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Image
Published: 01 December 2008
Fig. 22 Rotary plus cooling type shakeout system in which the castings and water-cooled mold sand are separated at the drum exit
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Image
Published: 01 December 2008
Fig. 23 Front (a) and side (b) views of a vibratory drum type shakeout system
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Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005355
EISBN: 978-1-62708-187-0
... Abstract After solidification and cooling, further processing and finishing of the castings are required. This article describes the general operations of shakeout, grinding, cleaning, and inspection of castings, with particular emphasis on automation technology. It illustrates the vertical...
Abstract
After solidification and cooling, further processing and finishing of the castings are required. This article describes the general operations of shakeout, grinding, cleaning, and inspection of castings, with particular emphasis on automation technology. It illustrates the vertical core knockout machine and the A-frame core knockout machine and lists the advantages and disadvantages of these machines. The article describes the general factors in automated or manual gate removal process. It concludes with discussion on the various types of inspection, such as the liquid penetrant inspection, pressure testing, radiographic inspection, magnetic particle inspection, and ultrasonic inspection.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005327
EISBN: 978-1-62708-187-0
... Abstract This article presents a discussion on the melting, pouring, and shakeout practices; composition control; molds, patterns, and casting design; heat treatment; and applications of different classes of nickel-chromium white irons and high-chromium white irons. iron castings heat...
Abstract
This article presents a discussion on the melting, pouring, and shakeout practices; composition control; molds, patterns, and casting design; heat treatment; and applications of different classes of nickel-chromium white irons and high-chromium white irons.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005243
EISBN: 978-1-62708-187-0
... sand media preparation mold finishing shakeout GREEN SAND MOLDING is one of many methods available to the foundryman for making a mold into which molten metal can be poured. Green sand molding and chemically bonded sand molding are considered to be the most basic and widely used moldmaking...
Abstract
Green sand molding and chemically bonded sand molding are considered to be the most basic and widely used mold-making processes. This article describes the sand system formulation, preparation, mulling, mold fabrication, and handling of green sand molds. It lists the advantages and disadvantages of green sand molding. The article discusses the primary control parameters for the sand system formulation. It describes two basic types of green sand molds: flask molds and flaskless molds. The article provides a discussion on molding problems, including springback and expansion defects. It considers a variety of sand reclamation systems, including wet washing/scrubbing and thermal-calcining/thermal-dry scrubbing combinations.
Image
Published: 01 December 2008
Fig. 25 Cutaway view of a sand cooling drum system. Sequence of operations proceeds from right to left: 1, hot shakeout and spill sand enter, and helical flights convey sand forward to begin blending process; 2, cascading effect provides sand cooling as well as sand homogenization; 3, blended
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Image
Published: 01 December 2008
is submerged into the melt, thus causing metal to flow into the individual molds. (d) After the metal has solidified, the mold tube assembly is moved to the shakeout area, and vacuum is discontinued.
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Image
Published: 01 October 2014
Condition of gray iron castings Δ T cr (measured between hat and wear plate) σ(circumferential in wear plate) Predicted by Pribyl's equation Measured °C °F MPa psi MPa psi Air cooled, shakeout at∼980°C(∼1800°F) 36 97 −39.6 −5750 −26.2 to −43.4 −3800 to −6300 Mold cooled 6 43
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Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005354
EISBN: 978-1-62708-187-0
..., floor molds of green sand require slingers to achieve adequate compaction (see the article “Green Sand Molding” in this Volume). Fig. 1 No-bake molding Each of the major no-bake processes has advantages and disadvantages in moldmaking or coremaking. In terms of shakeout and sand...
Abstract
No-bake sand molds are based on the curing of inorganic or organic binders with either gaseous catalysts or liquid catalysts. This article reviews the major aspects of no-bake sand bonding in terms of coremaking, molding methods, and sand processing. It discusses the points to be noted in handling sand-resin mixtures for no-bake molds or cones and lists some advantages of no-bake air-set cores and molds. The article describes the process procedures, advantages, and disadvantages of gas curing and air-setting hardening of sodium silicates. It examines the members of the air-setting organic binders, namely, furan no-bake resins, phenolic no-bake resins, and urethanes. The article provides an overview of gas-cured organic binders. It also illustrates the three commercial systems for sand reclamation: wet reclamation systems, dry reclamation systems, and thermal reclamation.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005242
EISBN: 978-1-62708-187-0
.... (a) Pattern assembly for cope and drag sections of a mold. (b) Cross section of sand mold assembly with core After the part is cast and solidified in an expendable mold, the next step is a shakeout operation, which breaks up the mold and separates it from the cast part. The sand or mold aggregates can...
Abstract
This article reviews the basic types of mold aggregates and bonding methods for expendable molds and coremaking. It provides an overview of mold media and the basic types of sands and their properties. The most significant clays used in green sand operations, such as bentonites, are discussed. The article describes the methods of sand bonding with inorganic compounds. It provides a description of resin-bonded sand systems: no-bake binder systems, heat-cured binder systems, and cold box binder systems. The article concludes with a discussion on the media used for expendable molds, namely, ceramic shells and rammed graphite, for casting reactive metals such as titanium or zirconium.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005241
EISBN: 978-1-62708-187-0
... Finally, the fourth basic attribute of the molding medium is being able to be removed from the cast part. The expendable mold must be broken away and stripped from the solidified part ( Fig. 6 ). More cast parts, especially those with intricate internal passages, are rendered unusable during this shakeout...
