In this post, we will see the book Foundry Practice by N. D. Titov and Yu. A. Stepanov.

About the book

The book is based on the lectures read to the students of machine- building secondary schools and also on the foundry practice course included in the curriculum of the Bauman Higher Technical School of Moscow.
The book opens with a detailed description of sand molding techno­logy, melting, pouring, and fettling of castings from gray iron which is one of the most widely used casting alloys. Subsequent chapters treat the methods of fabrication of castings from malleable iron, steels, and alloys of copper, aluminum, and magnesium. One part of the book places a particular emphasis on the theory of casting. The last part which includes several chapters contains basic infor­mation on special casting processes such as permanent mold casting, die casting, investment casting, and shell casting. The authors have paid special attention to the sequential presentation of various as­pects of founding in a clear and readable language.
Each chapter first describes the essence of production processes, the influence of operating conditions on the quality of castings, and then presents the rational fields of application of the production methods. In the authors’ opinion, such a presentation of the mate­rial helps the reader to acquire more readily the basic knowledge of foundry practice.

The book was translated from Russian by P. S. Ivanov and was published in 1981 by Mir.

Credits to the original uploader.

You can get the book here (~ 14 MB).

The link above is an optimised version of the original file of ~ 310 MB

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Contents

Preface 9

Part I. Molding Technology. 11

Chapter 1. Casting Mold 11

Chapter 2. Basics of Pattern Design and Making 18

2.1. General 18
2.2. Wood Patterns 18
2.3. Metal Patterns 35
2.4. Plastic Patterns 44

Chapter 3. Molding Materials 49

3.1. General 49
3.2. Sand Types 51
3.3. Clay. Type Binders 55
3.4. Other Binders 57
3.5. Auxiliary Molding Materials 61
3.6. Molding and Core Sands 63
3.7. Washes, Pastes, Powders, and Other Dressings 80
3.8. Preparation of Molding and Core Sands 84
3.9. Sand Control 92

Chapter 4. Production of Molds 102

4.1. General 102
4.2. Hand Molding 107
4.3. Machine Molding 124
4.4. Organization of In-Line Production, Integral Mechanization and
Automatization in the Molding Shop 140

Chapter 5. Gating Systems 146

5.1. Elements of the Gating System 146
5.2. Gating Methods and Types of Gating Systems 150
5.3. Calculation of Gates for Gray Iron Castings 153

Chapter 6. Coremaking 163

6.1. General 163
6.2. Core Design 163
6.3. Hand Coremaking 167
6.4. Machine Coremaking 171
6.5. Finishing, Inspection, and Storing of Cores 177
6.6. Mold and Core Drying 180

Chapter 7. Mold Assembly and Fastening 186

7.1. Mold Assembly 186
7.2. Mold Fastening and Weighting 187

Chapter 8. Design of Castings, Molds, and Cores 190

8.1. Design of Castings 190
8.2. Design of Molds and Cores 194

Chapter 9. Cost Effectiveness of Metal Casting 213

9.1. Technical-and-Economic Indexes 213
9.2. Economic Efficiency of a Casting Process 214
9.3. Ways of Increasing Economic Efficiency of Metal Casting 218

Part II. Basic Theory of Casting.

Chapter 1. Interaction of the Mold with Molten Metal 219

1.1. Gases in Castings 219
1.2. Effect of Molten Metal on the Mold 224
1.3. Crystallization of Alloys in the Mold 227
1.4. Internal Casting 230

Chapter 2. Casting Properties of Metals and Alloys 235

2.1. Fluidity 235
2.2. Shrinkage 237
2.3. Segregation 243

Part III. Production of Gray Iron Castings.

