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METAL CASTING AND JOINING

K.C. John Metal Casting and Joining

Metal Casting and Joining

K.C. JOHN Professor and Head Department of Mechanical Engineering Jyothi Engineering College Cheruthuruthy, Thrissur

Delhi-110092 2015 METAL CASTING AND JOINING K.C. John

© 2015 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher.

ISBN-978-81-203-5077-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111, Patparganj Industrial Estate, Delhi-110092 and Printed by Rajkamal Electric Press, Plot No. 2, Phase IV, HSIDC, Kundli-131028, Sonepat, Haryana. Contents

Preface xiii

Module A Preliminaries

1. Principles of Metal Casting 3–13 1.1 Conventional Metal Casting Process 4 1.2 History of Casting 5 1.3 Classification of Casting Processes 8 1.4 Advantages of Casting 9 1.5 Metals Cast in Foundries 10 1.6 Application of Metal Casting 12 Exercises 13 2. Principles of Metal Joining 14–39 2.1 Classification of Metal Joining Methods 14 2.2 History of Metal Joining 15 2.3 Principle of Metal Joining by Welding 17 2.4 Principle of Metal Joining by Metal Deposition 20 2.5 Metal Joining by Mechanical Fastening 21 2.6 Metal Joining by Adhesive Bonding 33 2.7 Application of Metal Joining 36 Exercises 38

Module B Conventional Sand Mould Casting 3. Pattern Making 43–54 3.1 Functions of Pattern 43 3.2 Pattern Materials 44

v vi Contents

3.3 Types of Patterns 46 3.4 Types of Core Boxes 48 3.5 Pattern Allowances 49 3.6 Pattern Making 51 Exercises 53 4. Mould and Core Materials 55–73 4.1 Desirable Properties of Moulding Sand 55 4.2 Ingredients of Moulding Sand 56 4.3 Types of Moulding Sands 60 4.4 Preparation of Moulding Sand 62 4.5 Core Materials 63 4.6 Ingredients of Core Sands 64 4.7 Sand Testing 65 Exercises 73 5. Moulding 74–95 5.1 Types of Sand Moulds 74 5.2 Tools and Equipment for Hand Moulding 77 5.3 Flask Moulding 80 5.4 Pit Moulding 85 5.5 Loam Moulding 86 5.6 Machine Moulding 87 Exercises 94 6. Core Making 96–106 6.1 Functions of Core 96 6.2 Types of Cores and Core Prints 97 6.3 Core Moulding 99 6.4 Core Reinforcing and Venting 100 6.5 Core Drying and Baking 101 6.6 Finishing of Cores and Storing 103 6.7 Mould Assembly 103 Exercises 105 7. Gating System and Risers 107–122 7.1 Introduction to Gating System 107 7.2 Functions of Gating System 108 7.3 Classification of Gating Systems 108 7.4 Types of Gates and Their Layouts 111 7.5 Introduction to Risers 115 7.6 Types of Risers 116 7.7 Shape, Size and Location of Risers 118 7.8 Use of Chills and Pads 119 7.9 Use of Insulators and Exothermic Compounds 121 Exercises 122 Contents vii 8. Metal Melting and Pouring 123–170 8.1 Introduction to Melting 123 8.2 Classification of Melting Furnaces 125 8.3 Crucible Furnaces 127 8.4 Cupola Furnace 131 8.5 Cupola Operation 135 8.6 Water Cooled Cupolas 142 8.7 Coke-less Cupola 143 8.8 Miscellaneous Fuel Fired Furnaces 144 8.9 Arc Furnaces 149 8.10 Induction Furnaces 152 8.11 Miscellaneous Melting Methods using Electricity 156 8.12 Refractory Materials for Furnaces 158 8.13 Temperature Measurement 161 8.14 Molten Metal Refining and Inoculation 164 8.15 Foundry Ladles 165 8.16 Molten Metal Handling and Pouring 168 Exercises 169 9. Shakeout and Cleaning of Castings 171–185 9.1 Cooling of Castings 171 9.2 Shakeout of Castings 172 9.3 Cleaning of Castings 173 9.4 Fettling of Castings 178 9.5 Heat Treatment of Castings 179 9.6 Inspection of Castings 182 Exercises 184 10. Foundry Mechanization and Management 186–208 10.1 Areas for Foundry Mechanization 186 10.2 Preparation of Moulding Sand 187 10.3 Moulding and Core Making 192 10.4 Melting and Pouring 193 10.5 Shakeout and Cleaning 194 10.6 Material Handling 195 10.7 Mechanized Foundry Layout 201 10.8 Foundry Management 204 Exercises 207

