence issued by the Copyright Licensing Agency Ltd,
90 Tottenham Court Road, London, England W1P 9HE.
Applications for the copyright holder’s written permission
to reproduce any part of this publication should be
addressed to the publishers
British Library Cataloguing in Publication Data
Brown, John R.
Foseco ferrous foundryman’s handbook.
1. Founding – Handbooks, manuals, etc.
I Title II Foseco International III Foundryman’s handbook
671.2
Library of Congress Cataloguing in Publication Data
Foseco ferrous foundryman’s handbook/revised and edited by John R. Brown.
p. cm.
Includes index.
ISBN 0 7506 4284 X
1 Founding – Handbooks, manuals, etc. 2 Iron founding – Handbooks,
manuals, etc. 3 Cast-iron – Handbooks, manuals, etc. I Title: Ferrous
foundryman’s handbook II Brown John R.
TS235 F35 2000
672.2–dc21 00-033679
ISBN 0 7506 4284 X
Typeset at Replika Press Pvt Ltd, Delhi 110 040, India
Printed and bound in Great Britain
Contents
Preface xi
Acknowledgements xii
Chapter 1 Tables and general data 1
SI units and their relation to other units 1
SI, metric, non-SI and non-metric conversions 2
Conversion table of stress values 5
Areas and volumes of circles, spheres, cylinders etc. 6
The physical properties of metals 7
Densities of casting alloys 9
Approximate bulk densities of common materials 10
Patternmakers’ contraction allowances 11
Volume shrinkage of principal casting alloys 13
Comparison of sieve sizes 14
Calculation of average grain size 15
Calculation of AFS grain fineness number 16
Recommended standard colours for patterns 17
Dust control in foundries 18
Buoyancy forces on cores 18
Opening forces on moulds 19
Dimensional tolerances and consistency achieved in castings 21
Chapter 2 Types of cast iron 23
Introduction 23
Physical properties of cast irons 27
Iron casting processes 28
Chapter 3 Grey cast iron 30
Specifications 30
Relationship between composition, strength and structure of
grey cast iron 32
Applications of grey iron castings 37
The production of grey irons 37
Chapter 4 Melting cast iron 40
Introduction 40
Cupola melting 40
Electric melting 53
Shop floor control of metal composition 60
Chapter 5 Inoculation of grey cast iron 62
Introduction 62
Ladle inoculation 64
Late stream inoculation 66
Mould inoculation 69
Chapter 6 Ductile iron 70
Production of ductile iron 70
Melting ductile iron base 74
Cupola melting and duplexing 74
Induction furnace melting 75
Use of the tundish cover ladle 75
Sandwich treatment 77
NODULANT 77
Pure magnesium converter process 77
Cored wire treatment 78
In-the-mould treatment 78
Inhibiting elements 78
Inoculation and fading 79
Specifications for ductile cast iron 79
Heat treatment of ductile iron 82
Casting ductile iron 84
Compacted graphite irons 84
Chapter 7 Malleable cast iron 90
Introduction 90
Whiteheart malleable 90
Blackheart malleable iron 92
Chapter 8 Special purpose cast irons 95
Heat resisting alloys 95
Corrosion resistant cast irons 101
Wear resistant cast irons 102
vi
Contents
Chapter 9 Types of steel castings 108
Introduction 108
Specifications for steel castings 109
Types of steel castings 111
Carbon steels 112
Low alloy and medium alloy steels 112
Austenitic manganese steel 114
High alloy steels 114
Duplex steels 117
Physical properties of steels 117
Selection of suitable steel for casting 117
Chapter 10 Melting and treatment of steel for casting 121
Arc furnace melting 121
Induction furnace melting 123
AOD refining 125
Melting and casting quality 125
Chapter 11 Molten metal handling 130
Iron foundries 130
Metal handling systems 130
Ladle lining 130
KALTEK ladle lining system for iron foundries 132
KALTEK insulating lining system for automatic pouring boxes 136
Casting defects due to poor ladle maintenance 137
Molten metal handling in steel foundries 138
Ladle practice 138
The KALTEK ladle lining system 142
Pouring temperature for steels 144
Chapter 12 Sands and green sand 146
Silica sand 146
Measurement of sand properties 149
Non-silica sands 151
Green sand 152
Parting agents 163
Special moulding materials, LUTRON 163
Green sand moulding machines 164
Contents
vii
Chapter 13 Resin bonded sand 167