Chapter 1. Gray Cast Iron 246

1.1. General 246
1.2. Effect of the Chemical Composition on the Structure and Properties of Iron 247
1.3. Classification of Irons 252
1.4. Mechanical Properties of Cast 254
1.5. Inoculation of Gray Iron 256
1.6. High-Strength Irons 256
1.7. Alloy Cast Irons 259

Chapter 2. Charge Materials. Charge Calculation 262

2.1. Metal Charge 262
2.2. Fuels 267
2.3. Fluxes 269
2.4. Charge Calculation 271

Chapter 3. Melting Cast Iron in the Cupola 279

3.1. General 279
3.2. Metallurgical Principles of Melting Iron in the Cupola 284
3.3. Stepping up the Process of Cupola Melting 289
3.4. Disturbances іп the Cupola Run 291
3.5. Melting Process Control 292

Chapter 4. Melting Iron in Reverberatory and Electric Furnaces.297

4.1. Melting in Reverberatory Furnaces 297
4.2. Melting in Electric Arc Furnaces 298
4.3. Melting in Coreless Induction Furnaces 302
4.4. Melting in Core Induction Furnaces 305

Chapter 5. Running, Shakeout, Fettling and Acceptance of Gray Iron Castings 308

5.1. Pouring into Molds 308
5.2. Cooling and Shakeout of Castings 312
5.3. Fettling of Castings 313
5.4. Chipping and Grinding of Castings321
5.5. Heat Treatment of Iron Castings 322

Chapter 6. Casting Defects 324

6.1. General 324
6.2. Types and Causes of Defects. Preventive Measures 324
6.3. Inspection 329
6.4. Salvaging Operations 331
6.5. Product Quality Control Management 333

Part IV. Production of Malleable Castings 336

Chapter 1. Molding Practice and Melting 336

1.1. General 336
1.2. Some Features of Molding Practice 338
1.3. Melting White Cast Iron 340
1.4. Fettling of Castings 345

Chapter 2. Annealing of Castings 347

2.1. Malleable Annealing 347
2.2. Short-Cycle Malleable Annealing 351

Part V. Production of Steel Castings 353

Chapter 1. Steels for Shaped Castings 353

1.1. General 353
1.2. Carbon Steels 354
1.3. Alloy Cast Steels 355

Chapter 2. Design of Steel Castings and Molding Practice 357

2.1. Design of Steel Castings and Molds 357
2.2. Construction and Calculation of Gating Systems and Risers 359

Chapter 3. Melting and Casting of Steels 363

3.1. Melting in Open-Hearth Furnaces363
3.2. Melting in Basic and Acid Electric Furnaces 366
3.3. Pouring, Cleaning, and Heat Treatment of Castings 370

Part VI. Production of Nonferrous Castings 373

Chapter 1. Production of Copper-Alloy Castings 374

1.1. Composition and Properties of Copper Alloys 374
1.2. Gating and Risering… css 376
1.3. Melting Copper Alloys 378

Chapter 2. Production of Aluminum Castings 383

2.1. Composition and Properties of Aluminum Alloys 383
2.2. Molds, Gates, and Risers 386
2.3. Melting Aluminum Alloys and Pouring Molds 387

Chapter 3. Production of Magnesium Castings 393

3.1. Composition and Properties of Magnesium Alloys 393
3.2. Molds and Gates 394
3.3. Melting Magnesium Alloys 395

Part VII. Special Casting Processes 398

Chapter 1. Permanent-Mold Casting 398

4:1. General 398
4.2. Permanent Molding 399
1.3. Casting Various Alloys 404
1.4. Permanent Molding Machines 406

Chapter 2. Centrifugal Casting 408

2.1. General 408
2.2. Molds and Machines 411

Chapter 3. Die Casting 414

3.1. General 414
3.2. Pressure Casting Dies 418
3.3. Die Casting Machines 420
3.4. Gating Systems and Operating Conditions 422
3.5. Low-Pressure Die Casting 425

Chapter 4. Investment 427

4:4. General 427
4.2. Production of 429
4.3. Production of the Investment Mold 433
4.4. Investment Casting Process 436
4.5. Melting and Pouring Metal into Molds, Shakeout and Fettling of Castings 439

Chapter 5. Shell 440

5.1. General 440
5.2. Production of Shell Molds and Cores 443
5.3. Assembling and Pouring of Shell Molds. Shakeout of Castings 444

Chapter 6. Other Special Casting 446

6.1. Continuous 446
6.2. Chill Casting 448
6.3. Casting by Squeezing 451
6.4. Liquid 452

Index 454