![]() • • Title • Metal casting: a sand casting manual for the small foundry / Steve D. Author • Chastain, Steve. Metal Casting: A Sand Casting Manual for the Small Foundry, Vol. 1 Just like volume 1, this book pushes the amount of information that can be crammed. Casting Manual for the Small Foundry Volume 1. When a casting is poured into a mold and the metal cools and solidifies. By simulating 50% for large sand castings to 35% for small investment. Published • Jacksonville, FL: Steve Chastain, c Physical Description • v.: ill.; 22 cm. Series • • Subjects • • • Summary • In volume one (1) the author shows the beginer how to make a sand mold and then how to hone your skills to produce high quality castings. Written in non-technical terms, the sand casting manuals begin by melting aluminium cans over a charcoal fire and end by casting a cylinder head. Volume two (2) coniinues tje sand cassting manual by describing more advanced techinques. Contents • Volume 1: 1. The sand casting process • 2. Foundry projects • 3. ![]() Melting equipment • 4. Temperature measurement • 5. Foundry sands and binders • 6. Solidification of metals • 2. Aluminium alloys • 3. Copper alloys, brass & bronze • 4. Metallurgy of iron • 5. Gating systems • 6. Risers and feeding of castings • 7. Pattern making • 8. Foundry projects • 10. Automotive castings • 11. Misclanenious • 11. • Notes • Includes bibliographical references. Language • English ISBN • (pbk.) Dewey Number • 671.2 Libraries Australia ID • Contributed by Get this edition. [ ] [ ] FOUNDRY SAND Material Description ORIGIN Foundry sand consists primarily of clean, uniformly sized, high-quality silica sand or lake sand that is bonded to form molds for ferrous (iron and steel) and nonferrous (copper, aluminum, brass) metal castings. Although these sands are clean prior to use, after casting they may contain Ferrous (iron and steel) industries account for approximately 95 percent of foundry sand used for castings. The automotive industry and its parts suppliers are the major generators of foundry sand. The most common casting process used in the foundry industry is the sand cast system. Virtually all sand cast molds for ferrous castings are of the green sand type. Green sand consists of high-quality silica sand, about 10 percent bentonite clay (as the binder), 2 to 5 percent water and about 5 percent sea coal (a carbonaceous mold additive to improve casting finish). ![]() The type of metal being cast determines which additives and what gradation of sand is used. The green sand used in the process constitutes upwards of 90 percent of the molding materials used. (1) In addition to green sand molds, chemically bonded sand cast systems are also used. These systems involve the use of one or more organic binders (usually proprietary) in conjunction with catalysts and different hardening/setting procedures. ![]() Foundry sand makes up about 97 percent of this mixture. Chemically bonded systems are most often used for 'cores' (used to produce cavities that are not practical to produce by normal molding operations) and for molds for nonferrous castings. The annual generation of foundry waste (including dust and spent foundry sand) in the United States is believed to range from 9 to 13.6 million metric tons (10 to 15 million tons). (2) Typically, about 1 ton of foundry sand is required for each ton of iron or steel casting produced. Additional information on the production and use of spent foundry sand in construction materials applications can be obtained from. ![]() Simplified schematic of green sand mold system. Little information is available regarding the amount of foundry sand that is used for purposes other than in-plant reclamation, but spent foundry sand has been used as a fine aggregate substitute in construction applications and as kiln feed in the manufacture of Portland cement.
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