Recommendations

1. Distortion allowance
Vertical edges will be curved or distorted, this is prevented by shaped pattern
converge slightly inward so that the casting after distortion will have its side
vertical. Prevention also can be done by providing sufficient machining
allowance to cover the distortion effect and by providing suitable allowance
on the pattern called camber or distortion allowance.

2. Ramming a mold
Few inches of sand over the pattern should be carefully rammed and tightly
packed. Soft spots, packets should be rammed properly. The mould should be
rammed layer by layer. Besides ramming should be done as close to vertical
surfaces of pattern.
3. Moulding sand preparation and moisture content determination
The moisture content controls practically all other properties of the sand. It is
a varying property since water content constantly evaporates during mold
preparation. So water should be add sufficiently to bring the moisture content
to within desired limits and uniform distribution of water all over the sand so
that all part of the sand receive has same moisture property. Do not let the
sand dry out. Use sand riddle to cover the first layer just the pattern only and
make sure there is no lumps. The riddle fluffs the sand up so it can be packed
properly and avoid defects. If the sand is too wet torch the casting area about
a minute, this will dry out excess moisture.
4. Gases in metals
The gases in metal is important in deciding the defect free castings. In metal
castings, gases may be mechanically trapped, due to variation in their
solubility at different temperatures and phases and mechanical reaction with
surrounding air during melting and pouring of the metal. So precaution had to
take to overcome this for example by bubbling dry insoluble gases through
molten melt. Do not overheat any metal that use in the melting process.
5. Pouring and gating design
A good design gating design should be made to ensure proper distribution of
molten metal without excessive temperature loss, turbulence, gas trapping
and slags. Molten metal should be poured very slowly, since time taken to fill
the mould cavity will become longer, solidification will start even before the
mould is completely filled. A steady rate of pouring should be use. Molten
metal also should not be poured very faster because it can erode the mouled
cavity. So gating design is important and it depends on the metal pouring and
molten metal composition.

6. Additives
Additives like coal dust, pulverized slag, manganese dioxide and others
should be added to the sand mixture to improve surface finish and avoid
thermal cracking during pouring. The lubricants such as calcium stearate can
be added to improve the flowability of the sand and permit easy release of
the shell from the pattern.
7. Avoid and overcome defects
Shrinkage use large sprue and riser to promote directional solidification.
Locate risers and
gating systems in correct positions.
Gates to be cut as wide as possible.
Porositiy avoid excess ramming of mould and provide proper vent holes.
Avoid use of excess
carbonaceous or other organic material
in the sand /core binders, because these
materials react with
the molten metal producing large amount of gases.
Misrun fluidity of metal should be high. Pouring rate and time should be
controlled.
Penetration sand should be properly rammed and moulding sand should not
be too coarse to
promote metal penetration and control the
metal temperature.
Hot tears provide adequate fillets at sharp corners. Proper metallurgical and
pouring
temperature. Place gates and risers at proper
locations.

Conclusion

The molding operation aboard ship depends primarily on the molder and ability on
certain people. A molding technique based on careful attention to the various
details involved in making a mold. As a conclusion this experiment should have the
following qualities to a degree suitable for the purpose intended:
1. Refractoriness to withstand the casting heat. This is obtained by selection
material and proper processing.
2. Strength to withstand handling and casting forces. This is obtained by the
use of the proper amount of binders and by good internal structural
supports.
3. Collapsibility to permit breakdown during contraction of the casting and
ease of cleaning. By avoiding the use of sands bonded too strongly and by
hollowing out the center or filling it with coke, cinders, gravel, or weak
sand, this quality may be obtained.
4. Smooth strong surface to provide a good casting finish, internal
cleanliness, and ease of cleaning. This quality is obtained by the use of an
adequately bonded refractory sand, uniformly hard rammed, baked
immediately after being made, and used shortly after baki.ng.
5. Low gas content to prevent unsoundness in the casting. This quality is
obtained by using the minimum of organic binding materials, baking well,
and venting thoroughly. All of the above features are essential in core
making and are regularly obtained only by good core practice
Molding consists of all operations necessary to prepare a mold for receiving molten
metal. Molding usually involves placing a molding aggregate around a pattern held
with a supporting frame, withdrawing the pattern to leave the mold cavity, setting
the cores in the mold cavity and finishing and closing the mold. The preparation of
molten metal for casting is referred to simply as melting. Melting is usually done in
a specifically designated area of the foundry, and the molten metal is transferred to
the pouring area where the molds are filled. In a nutshell, the principles and
terminology underlying the sand casting process has been investigated. Overall,
this experiment has been done well and all the understanding and knowledge about
molding preparation and pouring are obtained.