EDUCATI ON FOR THE FOUNDRY I NDUSTRY ii By JOE}J TI. SI-iEPLEY,, Bachelor of Science Millersville Gtate Teachers College Millersville, Pennsylvania. 1948 Submitted to the Department of Industrial A:t•ts Education and Engineering Shopwo.rk Oklahoma. J.gricu.lturel a.no. :.rechenical College I:n Partial Fulfillment of the Bequi:reme~ats Foi0 the Degree of' 1949 The writer is indeed glad to acknowledge his indebted­ ness and expNes his gratitude and .appreciation to Dr,. DeWitt Hunt. Bead of Industrial Arts Education and Engineering Shop­ work, Oklahoma Agricultural and Mechallieal College, St1llwater;J Oklahoma. for his edu.catio,n.al leadership, valuable suggestions, and ltindl.y criticisms so ·generously given on this thesis. Ackno-wledgement is also made to Associate Professor. E. ». Soderstrom:, Associate Pro.:fessor of Industrial Arts Education and Engineering Shops, Oklahoma. A.gricultural and Mechanieal Coll:ege, and Mr. George K. Dreher, Executive Director, .Fcn.mdry Ed.ucatione.J. Foundation, Cleveland, Ohio, for their helpful s11ggestions and criticisms. Gratitude is al.so extended to my wUe, Alm.a Shep.le;y,., l<rr ~ration of this thesis. ;J. a:. a. iv APPROVED BY: t .._;:J..._____ ;....,z.(~ > ~ ThesISVser and Head , School of· Industrial Arts Education and Engineering Shopwork C ~.I /i_,(__f} Associate. Professor, School of Industrial Arts Educa t:ton and Engineering Shopwork bean, okiahoma~te of Technology V TABL OF CONTE TS CHAPTER PAGE ! . PUR OSES A.TiJD TECHN IQUES . • • . • • . • l Ho th Proble1: Originatea . 2 Statement of the Problem • • • • . • • • • • 3 The Pu.r ... ,o se t o be Realized from t his Study 4 Deli!Ilitations • • • • • . • . • • . 4 Definition of Terms . 5 Research Methods Used in this Study • • • • • 7 II. EVOLUTION OF THE CASTING PROCESS . • • . • . 8 Tubal Cain • • • . • . • . • • • • • 8 Aristotle B .c. 322 • . • . • • • • • . • 8 England B.C. 200 • • • . • • • • • . 8 .Japan 70 A. D. • • • • • • • • • • • . • • 9 El eventh and Twelfth Centuries . • . • 9 Fig-iron 1311 • . • • . • . • . 9 Memmingen , En land 1388 . • . • • 9 Grave Slab 1450. • 10 England 1500 • . • • . • . • • • 11 Neuhutte in Ger~any 1592 . • . 11 Brede Fourne s, England 162,6 • . • • • • . • . 11 Lynn, Hassachusetts 1644 . • . 12 Reaumur of France 1721 . • . • 12 Christopher Polh8!Il!ller, Sweden 1750 • . • • . 12 New York City 1798 • • • • • • • • • 13 Manchester, Connecticut . • . • . 14 Thomas Tredgold 1822 • • . 14 South Boston Iron Company 1827 . • . 15 France , En land 1850 to 1860 • . • . 15 The Capitol Buildin , Washington, D. C. 1865 . 15 Thomas D. We st 1882 . • • • . • • • • • . 15 Founding Grows in the United States . • . 16 III. INDUSTRIAL ARTS COURSES AND TEE FOUNDRY INDUSTRY 17 The Purpo~e of this Chapter. • • • • • • • • 17 A. Industrial Arts Objectives • . • . • . • . 18 Attaining the Industr ial Arts Objectives • . 19 Foundry Practice and other Industr ial Arts Subjects . • • . • • • . • • • • . • • • 22 Tools and Equipment for an Industrial Arts Fotmdry • • . • • . • . • . • 22 B. Proposed Course Outline for Foundry Work • • 23 Sho rganization . • . • • . 