Foseco Non-Ferrous Foundryman's Handbook by John Brown

By John Brown

The Non-Ferrous Foundryman's guide presents a pragmatic reference booklet for all these taken with facing aluminium, copper and magnesium casting alloys.International SI devices are used all through, yet in just about all situations conversions to the extra known Metric and Imperial devices are given. at any place attainable, Casting Alloy requisites contain identical requisites for a number of international locations in addition to foreign necessities. person chapters hide the casting of all kinds of non-ferrous metals. for every staff of alloys, requirements, and commonplace functions are defined, including info of melting perform, steel therapy and casting perform. Sand moulding fabrics, together with eco-friendly sand and chemically bonded sands also are integrated. lately there were many significant technical advancements together with new sand binders, the adoption of steel filtration of castings and frequent use of desktops for the optimisation of feeder layout.

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This has allowed designers to have greater confidence in castings so that thinner sections and lower weight components can be used. The stages in the aluminium casting process where the greatest improvements have been made are: Efficient degassing Grain refinement Modification of structure Metal filtration Non-turbulent filling of moulds Chill casting (into metal moulds) has inherently a greater possibility of producing higher quality than sand casting because the higher rate of solidification reduces pore size and refines grain size.

Chapter 2 Aluminium casting alloys Introduction Aluminium casting is dominated by the automotive industry. Roughly two thirds of all aluminium castings are automotive where the use of aluminum castings continues to grow at the expense of iron castings. Although aluminium castings are significantly more expensive than ferrous castings, there is a continuing market requirement to reduce vehicle weight and to increase fuel efficiency. It is this requirement which drives the replacement of ferrous parts by aluminium.

Typical shaft furnaces range in size from a holding capacity of 1000 kg and a melting rate of 1000 kg/hour to over 3000 kg holding and 3000 kg/hr melting capacity. Shaft furnaces of much larger capacity are also available. Molten aluminium is discharged to a transfer ladle or launder either by hydraulically tilting the holding bath or by a tap-out system. 3 Gas-fired shaft furnace. The STRIKO ETAmax system. 5% when melting 50/50–ingot/foundry returns. Operating the furnace below rated capacity has a significant effect on energy consumption.

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