Foseco Non-Ferrous
Foundrymans Handbook
Eleventh edition
OXFORD
AUCKLAND
BOSTON
JOHANNESBURG
MELBOURNE
NEW DELHI
Preface
The last edition of the Handbook was published in 1994 and like all the earlier
editions, it aimed to provide a practical reference book for all those involved
in making castings in any of the commonly used alloys by any of the usual
moulding methods. In order to keep the Handbook to a reasonable size, it was
not possible to deal with all the common casting alloys in detail. Since 1994
the technology of casting has continued to develop and has become more
specialised so that it has been decided to publish the 11th edition of the
Handbook in three separate volumes:
Non-ferrous
Iron
Steel
................................... Preface
...................................................
Acknowledgements
1 Tables and general data .........................................
1
2
5
6
7
8
9
10
11
13
14
15
16
17
18
18
19
19
21
......................................
2 Aluminium casting alloys
.....................................................
Introduction
Casting alloys ..........................................................................
Casting processes ...................................................................
The effect of alloying elements................................................
Heat treatment of aluminium alloys .........................................
25
39
39
42
.......................................
3 Melting aluminium alloys
.....................................................
Introduction
Raw materials..........................................................................
Melting furnaces ......................................................................
Corundum growth ....................................................................
Choice of melting unit ..............................................................
47
47
54
55
.....................................4 Fluxes
Application
..................................
of COVERAL powder fluxes
Granular COVERAL fluxes ......................................................
61
65
6 Treatment of aluminium
.....................
alloy melts
Hydrogen gas
...............................
pick-up in aluminium melts
Degassing aluminium alloys ....................................................
Grain refinement of aluminium alloys ......................................
Modification of aluminium alloys..............................................
Sodium modification ................................................................
Strontium modification .............................................................
Permanent modification ...........................................................
Sand, gravity die and low pressure diecasting ........................
Medium silicon alloys, 4 7% Si ................................................
Eutectic silicon alloys, 12% Si .................................................
Treatment of hypereutectic Al Si alloys (over 16% Si) ...........
Melting and treatment of aluminium magnesium alloys (
4 10% Mg) ..............................................................................
Special requirements for gravity diecasting .............................
Treatment of alloys for pressure diecasting.............................
72
77
79
81
82
83
83
84
84
85
86
87
87
75
90
93
94
98
8 Filtration of aluminium
..................
alloy castings
SIVEX FC filters.......................................................................
Use of filters in conventional running systems ........................
Direct pouring of aluminium alloy castings ..............................
KALPUR combined sleeve and SIVEX FC filter for
aluminium castings ..................................................................
Direct pouring into metal dies ..................................................
100
101
104
105
107
...................................................Die design
Process control........................................................................
Modification of the diecasting process.....................................
Applications of diecastings ......................................................
The diecasting foundry ............................................................
Die coating...............................................................................
111
113
114
114
116
124
127
.......................................
11 Sand casting processes
Green sand..............................................................................
Moulding machines..................................................................
Core assembly sand processes ..............................................
The Lost Foam process ...........................................................
136
137
140
144
...............................................
13 Resin bonded sand
151
152
153
153
153
154
156
156
157
160
163
164
165
165
166
166
.........................................................
Chemically bonded sand
Self-hardening process (also known as self-set, no- bake
..........................................................
or cold- setting process)
Testing chemically bonded, self-hardening sands...................
Mixers ......................................................................................
Sand quality .............................................................................
Pattern equipment ...................................................................
Curing temperature..................................................................
Design of moulds using self-hardening sand...........................
Foundry layout .........................................................................
Sand reclamation.....................................................................
Typical usage of sand reclamation ..........................................
Furanes ...................................................................................
Phenolic-isocyanates (phenolic-urethanes).............................
Alkaline phenolic resin, ester hardened...................................
Heat triggered processes ........................................................
Gas triggered systems.............................................................
The shell or Croning process...................................................
Hot-box process ......................................................................
Warm-box process ..................................................................
Oil sand ...................................................................................
Phenolic-urethane-amine gassed (cold-box) process .............
ECOLOTEC process (alkaline phenolic resin gassed with
CO2) ........................................................................................
The SO2 process.....................................................................
SO2- cured epoxy resin ...........................................................
Ester-cured alkaline phenolic system ......................................
Review of resin core-making processes..................................
169
171
172
172
173
173
173
175
178
180
182
183
185
186
187
189
190
191
193
195
196
198
198
199
14 Sodium
..............................
silicate bonded sand
...........................................................
Sodium silicate
CO2 silicate process ( basic process) .....................................
Gassing CO2 cores and moulds..............................................
Improvements to the CO2 silicate process..............................
The CARSIL range of silicate binders .....................................
SOLOSIL .................................................................................
Self-setting sodium silicate processes.....................................
Ester silicate process...............................................................
Adhesives and sealants...........................................................
CORSEAL sealants .................................................................
205
207
208
209
209
210
210
215
215
215
..............................................
15 Magnesium casting
.........................................................
Casting alloys
The melting, treatment and casting of magnesium alloys .......
218
226
227
232
238
242
243
243
243
244
248
250
250
250
251
251
...................................................
17 Feeding systems
...........................................................
Natural feeders
Aided feeders ..........................................................................
Feeding systems .....................................................................
The calculation of feeder dimensions ......................................
Steel, malleable iron, white irons, light alloys and copperbased alloy castings ................................................................
Grey and ductile irons..............................................................
Introduction..............................................................................
Range of feeder products ........................................................
Breaker cores ..........................................................................
The application of feeder sleeves............................................
Williams Cores.........................................................................
FERRUX anti-piping compounds for iron and steel
castings ...................................................................................
Metal-producing top surface covers ........................................
FEEDOL anti-piping compounds for all non-ferrous alloys......
253
254
257
262
266
268
269
279
280
283
284
285
286
................................
Index
286
287
287
288
Acknowledgements
Acknowledgements
xiii