Chemical binders 167
Self-hardening process 167
Sand reclamation 173
Self-hardening resin binder systems 180
Triggered hardening systems 184
Heat triggered processes 186
Gas triggered processes 192
Review of resin coremaking processes 198
Chapter 14 Sodium silicate bonded sand 204
CO
2
silicate process (basic process) 204
Improvements to the CO
2
silicate process 207
Self-setting sodium silicate processes 209
Adhesives and sealants 213
Chapter 15 Lost foam casting 216
Principle of the process 216
Patternmaking 217
Assembling clusters 218
Coating the patterns 218
Investing in sand 218
The mechanism of casting into foam patterns 218
Advantages of lost foam casting 221
Disadvantages 222
Applications 222
The future 224
Chapter 16 Coatings for moulds and cores 226
The need for a coating 226
Choice of coating and form of supply 227
Components of a coating 228
Application methods for coatings 230
Coatings for iron and steel foundries 234
Coatings for high production foundries 234
Coatings for jobbing moulds and cores 237
Spirit based coatings 237
The TRIBONOL process 240
Miscellaneous coatings 241
Coatings for foundry tools 243
viii
Contents
Chapter 17 Filtration and the running and gating of iron castings 245
Introduction 245
Conventional running systems without filters 245
Filtration of iron castings 250
SEDEX ceramic foam filters 256
Cellular ceramic filters 259
Combined filter, feeder and pouring cup, the KALPUR direct
pouring system 266
Chapter 18 Filtration and the running and gating of steel castings 272
Introduction 272
Controlling the flow of metal 272
Conventional running systems without filters 274
The use of ceramic foam filters 277
Inclusions in steel castings 277
STELEX ZR ceramic foam filters 279
KALPUR ST direct pour unit 286
Cost savings through the use of STELEX and KALPUR 294
Chapter 19 Feeding of castings 296
Introduction 296
Natural feeders 296
Aided feeders – feeding systems 297
The calculation of feeder dimensions 301
Determination of feeding requirements 305
Steel, malleable iron, white irons, light alloys and copper based
alloy castings 305
Grey and ductile irons 307
Foseco feeding systems 310
KALPUR filter feeder units 322
Breaker cores 323
Application of feeder sleeves 325
FERRUX anti-piping compounds for iron and steel castings 331
Aids to the calculation of feeder requirements 334
FEEDERCALC 335
Chapter 20 Computer simulation of casting processes 344
Introduction 344
Solidification modelling 344
Contents
ix
Mould filling simulation 346
The SOLSTAR solidification program 346
Cost benefits of solidification simulation 351
Conclusions 352
Index 353
x
Contents
Preface
The last edition of the Foseco Foundryman’s Handbook was published in 1994
and like all the earlier editions, it aimed to provide a practical reference
book for all those involved in making castings in any of the commonly used
alloys by any of the usual moulding methods. In order to keep the Handbook
to a reasonable size, it was not possible to deal with all the common casting
alloys in detail. Since 1994 the technology of casting has continued to develop
and has become more specialised so that it has been decided to publish the
new edition of the Handbook in two volumes:
Ferrous dealing with grey, ductile and special purpose cast irons
together with carbon, low alloy and high alloy steels
Non-ferrous dealing with aluminium, copper and magnesium casting
alloys
Certain chapters (with slight modifications) are common to both volumes:
these chapters include tables and general data, sands and sand bonding
systems, resin bonded sand, sodium silicate bonded sand and feeding systems.
The remaining chapters have been written specifically for each volume.
The Handbook refers to many Foseco products. Not all of the products are
available in every country and in a few cases, product names may vary.
Users should always contact their local Foseco company to check whether
a particular product or its equivalent is available.
The Foseco logo and all product names appearing in capital letters are
trademarks of the Foseco group of companies, used under licence.
