Solidification Time of a Casting

During the early stages of solidification of a casting, a thin skin begins to form at the relatively cool mold walls and as time passes, the thickness of the skin increases (as shown in figure 2). For flat mold walls, thickness is proportional to the square root of the solidification time. Thus, doubling the solidification time will make the skin 21/2 = 1.414 times or…

A Brief History of Metal Casting

The story of metal casting begins some five and a half thousand years ago in Mesopotamia, the cradle of civilisation. The process, which involves pouring molten metal into a mould, was used by the Mesopotamians to create all manner of things including tools and weaponry, typically out of the copper — tin alloy, bronze. Civilisation had finally dragged itself out…

Molding Sand: Constituents, Types and Properties

The general sources of receiving molding sands are the sea shores, rivers, lakes, deserts and granular elements of rocks. Molding sands can be classified mainly into two types namely natural or synthetic. Natural molding sands contains sufficient amount of binder material. Whereas synthetic molding sands are prepared artificially using basic sand molding constituents (silica sand in 85-91%, binder 6-11%, water or…

NINE GREEN SAND FACTS TO KNOW

The green sand casting process is the most widely-used process for casting ferrous and nonferrous metals. The process has evolved from a manually intensive operation to a highly mechanized and fully automated process that can produce more than 300 molds per hour. In terms of weight, complexity and alloy composition, a wide range of castings can be produced via green…

THE CASE FOR STEEL LOST FOAM CASTING

Steel is a widely used material in most industrial applications despite the increasing use of nonferrous alloys, composites and polymers. Although the lost foam casting method can produce steel parts, the process has not yet been adopted in the industry. However, lost foam casting could provide significant benefits for the production of steel castings. Some manufacturers have adopted lost foam…

Casting Process: Advantages and Limitations

Casting is also known as foundering, is the oldest manufacturing process in which liquid molten metal is poured into a perforated casting cavity of refractory material. Allow liquid metal to solidify, after solidification the casting metal can be taken out by breaking the mold. The casting process is used to produce components such as pistons, mill rolls, wheels, cylinder blocks, liners,…

Does Water Quality Affect Green Sand Properties?

Water-soluble salts or electrolytes are just some of the mineral contaminates found in everyday tap water used by foundries across the U.S for their green sand systems. Bentonite is the main bonding compound of green sand systems, and fort it to have quality bonding, it first must be activated with the use of an agent. A good activating agent must…

U.S. Metal Casting at A Glance

We break down the U.S. metalcasting industry by metal, process, state, and value-added services. Using data gathered from a nationwide survey of the U.S. metal casters, Modern Casting can paint a picture of the industry in 2017. The data was compiled from a survey of 1,633 domestic metal casting facilities, 84% if the country's estimated 1,949 plants in 2017. Following is a…

THINK GLOBAL, ACT LOCAL

The well-worn colloquialism, “Think Global, Act Local,” has been around for over 100 years. Different groups such as city planners, environmentalists, and even corporations have adopted the expression to encourage behavior and describe their engagement philosophy. The underlying message is that it is important to have a long term or big picture goal, but action needs to take place where…

EMPLOYMENT LAWS TO KNOW AND UNDERSTAND

Manufactured products, particularly foundry products, cannot reach their intended market without the labor of humans. That means there is always an opportunity for issues related to employment and labor to come to the fore and perhaps steal attention away from the critical operational issues of the foundry in favor of employment or labor issues. Indeed, manufacturers are often prime targets…

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