24 aking a Pattern V1th Hand Tools • • 24 Use of ,:achtnery in Pattern Makir.g • • • 24 :Preparation of Sand for Mo ld • . • .. • • 24 Ram.Tiling a MO ld • • . • . 25 elting and Casting Aluminum , Lead and Type Metal . • • • . - 25 Finishing . • • . • . • . 25 vi TABLE OF CONTENTS ( CONTINUED) CHAPTER PAGE III. (Continued) Making Core Boxes and Cores ......•.• 25 a.king a Casting with Cored Cavities ••.•. 25 Recommended Textbooks ••••...•...• 26 Equipment and Materials Required for a Foundry ~ork Area for Four Students ••••..•• 26 Specifications for Equipment •••.••. 26 a terials . .. .. .. 28 C. Suitable Projects for the Industrial Arts Folllldry • . • . • • . • . 28 Flat Back Projects . • • . • . • ••..• 28 Split Pattern rejects . • • . •. 29 Irregular Partin Patterns •......... 29 Projects Requiring Cores . • • . 30 IV. VOCATIONAL EDUCATIO I .FOR THE FOUNDRY INDUSTRY •• 31 The Purpose of this Chapter ••...•••. 31 Need for Vocational Education 1n the Foundry Industry . 32 A. Trades Related to the Foundry Industry •. 33 Patternmaking • • . • . .. • • . • . 33 Col'e aking • • . • . .. 34 Molding • • . 34 Cupola and Furnace Tending ••••.•.••. 35 Metal Finishing • . • • • • • • • • . • . 35 B. Proposed Course Outline For Foundry ork •.• 36 Introduction • . • • • • . • . • . • . 36 Foundry Tools, Equipment and Terminology •.• 36 Patterns . • . 37 Foundry Sands • • • • • • • • • • • • • • 37 Fundamental Principles of Molding ••...• 37 elting Theory, Operation and Equipment . • . 38 e tal Handlin • • . • . • . • • • . • . 38 Coremaking • • . • . • . 38 Cleaning and Inspecting Castings • . 38 Safety and Good Shop Keeping ••• . 39 Elements of ~etallurgy .••... 39 v. APPRENTICESHI EDUCATION FOR TIIE FOUNDRY INDUSTRY 40 A. Recommended Standards of Four-Year Foundry Apprenticeship . • . • • 41 ~agemen t . • . 41 Selection of l.p rentices • . • . • . • . 41 Term of Apprenticeship. • • . • . • • . 42 Schedules of Advancement . • . • . 42 Re commended rogram • . • • . 43 Related Instruction . • • . 44 Supervision • • • • • . • . • . • • . 44 B. General s ge s "Lions • . • . 45 Attracting Interest of Boys, arents, and School Authorities . • ·· • • 45 vii TABI.E OF CONTENTS (CONTINUED) CHAPTER PAGE v. ( Continued) Selecting Applicants for Apprenticeship •• 46 The Schedule of Advancement •••••••• 46 Following the Schedule ••••••.•. 47 Keeping Apprentices Interested 1n Jork • • . 47 Cooperation with Foreman and Ot her Executives 48 Interesting A prentices in School Wi .rk ••• 48 Planning Lessons for School •••••••. 49 The First Class Meeting ••••...••. 50 The Test of Instruction •.•.•.•.•• 50 Te chnical Foundry Subjects 1n the School • • 51 Fundamental School Subjects , .•••• 52 Cooperating with Foremen and Execut-ives 1n the Matter of School Attendence ••• 5£ 1nta1n1ng Interest by eans of School lnstruc tion • • . • • • • • • • • • • . 53 Social Activities of Apprentices •.•. 53 ·Gradu.ation • • • • • • • • • . • . • • • 54 VI. TECHNICAL EDUCAT ION FOR TBE FOUNDRY I DUSTRY 56 The Purpose of this Chapter • •••. •.• 56 Need for Technicians 1n the Foundry Industry 57 A. Common Technical Positions of the Foundry Indus try • • • • • • • • • • . 58 Foreman of Moldin · Department . • • . 