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The casting process is one of the most efficient and unique cost-competitive methods of shaping a component. We have come a long way from the age-old foundries of the past which were noisy, dusty, dark, hot, and labor-intensive. Today’s automated casting facilities are relatively quiet, less dusty, and bright. Modern machines and automation offer a high degree of productivity and consistency of product quality.

Labor shortages, difficulty of operator retention against competing industries, and increasing wages, have also compelled innovation in engineering and automation in machinery. The focus of mechanization has been to replace operators in hazardous and uncomfortable areas, reduce the risk of injury, and improve the overall environment.

Iron, steel, and aluminum casting manufacturers, as well as those pursuing manufacturing engineering of equipment for metal castings, benefit from a compilation of all aspects of preparation and manufacturing including sand and metal storage and handling, equipment for sand preparation, retrieval, conditioning, and reclamation, molding flask design options, melting and metal handling of iron steel and aluminum, sand molding, and core making equipment for iron and steel, and all aspects of material movement through the manufacturing processes of aluminum die casting, aluminum gravity permanent and semipermanent mold casting, low pressure permanent and semipermanent mold casting, and counter-pressure casting.

New casting facilities depend on consulting companies well-versed in the field of project planning and plant layouts. Many production facilities engaged in expansions of their current operations involve their staff and operators in designing the changes or expansions, and utilize their experience and expertise in their products. New market opportunities or changes in businesses also prompt new layouts, modern equipment, and improved automation.

The purpose of this book is to highlight all aspects of the entire line of equipment involved in the preparation and production of iron, steel, and aluminum castings, and their distinguishing features and innovations for higher productivity, higher dimensional capability, high integrity, and cost competitiveness. The book also offers guidelines for the selection of the right equipment, and for positioning them suitably, ensuring smooth product flow with high productivity.

This practical guide should be of special interest to all those involved in the casting manufacturing engineering field and those who are engaged in new equipment purchases, expansions, modifications, and automation of new machinery. Casting buyers and purchasing managers would also find this guide very useful.

Jagan Nath

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