A Study of Core and Its Types for Casting Process
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Mold Making for Glass Art
Mold Making for Glass Art a tutorial by Dan Jenkins When Dan Jenkins retired he did not originally intend to make tools and molds for glass artists. However, his wife and friends who work in fused glass were constantly calling on the skills he developed during 30 years as a marine engineer in the Canada Navy to produce items that were needed but unavailable. He began his career on steam driven ships for which it was impossible to get parts. The engineers had to fabricate their own parts out of whatever was available to them. Dan has drawn on his knowledge of woodworking, metalworking, design, engineering and making something out of nothing. He discovered that he enjoys the challenge of designing new tools that are practical economical, and easy to use. Dan has always enjoyed teaching and spent much of his time in the navy as an instructor both at sea and onshore. Dan currently lives in Victoria B.C. with his wife, two cats, and 3 dogs. Mold Making For Glass Art by Dan Jenkins Choosing a Prototype The first projects you wish to tackle should be fairly simple because failure the first few times is Making molds for your own use or for not only possible it is probably inevitable. The reproduction is fairly easy to do and very first objects I tried to cast were self-produced satisfying. Making your own molds frees you wood blocks in the form of squares and from relying on molds made by others and triangles, simple shapes which should have allows you to tailor your mold for your own taste. -
Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting
applied sciences Article Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting Wei-Hao Lee, Yi-Fong Wu, Yung-Chin Ding and Ta-Wui Cheng * Institute of Mineral Resources Engineering, National Taipei University of Technology, Taipei 10608, Taiwan; [email protected] (W.-H.L.); [email protected] (Y.-F.W.); [email protected] (Y.-C.D.) * Correspondence: [email protected] Received: 1 June 2020; Accepted: 29 June 2020; Published: 1 July 2020 Abstract: Lost-wax casting, also called precision casting, is the process of casting a duplicate metal sculpture cast an original sculpture. The ceramic shell mould used in lost-wax casting usually consists of several layers formed with fine zircon and granular mullite particles using silica gel as a binder. However, it is a complicated and time-consuming process. Large amounts of waste moulds that need to be disposed and recycled become an environmental concern. In this study, waste shell sand from the recycled mould and calcium carbonate/metakaolin were used as raw materials to prepare geopolymer slurry and coating. The influence of mixing ratio and the SiO2/K2O modulus of the alkali solution on the setting time and green/fired strength were evaluated. Ceramic shells with one to four layers of geopolymer slurry and waste sand sprinkling were fabricated and tested for their permeability and green/fired strength. It was found that geopolymer shells had higher green/fired strength and better permeability than the original zircon/mullite shell. For foundry practice, metal casts were fabricated using recycled ceramic shell moulds with one to four layers of geopolymer coating. -
Compositions for Ceramic Cores Used in Investment Casting
(19) TZZ¥_Z_T (11) EP 3 170 577 A1 (12) EUROPEAN PATENT APPLICATION (43) Date of publication: (51) Int Cl.: 24.05.2017 Bulletin 2017/21 B22C 9/10 (2006.01) (21) Application number: 16199374.6 (22) Date of filing: 17.11.2016 (84) Designated Contracting States: • LEMAN, John Thomas AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Niskayuna, NY 12309 (US) GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO • KU, Anthony Yu-Chung PL PT RO RS SE SI SK SM TR Niskayuna, NY 12309 (US) Designated Extension States: • LI, Tao BA ME Evendale, OH 45215 (US) Designated Validation States: • POLLINGER, John Patrick MA MD Niskayuna, NY 12309 (US) (30) Priority: 19.11.2015 US 201514945602 (74) Representative: Pöpper, Evamaria General Electric Technology GmbH (71) Applicant: General Electric Company GE Corporate Intellectual Property Schenectady, NY 12345 (US) Brown Boveri Strasse 7 5400 Baden (CH) (72) Inventors: • YANG, Xi Alpha, OH 45301 (US) (54) COMPOSITIONS FOR CERAMIC CORES USED IN INVESTMENT CASTING (57) The present disclosure generally relates to a ce- body, but is largely unavailable for reaction with metal ramic core comprising predominantly mullite, which is alloys used in investment casting. Methods of making derived from a precursor comprising alumina particles cast metal articles are also disclosed. and siloxane binders. Free s ilica is present in the ceramic EP 3 170 577 A1 Printed by Jouve, 75001 PARIS (FR) EP 3 170 577 A1 Description TECHNICAL FIELD 5 [0001] The present disclosure generally relates to compositions for investment casting cores and methods for making them. -