John R. Brown
[...]... (pure) 4.0 Brass Bronze 6.5 7.5 Al bronze Sn bronze 4.0 4.5 14 Foseco Ferrous Foundryman’s Handbook Comparison of sieve sizes Sieves used for sand grading are of 200 mm diameter and are now usually metric sizes, designated by their aperture size in micrometres (µm) The table lists sieve sizes in the British Standard Metric series (BS410 : 1976) together with other sieve types Sieve aperture, micrometres... Conversions 10 000 22 399 14 223 14 504 4.464 10 6.349 6.475 7.031 15.749 10 10.197 68.947 154.438 98.066 100 6 Foseco Ferrous Foundryman’s Handbook Areas and volumes of circles, spheres, cylinders etc π = 3.14159 (approximation: 22/7) 1 radian = 57.296 degrees Circle; radius r, diameter d: circumference = 2 r = πd area = r2 = π/4 × d2 Sphere; radius r: surface area = 4 r2 volume = 4/3 r3 Cylinder; radius... derived units for the foundryman are: Quantity Unit Symbol Force Pressure, stress Work, energy Power, heat flow rate Temperature Heat flow rate Thermal conductivity Specific heat capacity Specific latent heat newton newton per square metre or pascal joule watt, joule per second degree Celsius watt per square metre watt per metre degree joule per kilogram degree joule per kilogram N (kg m/s2) N/m2 (Pa)... While average grain size and AFS grain fineness number are useful parameters, choice of sand should be based on particle size distribution Tables and general data 17 Recommended standard colours for patterns Part of pattern Colour As-cast surfaces which are to be left unmachined Red or orange Surfaces which are to be machined Yellow Core prints for unmachined openings and end prints Periphery Ends... the iron carbide to graphite Under the right conditions the graphite developed in discrete, roughly spherical aggregates (Fig 2.3) so that the casting became ductile with elongation of 10% or more The first malleable iron, ‘whiteheart iron’ Types of cast iron 25 Figure 2.2 Random flake graphite, 4% picral, ×100 (From BCIRA Broadsheet 138, reproduced by courtesy of CDC.) was made by R aumur in France... Black Black Core prints for machined openings Periphery Ends Yellow stripes on black Black Pattern joint (split patterns) Cored section Metal section Black Clear varnish Touch core Cored shape Legend Black “Touch” Seats of and for loose pieces and loose core prints Green Stop offs Diagonal black stripes with clear varnish Chilled surfaces Outlined in Legend Black “Chill” Foseco Ferrous Foundryman’s Handbook... were cast directly from the blast furnace Liquid iron from a blast furnace contains around 4%C and up to 2%Si, together with other chemical elements derived from the ore and other constituents of the furnace charge The presence of so much dissolved carbon etc lowers the melt point of the iron from 1536°C (pure iron) to a eutectic temperature of about 1150°C (Fig 2.1) so that blast furnace iron is fully... temperatures around 1200°C When the iron solidifies, most of the carbon is thrown out of solution in the form either of graphite or of iron carbide, Fe3C, depending on the composition of the iron, the rate of cooling from liquid to solid and the presence of nucleants If the carbon is precipitated as flake graphite, the casting is called ‘grey iron’, because the fractured surface has a dull grey appearance... forms of graphite through inoculation of liquid iron, has vastly improved the reliability of grey iron as an engineering material Even so, the inherent lack of ductility due to the presence of so much graphite precipitated in flake form (Fig 2.2) limits the applications to which grey iron can be put A malleable, or ductile form of cast iron was first made by casting ‘white 24 Foseco Ferrous Foundryman’s. .. 1.3 For the comfort and safety of operators, air flows of around 0.5 m/sec are needed to carry away silica dust If air flow rate is too high, around the shake-out for example, there is a danger that the grading of the returned sand will be altered Buoyancy forces on cores When liquid metal fills a mould containing sand cores, the cores tend to float and must be held in position by the core prints or by . Foseco Ferrous Foundryman’s Handbook
Foseco Ferrous
Foundryman’s Handbook
Edited by
John R. Brown
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW. πd
area = r
2
= π/4 × d
2
Sphere; radius r:
surface area = 4 r
2
volume =
4
/
3
r
3
Cylinder; radius of base r, height h:
area of curved surface = 2πrh
volume
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