58 Foreman of Core:!llak1ng Department • • . • 59 Me lting Department Technician .•..•.. 60 Foreman of Finishing Department • . • . • . 60 Control Laboratory Technicians .•.••.. 61 B. cilitary Assignments Related to the Foundry Industry • • • . • . • • • • • • . 62 Army Assignments • . • . • . • • • . • 63 Navy .Assignments • . • • . • . • . 64 Foundry Occupations • • . • • • • . • 66 C. Proposed Course of Study for Technical Foundry Positions ••••...•...•.. 72 Blue Prints - Sketches - Uodels •• . 73 History of the Foundry Industry • • 73 Mathe!118.tics • • • • • • • •••.• 73 Safety . • . 7o Elementary Costs • • • . 73 Pattern, Molds and Dies •••.•. 73 Core a.king • • • • • . • . 73 Moldin . • . 74 Meta.ls , Melting and Pourin ••••.•.• 74 Gatin and Risering •••.•••• . 74 Quality Control • • . • . 74 Finishing • • . • . • . • . • • . 74 Maintenance roblems •••..••. 74 viii TABLE OF CONTENTS (CONTINUED) CHAPTER PAGE VI. (Continued) Cost Control • • • • • • • • • • • • • • • • 74 Job Estimating •••••••••• • • • • • 74 Advance Foundry Problems ••••• • • • • • 75 Labor, Industrial and Contract Law • • • • • 75 VII. ENGINEERING EDUCATI ON FOR THE FOUNDRY INDUSTRY • 76 Foundry Industry Last to Change to Engi neering Education • • • • • • • • • • • • • • • • • 76 The Purpose of this Chapter. • • • • • • • • 77 A. Foundry lndust17 • • • • • • • • • • • • • • 77 The Growth of Engineering Profe ss1ons Since 1910 • • • • • • • • • • • • • • • • • • • 78 Foundry Industry Developed by Engineering Methods • • • • • • • • • • • • • • • • • • 78 The Foundry Industry 1n Cooperation With Educational Institutions • • • • • • • • • 78 Non-Schoolastic Qualifications • • • • • • • 79 B. The Universities • • • • • • • • • • • • • • 80 Functions of the University. • • • • • • • • 81 Industry Should Train Engineers. • • • • • • 82 Student Selection • • • • • • • • • • • • • • 82 Student Options. • • • • • • • • • • • • • • 82 c. Conclusions. • • • • • • • • • • • • • • • • 83 Education for the Foundry Industry • • • • • 84 Curriculum Changes Needed. • • • • • • • • • 85 Program Suggested-by the Foundry Educational Founda. t1on • • • • • • • • • • • • • • • • 87 Educational Stems of Interest to Foundry Management • • • • • • • • • • • • • • • • 89 VIII. SUMMARY , CONCLUSIONS• AND RECO NDATIONS • • • 95 A. SlllDllla.ry • • • • • • • • • • • • • • • • • • • 95 B. Conclusions • • • • • • • • • • • • • • • • • 96 Industrial Arts Courses. • • • • • • • • • • 96 Vocational Education • • • • • • • • • • • • 97 Apprenticeship Education • • • • • • • • • • 97 Technical Education. • • • • • • • • • • • • 97 Engineering Education. • • • • • • • • • • • 97 c. Recommendations. • • • • • • • • • • • • • • 98 Problems for Further Study • • • • • • • • • 99 BIBLIOGRAPHY • • • • • • • • • • • • • • • • • • • • • 101 C1ffiPTER I fhe :important position that foundry practicet as an ed­ cationa.l subject, is achieving in the educational programs ot our public schools, trade schools, technical schools 1 col­ leges and tllliversities of today is causing .more emphasis to be placed upon it. Engineering colleges, technical institutions, trade and public schools of this country are almost univer­ sally making it an .integral part of