Abstract
Casting can be done with either expendable molds for one-time use or permanent molds for reuse many times. This article lists the various methods used to fabricate expendable molds from permanent patterns. The methods include molding of sand with clay, inorganic binders, or organic resins; shell molding of sand with a thin resin-bonded shell; no-bond vacuum molding of sand; plaster-mold casting; ceramic-mold casting; rammed graphite molding; and magnetic (no-bond) molding of ferrous shot. The article tabulates a general comparison of casting methods and discusses the basic requirements of foundry molds.
Series: ASM Handbook
Volume: 1A
Publisher: ASM International
Published: 31 August 2017
DOI: 10.31399/asm.hb.v01a.a0006297
EISBN: 978-1-62708-179-5
... agents: hydrogen, carbon monoxide, carbon dioxide, methane, and nitrogen) ( Ref 2 ) Good gas permeability to help venting Thermal stability—adequate refractoriness, favorable thermal expansion rates, suitable degradation temperatures Good collapsibility to obtain easy shakeout Reclaimability...
Abstract
Aggregate molding, or sand casting, is the gravity pouring of liquid metal into a mold that is made of a mixture molded against a permanent pattern. This article summarizes the most important materials in the process of sand casting of cast iron, including different types of molding aggregates, clays, water, and additives in green sand, chemically bonded organic resins, and inorganic binders in self-setting, thermosetting, and gas-triggered systems. It discusses three main types of reclamation systems: wet, dry, and thermal. The article concludes with a description of both nonpermanent and permanent mold processes.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005251
EISBN: 978-1-62708-187-0
.... The magnetic field is turned off after solidification and cooling, resulting in immediate shakeout. The free-flowing magnetic shot molding material is returned to its point of origin after cooling, dedusting, and metal splash removal. Fig. 1 Magnetic molding process. Source: Ref 3 Advantages...
Abstract
This article describes the process and advantages of no-bond methods of vacuum molding and magnetic molding, with schematic illustrations. It also discusses the characteristics of plastic film and dimensional specifications of vacuum molding.
Series: ASM Handbook
Volume: 1A
Publisher: ASM International
Published: 31 August 2017
DOI: 10.31399/asm.hb.v01a.a0006332
EISBN: 978-1-62708-179-5
... castability can be achieved without having a significant negative effect. Additional precautions are taken through postpour steps, including slow cooling in sand, gentle shakeout, and other related processing and handling. Obviously, chemical composition, especially carbon and chromium contents, can...
Abstract
Castability of alloys is a measure of their ability to be cast to a given shape with a given process without the formation of cracks/tears, pores/shrinkage, and/or other significant casting defects. This article discusses the factors which affect the fluidity of an iron melt: alloy composition and initial melt condition. Besides the basic alloy properties, the effective castability of high-alloy irons can be significantly improved through casting and casting system design. The article describes the product design and processing factors of high-alloy graphitic irons and high-alloy white irons. It explains the heat treatment of high-silicon irons for high-temperature service and concludes with a discussion on machining and finishing of high-alloy iron castings.
Series: ASM Handbook
Volume: 4D
Publisher: ASM International
Published: 01 October 2014
DOI: 10.31399/asm.hb.v04d.a0005942
EISBN: 978-1-62708-168-9
...-temperature tensile strength. Figure 5 shows the effect of temperature and time on the relief of stresses for seven low-alloy irons, and the tabulation below the graphs indicates that these irons, depending on shakeout time, can be stress relieved for 8 h at 620 °C (1150 °F) with no adverse effect...
Abstract
Gray irons are a group of cast irons that form flake graphite during solidification, in contrast to the spheroidal graphite morphology of ductile irons. The heat treatment of gray irons can considerably alter the matrix microstructure with little or no effect on the size and shape of the graphite achieved during casting. This article provides a detailed account of classes of gray iron, and heat treating methods of gray irons with examples. These methods include stress relieving, annealing, normalizing, transformation hardening, austenitizing, quenching, austempering, martempering, flame hardening, induction hardening, and nitriding.
Book Chapter
Series: ASM Handbook
Volume: 1A
Publisher: ASM International
Published: 31 August 2017
DOI: 10.31399/asm.hb.v01a.a0006321
EISBN: 978-1-62708-179-5
..., depending on shakeout time, can be stress relieved for 8 h at 620 °C (1150 °F) with no adverse effect on hardness. Fig. 5 Effect of stress-relieving time and temperature on degree of stress relief obtained in low-alloy gray irons. Table shows compositions and negligible effect of maximum stress...
Abstract
Gray irons are a group of cast irons that form flake graphite during solidification, in contrast to the spheroidal graphite morphology of ductile irons. This article describes surface hardening of gray irons by flame and induction heating. It provides information on the classification of the gray irons in ASTM specification. The article presents examples that illustrate the use of stress relieving to eliminate distortion and cracking. It describes the three annealing treatments of gray iron: ferritizing annealing, medium (or full) annealing, and graphitizing annealing. The article discusses the parameters of the tensile strength and hardness of a normalized gray iron casting. These include combined carbon content, pearlite spacing, and graphite morphology. The article concludes with a discussion on the induction hardening of gray iron castings.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005328
EISBN: 978-1-62708-187-0
... the mold cavity. Shakeout Practice As mentioned previously, room-temperature impact resistance is low; therefore, riser and gate removal is somewhat easier with these alloys than with standard ductile iron grades. These irons are quite ductile at elevated temperatures, and they should be allowed...
Abstract
This article discusses the melting and pouring practices, heat treatment, and applications of different types of high-alloy graphitic iron, namely, high-silicon gray irons, high-silicon ductile irons, nickel-alloyed austenitic irons, austenitic gray irons, austenitic ductile irons, and aluminum-alloyed irons.
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