Module C Special Casting Processes 11. Shell Mould Casting 211–217 11.1 Moulding Materials and Their Preparation 211 11.2 Production of Moulds and Cores 212 viii Contents

11.3 Advantages and Limitations 216 11.4 Characteristics and Applications of the Process 216 Exercises 217 12. Investment Casting 218–226 12.1 Principle of Investment Casting Process and Its Classification 218 12.2 Traditional Investment Casting 219 12.3 Precision Investment Casting using Expendable Pattern 220 12.4 Refractory Slurry and Coating 223 12.5 Advantages and Limitations 225 12.6 Characteristics and Applications 226 Exercises 226 13. Pressure Die Casting 227–240 13.1 Principle of Pressure Die Casting Process 227 13.2 Die Casting Machines 229 13.3 Dies for Pressure Die Casting 233 13.4 Metals for Die Casting 236 13.5 Advantages and Limitations 238 13.6 Characteristics and Application 239 Exercises 240 14. Centrifugal Casting 241–249 14.1 Principle of Centrifugal Casting Process and Classification 241 14.2 True Centrifugal Casting 242 14.3 Semi-centrifugal Casting 244 14.4 Centrifuge Casting 244 14.5 Mould for Centrifugal Casting and Its Speed of Rotation 245 14.6 Manufacture of Pipes 247 14.7 Advantages and Limitations 248 Exercises 249 15. Continuous Casting 250–257 15.1 Principle of Continuous Casting and Its Classification 250 15.2 Continuous Casting of Steel 252 15.3 Alcova Direct Chill Process 254 15.4 Hazelett Process 255 15.5 Advantages, Limitations and Applications 256 Exercises 257 16. Miscellaneous Special Casting Processes 258–288 16.1 Gravity Die Casting 258 16.2 Squeeze Casting 261 16.3 Slush Casting 263 Contents ix

16.4 Counter Gravity Low Pressure Casting 265 16.5 Carbon Dioxide Mould Casting 267 16.6 Plaster Mould Casting 270 16.7 Ceramic Mould Casting 272 16.8 Lost Foam Casting 275 16.9 Graphite Mould Casting 277 16.10 Electro Slag Casting 279 16.11 Semi-solid Metal Casting 280 16.12 Single Crystal Casting 283 16.13 Vacuum Mould Casting 285 16.14 Composite Mould Casting 287 Exercises 287

Module D Conventional Metal Joining Processes 17. Arc Welding Processes 291–344 17.1 Shielded Metal Arc Welding (SMAW) 291 17.2 Electrodes for SMAW 304 17.3 Joint Design and Edge Preparation for SMAW 314 17.4 Submerged Arc Welding (SAW) 320 17.5 Gas Metal Arc Welding (GMAW) 329 17.6 Gas Tungsten Arc Welding (GTAW) 333 17.7 Flux Cored Arc Welding (FCAW) 338 Exercises 342 18. Resistance Welding Processes 345–363 18.1 Resistance Spot Welding (RSW) 345 18.2 Resistance Seam Welding (RSEW) 352 18.3 Projection Welding (PW) 355 18.4 Flash Welding (FW) 359 18.5 Upset Welding (UW) 361 Exercises 362 19. Oxy-fuel Gas Welding Processes 364–375 19.1 Oxy-Acetylene Welding (OAW) 365 19.2 Other Fuel Gas Welding Processes 374 Exercises 375 20. Brazing and Soldering 376–388 20.1 Brazing 376 20.2 Soldering 383 Exercises 388 Metal Casting & Joining

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Publisher : PHI Learning ISBN : 9788120350779 Author : JOHN, K. C.

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