DROSS in DUCTILE IRON by Hans Roedter, Sorelmetal Technical Services
98 DROSS IN DUCTILE IRON by Hans Roedter, Sorelmetal Technical Services WHAT IS “DROSS ”? magnesium with other elements. Dross also Dross is a reaction product which is formed from occurs in the form of long stringers instead of Mg treatment and during subsequent reoxidation concentrated “slag like” areas. When it occurs in of Mg rejected from the molten metal before it this string like form it acts like cracks or flake solidifies. It is therefore just another word for a graphite in the structure and so fatigue strength specific type of slag (reaction product). and impact strength of the material are lowered considerably. The reaction binds magnesium with sulphur, oxygen and silicon and forms continuously. This “dross” is light weight and so it will generally be found in the upper surfaces and under cores, but it can be entrained throughout the metal as well, especially with colder pouring tempera - tures. It is very difficult to completely avoid the reaction of magnesium with these other elements, since we need magnesium to form nodules. We are always confronted with the problem of dross in the production of Ductile Iron. WHAT IS PROMOTING “DROSS ” AND WHAT CAN BE DONE TO KEEP THE “DROSS ” OUT OF THE CASTING ? Since “dross” is always connected with magnesium, it is necessary to keep the magnesium level as low as possible. Good inoculation practice with some late inoculation in conjunction with sufficient magnesium will When looking at “dross” in the microscope you produce nice round small nodules. See will almost always find flake graphite in Suggestion Sheet 76. -
St Luke's Farnworth BELL CASTING
St Luke’s Farnworth BELL CASTING by Geoffrey Poole In the earliest days they were cast in different sizes to produce different notes but no attempt was made to tune bells until the 16th Century with the advent of change ringing. In those times bells were roughly tuned – where the inside of the bell or the edge of the lip was chipped away with a hammer and chisel – eight bells could be tuned to an octave of eight notes. Some deprived communities used a hagiosideron, a shaped piece of metal which was struck in a similar way to a bell. Also again due to lack of money bellcotes were used instead of costly towers. A bell-cot, bell-cote or bellcote is a small framework and shelter for one or more bells. Bellcotes are most common in church architecture but are also seen on institutions such as schools. The bellcote may be carried on brackets projecting from a wall or built on the roof of chapels or churches that have no towers. The bellcote often holds the Sanctus bell that is rung at the consecration of the Eucharist. Bellcote is a compound noun of the words bell and cot or cote. Bell is self-explanatory. The word cot or cote is Old English, from the Germanic. It means a shelter of some kind, especially for birds or animals (see dovecote), a shed, or stall. Examples of bellcotes In order St Luke’s Farnworth Bell-cot at St Edmund's Church, Church Road, Wootton, Isle of Wight, England Church of England parish church of St Alban the Martyr, CharlesStreet, Oxford. -
APPENDIX D Test Specification for Final Master Moldmaker Certification Test
APPENDIX D Test Specification for Final Master Moldmaker Certification Test Duty Task Task # Test Sequence Items A Advanced Planning and Review 1 Redline a mold design 5 2 Identify mold manufacturing cost issues 3 B Mold Design 3 Check mold components for fit and function 6 4 Design jigs and fixtures 4 C Plastic Injection Molding 5 Describe the process of plastic injection molding 2 6 Define functions of the plastic injection mold 3 7 Describe injection molded part features 3 8 Describe injection molded part defects 2 9 Control mold temperature 2 10 Describe parts and functions of the cavity/core assembly 3 11 Describe the plastic delivery system 2 12 Describe mold locating and spotting 2 13 Describe mold ejection systems 3 D Alternative Molding Process 14 Describe blow molding 1 15 Describe extrusion molding processes 1 16 Describe plastic/foam molding processes 1 17 Describe rotational molding process 1 18 Describe thermoform molding process 1 19 Describe metal injection molding 1 20 Define the die‐casting process 1 E CAD/CAM and other Software 21 Use CAD software to determine undocumented dimensions 6 22 Use CAD software to troubleshoot 4 23 Demonstrate concepts of programming using CAM software 3 24 Demonstrate knowledge of communication software 2 25 Use business production software 1 F Inspection and Measurement 26 Request and verify part dimensions and features data 6 27 Perform in‐process checks 13 G Assembly, Fit and Finish 28 Bench and polish steel 6 29 Perform or request specialty finishing 3 30 Spot together shut off areas -
Boilermaking Manual. INSTITUTION British Columbia Dept
