Foseco Non-Ferrous Foundryman’s Handbook

John Brown9780750642866, 0750642866

The Non-Ferrous Foundryman’s Handbook provides a practical reference book for all those concerned with dealing with aluminium, copper and magnesium casting alloys.International SI units are used throughout, but in almost all cases conversions to the more familiar Metric and Imperial units are given. Wherever possible, Casting Alloy Specifications include equivalent specifications for several countries as well as international specifications. Individual chapters cover the casting of all types of non-ferrous metals. For each group of alloys, specifications, and typical applications are described, together with details of melting practice, metal treatment and casting practice. Sand moulding materials, including green sand and chemically bonded sands are also included. Recently there have been many major technical developments including new sand binders, the adoption of metal filtration of castings and widespread use of computers for the optimisation of feeder design.

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Table of contents :
Melting copper– nickel alloys……Page 0
Foseco Non-Ferrous FoundrymanÌs Handbook……Page 1
Preface……Page 4
Acknowledgements……Page 11
SI units and their relation to other units……Page 14
SI, metric, non-SI and non-metric conversions……Page 15
Conversion table of stress values……Page 18
Areas and volumes of circles, spheres, cylinders etc…….Page 19
The physical properties of metals……Page 20
The physical properties of metals (Continued)……Page 21
Densities of casting alloys……Page 22
Approximate bulk densities of common materials……Page 23
Volume shrinkage of principal casting alloys……Page 26
Comparison of sieve sizes……Page 27
Calculation of average grain size……Page 28
Calculation of AFS grain fineness number……Page 29
Recommended standard colours for patterns……Page 30
Buoyancy forces on cores……Page 31
Opening forces on moulds……Page 32
Dimensional tolerances and consistency achieved in castings……Page 34
Introduction……Page 36
Casting alloys……Page 38
The effect of alloying elements……Page 52
Heat treatment of aluminium alloys……Page 55
Introduction……Page 59
Melting furnaces……Page 60
Corundum growth……Page 67
Choice of melting unit……Page 68
Application of COVERAL powder fluxes……Page 69
Granular COVERAL fluxes……Page 74
5 INSURAL refractory for ladles and metal transport……Page 76
Ladle liners……Page 78
Hydrogen gas pick-up in aluminium melts……Page 83
Degassing aluminium alloys……Page 85
Grain refinement of aluminium alloys……Page 90
Modification of aluminium alloys……Page 92
Sodium modification……Page 94
Strontium modification……Page 95
Sand, gravity die and low pressure diecasting……Page 96
Eutectic silicon alloys, 12% Si……Page 97
Treatment of alloys for pressure diecasting……Page 100
7 Running, gating and feeding aluminium castings……Page 102
Gating without filters……Page 103
Gating with filters……Page 106
Feeding mechanisms in Al alloy and other non- ferrous castings……Page 107
Simulation modelling……Page 111
8 Filtration of aluminium alloy castings……Page 112
SIVEX FC filters……Page 113
Use of filters in conventional running systems……Page 114
Direct pouring of aluminium alloy castings……Page 117
KALPUR combined sleeve and SIVEX FC filter for aluminium castings……Page 118
Direct pouring into metal dies……Page 120
9 Pressure diecasting of aluminium alloys……Page 121
Die design……Page 122
Process control……Page 124
Modification of the diecasting process……Page 126
The diecasting foundry……Page 127
Die coating……Page 129
Low pressure diecasting……Page 131
Gravity diecasting……Page 137
Die coatings for gravity and low pressure diecasting……Page 140
11 Sand casting processes……Page 148
Green sand……Page 149
Moulding machines……Page 150
Core assembly sand processes……Page 153
The Lost Foam process……Page 157
Properties of silica sand for foundry use……Page 162
Typical silica foundry sand properties……Page 164
Safe handling of silica sand……Page 165
Thermal characteristics of silica sand……Page 166
Zircon, ZrSiO4……Page 167
Olivine, Mg2SiO4……Page 169
Green sand additives……Page 170
The green sand system……Page 173
Green sand properties……Page 176
Control of green sand systems……Page 177
Control graphs……Page 178
Special moulding materials, LUTRON……Page 179
Self-hardening process (also known as self-set, no- bake or cold- setting process)……Page 180
Testing chemically bonded, self-hardening sands……Page 182
Mixers……Page 184
Pattern equipment……Page 185
Foundry layout……Page 186
Sand reclamation……Page 188
Typical usage of sand reclamation……Page 191
Furanes……Page 193
Phenolic-isocyanates (phenolic-urethanes)……Page 195
Alkaline phenolic resin, ester hardened……Page 196
Heat triggered processes……Page 198
Gas triggered systems……Page 199
The shell or Croning process……Page 200
Hot-box process……Page 202
Warm-box process……Page 203
Oil sand……Page 204
Phenolic-urethane-amine gassed (cold-box) process……Page 206
ECOLOTEC process (alkaline phenolic resin gassed with CO2)……Page 208
The SO2 process……Page 209
Ester-cured alkaline phenolic system……Page 211
Review of resin core-making processes……Page 212
Sodium silicate……Page 217
CO2 silicate process ( basic process)……Page 218
Gassing CO2 cores and moulds……Page 220
Improvements to the CO2 silicate process……Page 221
SOLOSIL……Page 222
Ester silicate process……Page 223
TAK sealant……Page 228
Casting alloys……Page 230
The melting, treatment and casting of magnesium alloys……Page 231
The main copper alloys and their applications……Page 238
Specifications for copper-based alloys……Page 239
Colour code for ingots……Page 240
Melting copper and copper-based alloys……Page 245
Melting and treatment of high conductivity copper……Page 251
Copper-silver……Page 255
Commercial copper……Page 256
Melting bronzes and gunmetals……Page 261
Melting high lead bronze……Page 263
Filtration of copper-based alloys……Page 264
Natural feeders……Page 265
Aided feeders……Page 266
Feeding systems……Page 267
The calculation of feeder dimensions……Page 270
Steel, malleable iron, white irons, light alloys and copper- based alloy castings……Page 275
Grey and ductile irons……Page 279
Introduction……Page 281
Range of feeder products……Page 282
Breaker cores……Page 292
The application of feeder sleeves……Page 293
Williams Cores……Page 296
FERRUX anti-piping compounds for iron and steel castings……Page 297
Metal-producing top surface covers……Page 298
Aids ot the calculation of FEEDER requirements……Page 299
FEEDERCALC……Page 300
Calculating feeder sizes for aluminium alloy castings……Page 301
Index……Page 302