Foseco Ferrous Foundryman’s Handbook

John Brown9780750642842, 0-7506-4284-X

The Foseco Ferrous Foundryman’s Handbook is a practical reference book for all those concerned with making castings in any of the commonly used alloys, by any of the usual moulding methods.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 light alloys, copper-based alloys, all types of cast-iron and steel. 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.

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Table of contents :
Contents……Page 4
Preface……Page 10
Acknowledgements……Page 11
SI units and their relation to other units……Page 12
SI, metric, non- SI and non- metric conversions……Page 13
Conversion table of stress values……Page 16
Areas and volumes of circles, spheres, cylinders etc…….Page 17
The physical properties of metals……Page 18
Densities of casting alloys……Page 20
Approximate bulk densities of common materials……Page 21
Patternmakers contraction allowances……Page 22
Volume shrinkage of principal casting alloys……Page 24
Comparison of sieve sizes……Page 25
Calculation of average grain size……Page 26
Calculation of AFS grain fineness number……Page 27
Recommended standard colours for patterns……Page 28
Buoyancy forces on cores……Page 29
Opening forces on moulds……Page 30
Dimensional tolerances and consistency achieved in castings……Page 32
2 Types of cast iron……Page 34
Physical properties of cast irons……Page 38
Iron casting processes……Page 39
Specifications……Page 41
Relationship between composition, strength and structure of grey cast iron……Page 43
The production of grey irons……Page 48
Cupola melting……Page 51
Electric melting……Page 64
Shop floor control of metal composition……Page 71
5 Inoculation of grey cast iron……Page 73
Ladle inoculation……Page 75
Late stream inoculation……Page 77
Mould inoculation……Page 80
Production of ductile iron……Page 81
Cupola melting and duplexing……Page 85
Use of the tundish cover ladle……Page 86
Pure magnesium converter process……Page 88
Inhibiting elements……Page 89
Specifications for ductile cast iron……Page 90
Heat treatment of ductile iron……Page 93
Compacted graphite irons……Page 95
Whiteheart malleable……Page 101
Blackheart malleable iron……Page 103
Heat resisting alloys……Page 106
Corrosion resistant cast irons……Page 112
Wear resistant cast irons……Page 113
9 Types of steel castings……Page 119
Specifications for steel castings……Page 120
Types of steel castings……Page 122
Low alloy and medium alloy steels……Page 123
High alloy steels……Page 125
Selection of suitable steel for casting……Page 128
Arc furnace melting……Page 132
Induction furnace melting a……Page 134
Melting and casting quality……Page 136
Ladle lining……Page 141
KALTEK ladle lining system for iron foundries……Page 143
KALTEK insulating lining system for automatic pouring boxes……Page 147
Casting defects due to poor ladle maintenance……Page 148
Ladle practice……Page 149
The KALTEK ladle lining system……Page 153
Pouring temperature for steels……Page 155
Silica sand……Page 157
Measurement of sand properties……Page 160
Non- silica sands……Page 162
Green sand……Page 163
Green sand properties……Page 171
Special moulding materials, LUTRON……Page 174
Self- hardening process ( also known as self- set, no- bake or cold- setting process)……Page 178
Testing chemically bonded self- hardening sands……Page 180
Sand reclamation……Page 184
Self- hardening resin binder systems……Page 191
Triggered hardening systems……Page 195
Heat triggered processes……Page 197
Gas triggered processes……Page 203
Review of resin coremaking processes……Page 209
CO2 silicate process ( basic process)……Page 215
Improvements to the CO2 silicate process……Page 218
Self- setting sodium silicate processes……Page 220
Adhesives and sealants……Page 224
Principle of the process……Page 227
Patternmaking……Page 228
The mechanism of casting into foam patterns……Page 229
Advantages of lost foam casting……Page 232
Applications……Page 233
The future……Page 235
The need for a coating……Page 237
Choice of coating and form of supply……Page 238
Components of a coating……Page 239
Application methods for coatings……Page 241
Coatings for high production foundries……Page 245
Spirit based coatings……Page 248
The TRIBONOL process……Page 251
Miscellaneous coatings……Page 252
Coatings for foundry tools……Page 254
Conventional running systems without filters……Page 256
Filtration of iron castings……Page 261
SEDEX ceramic foam filters……Page 267
Cellular ceramic filters……Page 270
Combined filter, feeder and pouring cup, the KALPUR direct pouring system……Page 277
Controlling the flow of metal……Page 283
Conventional running systems without filters a……Page 285
Inclusions in steel castings……Page 288
STELEX ZR ceramic foam filters……Page 290
KALPUR ST direct pour unit……Page 297
Cost savings through the use of STELEX and KALPUR……Page 305
Natural feeders……Page 307
Aided feeders – feeding systems……Page 308
The calculation of feeder dimensions……Page 312
Steel, malleable iron, white irons, light alloys and copper based alloy castings……Page 316
Grey and ductile irons……Page 318
Foseco feeding systems……Page 321
KALPUR filter feeder units……Page 333
Breaker cores……Page 334
The application of feeder sleeves……Page 336
FERRUX anti- piping compounds for iron and steel castings……Page 342
Aids to the calculation of feeder requirements……Page 345
FEEDERCALC……Page 346
Solidification modelling……Page 355
The SOLSTAR solidification program……Page 357
Cost benefits of solidification simulation……Page 362
Index……Page 364