DOCUMENT RESUME ED 246 301 CE 039 364 TITLE Boilermaking Manual. INSTITUTION British Columbia Dept. of Education, Victoria. REPORT NO ISBN-0-7718-8254-8. PUB DATE [82] NOTE 381p.; Developed in cooperation with the 1pprenticeship Training Programs Branch, Ministry of Labour. Photographs may not reproduce well. AVAILABLE FROMPublication Services Branch, Ministry of Education, 878 Viewfield Road, Victoria, BC V9A 4V1 ($10.00). PUB TYPE Guides Classroom Use - Materials (For Learner) (OW EARS PRICE MFOI Plus Postage. PC Not Available from EARS. DESCRIPTORS Apprenticeships; Blue Collar Occupations; Blueprints; *Construction (Process); Construction Materials; Drafting; Foreign Countries; Hand Tools; Industrial Personnel; *Industrial Training; Inplant Programs; Machine Tools; Mathematical Applications; *Mechanical Skills; Metal Industry; Metals; Metal Working; *On the Job Training; Postsecondary Education; Power Technology; Quality Control; Safety; *Sheet Metal Work; Skilled Occupations; Skilled Workers; Trade and Industrial Education; Trainees; Welding IDENTIFIERS *Boilermakers; *Boilers; British Columbia ABSTRACT This manual is intended (I) to provide an information resource to supplement the formal training program for boilermaker apprentices; (2) to assist the journeyworker to build on present knowledge to increase expertise and qualify for formal accreditation in the boilermaking trade; and (3) to serve as an on-the-job reference with sound, up-to-date guidelines for all aspects of the trade. The manual is organized into 13 chapters that cover the following topics: safety; boilermaker tools; mathematics; material, blueprint reading and sketching; layout; boilershop fabrication; rigging and erection; welding; quality control and inspection; boilers; dust collection systems; tanks and stacks; and hydro-electric power development. Each chapter contains an introduction and information about the topic, illustrated with charts, line drawings, and photographs. -
Metal Casting Terms and Definitions
Metal Casting Terms and Definitions Table of Contents A .................................................................................................................................................................... 2 B .................................................................................................................................................................... 2 C .................................................................................................................................................................... 2 D .................................................................................................................................................................... 4 E .................................................................................................................................................................... 5 F ..................................................................................................................................................................... 5 G .................................................................................................................................................................... 5 H .................................................................................................................................................................... 6 I .................................................................................................................................................................... -
Manufacturing Technology I Unit I Metal Casting
MANUFACTURING TECHNOLOGY I UNIT I METAL CASTING PROCESSES Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell – investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects. UNIT II JOINING PROCESSES Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt – Seam – Projection welding – Percusion welding – GS metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing – Soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding. UNIT III BULK DEFORMATION PROCESSES Hot working and cold working of metals – Forging processes – Open impression and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills – Flat strip rolling – Shape rolling operations – Defects in rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion – Equipments used. UNIT IV SHEET METAL PROCESSES Sheet metal characteristics – Typical shearing operations – Bending – Drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes – Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming – Magnetic pulse forming – Peen forming – Super plastic forming. -
Ironworks and Iron Monuments Forges Et
IRONWORKS AND IRON MONUMENTS FORGES ET MONUMENTS EN FER I( ICCROM i ~ IRONWORKS AND IRON MONUMENTS study, conservation and adaptive use etude, conservation et reutilisation de FORGES ET MONUMENTS EN FER Symposium lronbridge, 23-25 • X •1984 ICCROM rome 1985 Editing: Cynthia Rockwell 'Monica Garcia Layout: Azar Soheil Jokilehto Organization and coordination: Giorgio Torraca Daniela Ferragni Jef Malliet © ICCROM 1985 Via di San Michele 13 00153 Rome RM, Italy Printed in Italy Sintesi Informazione S.r.l. CONTENTS page Introduction CROSSLEY David W. The conservation of monuments connected with the iron and steel industry in the Sheffield region. 1 PETRIE Angus J. The No.1 Smithery, Chatham Dockyard, 1805-1984 : 'Let your eye be your guide and your money the last thing you part with'. 15 BJORKENSTAM Nils The Swedish iron industry and its industrial heritage. 37 MAGNUSSON Gert The medieval blast furnace at Lapphyttan. 51 NISSER Marie Documentation and preservation of Swedish historic ironworks. 67 HAMON Francoise Les monuments historiques et la politique de protection des anciennes forges. 89 BELHOSTE Jean Francois L'inventaire des forges francaises et ses applications. 95 LECHERBONNIER Yannick Les forges de Basse Normandie : Conservation et reutilisation. A propos de deux exemples. 111 RIGNAULT Bernard Forges et hauts fourneaux en Bourgogne du Nord : un patrimoine au service de l'identite regionale. 123 LAMY Yvon Approche ethnologique et technologique d'un site siderurgique : La forge de Savignac-Ledrier (Dordogne). 149 BALL Norman R. A Canadian perspective on archives and industrial archaeology. 169 DE VRIES Dirk J. Iron making in the Netherlands. 177 iii page FERRAGNI Daniela, MALLIET Jef, TORRACA Giorgio The blast furnaces of Capalbio and Canino in the Italian Maremma. -
Advanced Lost Foam Casting Technology Phase Iv
ADVANCED LOST FOAM CASTING TECHNOLOGY PHASE IV CHARLES E. BATES HARRY E. LITTLETON DON ASKELAND TARAS MOLIBOG JASON HOPPER BEN VATANKHAH 1998 - 2000 SUMMARY REPORT AND FINAL TECHNICAL REPORT TO THE DEPARTMENT OF ENERGY DOE CONTRACT NO. DEFC07-98ID13603 REPORT NO. UAB-MTG-EPC2000SUM NOVEMBER 2000 ADVANCED LOST FOAM CASTING TECHNOLOGY EXECUTIVE SUMMARY AND CONCLUSIONS Previous research, conducted under DOE Contracts #DE-FC07- 89ID12869,DE-FC07-931Dl2230AND DE-FC07-95ID113358 made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on six tasks listed as follows: Task 1: Pattern Pyrolysis Products and Pattern Properties Task 2: Coating Quality Control Task 3: Fill and Solidification Code Task 4: Alternate Pattern Materials Task 5: Casting Distortion Task 6: Technology Transfer This report describes the research done under the current contract in all six tasks in the period of October 1, 1998 through March 31, 2000. A brief summary of this research results is as follows: Task 1. A summary of the major accomplishments includes the results from research on: 1) pattern pyrolysis 2) mechanisms of defect formation in Lost Foam castings, 3)the effect of pattern material properties on casting quality and 4) vacuum assisted casting. Pattern Pyrolysis - An experimental technique for studying the process of foam pyrolysis was developed that mimics the conditions present in LF casting of aluminum and provides the data necessary for a computer model. A foam pyrolysis apparatus based on this technique was built. -
Lost Foam Casting
Emerging Technology and Successful Partnerships: Lost Foam Casting Harvey Wong, U.S. Department ofEnergy Kenneth M Green, BCS, Incorporated ABSTRACT In 1989, a consortium offoundries, suppliers, and academiajoined the U~So Department ofEnergy (DOE) .. in a research program to improve c'ontrol over the lost foam casting process thereby reducing defects and producing high quality precision castings. Lost foam casting is a process that offers many energy and environmental advantages and enables the production of complex parts. The government side,ofthis partnership is led by the u.s. DepartmentofEnergy (DOE), Office ofEnergy Efficiency and Renewable Energy, Office ofIndustrial Technologies (OIT), Metal Casting Industry ofthe Future. Research is conducted through the Lost Foam Technology Center at the University of Alabama em Birmingham. The Consortium has been credited as the driving force behind technical improvements in the lost foam casting process.. Ithas improved knowledge andcontrol inall stages oflostfoam casting.. The LostFoam Casting research was recently profiled by the International Energy Agency, Centre for the Analysis and DisselninationofDemonstrated Energy Technologies (CADDET). Lostfoam casting isjustone of many metal casting techniques. The Metal Casting Industry of the Future partnership is conducting research to improve productivity and energy efficiency innearly all areas ofcasting.. Usingthe ongoing Metal Casting Industry ofthe Future lostfoam research as anexample, paper discusses the be ts ofindustry-government consortia advancing R&D for critical U"S .. industries such as metal casting.. It describes how such partnerships can be pivotal in helping to move emerging technologies from concept to implementation~ Introduction metalcasting industry is vital to the U.S. 1\./lIt::lA'tt:1lmr"':'llC""t'llnn ~n~u"ul::li>CI the to complex parts to meet a variety engine blocks to plumbing fixtures.