1.

0 TITLE: Molding Preparation and Pouring

2.0 INTRODUCTION

Casting is one of the earliest metal shaping methods known to human being. It generally means
pouring molten metal into a refractory mold with a cavity of the desired shape to be made and
allowing it to solidify for some time before taking it out. When solidified, the desired metal
object is taken out from the refractory mold either by breaking the mold or taking the mold
apart. The solidified object is called casting. This process is also called founding. Casting
required a lot of processes and that includes fabrication of pattern, mold constructions and
pouring of molten metal.

In casting, a pattern is a replica of the object to be casted, used to prepare the cavity into which
molten material will be poured during the casting process. It provide the shape for object that
need to be casted. Typically, patterns used in sand casting may be made of wood, metal, plastics
or other materials. Patterns are made to exacting standards of construction, so that they can last
for a reasonable length of time, according to the quality grade of the pattern being built, and so
that they will repeatably provide a dimensionally acceptable casting.

The patternmaker or foundry engineer decides where the sprues, gating systems, and risers are
placed with respect to the pattern. Where a hole is desired in a casting, a core may be used
which defines a volume or location in a casting where metal will not flow into. Sometimes
chills may be placed on a pattern surface prior to molding, which are then formed into the sand
mould. Chills are heat sinks which enable localized rapid cooling. The rapid cooling may be
desired to refine the grain structure or determine the freezing sequence of the molten metal
which is poured into the mould. Because they are at a much cooler temperature, and often a
different metal than what is being poured, they do not attach to the casting when the casting
cools. The chills can then be reclaimed and reused.

Mold construction required some criteria. The choice of molding materials is based on
their processing properties. Generally, the properties are refractoriness, green strength, dry
strength, hot strength and permeability. Refractoriness is an ability of molding material to
withstand the high temperature of the metal so that it does not cause fusion.

The molding sand that contains moisture is termed as green sand. The sand selected should
have enough strength so that the constructed mold retains its shape. In the mean time, when the
moisture in the molding sand is completely expelled, it is called dry sand. While the strength
of the sand that is required to hold the shape of the mold cavity then is called hot strength.
Finally, the permeability is a term used to measure gas evolution capability during
solidification of a casting.

Pouring of molten metal (melting practice) required a good discipline both from gating system
design and risering system application. Several parameters are applied such as pouring time,
gating elements, gating ratios, and slag trap system, methods of solidification behaviour,
feeding distances and feeding aids.
3.0 OBJECTIVE

To investigate the principles and terminology underling the sand casting process.
To have hands on experience on the overall casting process including mould making,
melting, pouring, shake out and visual inspection of casting.

4.0 APPARATUS
4.1 MATERIALS
Aluminium
The aluminium was used as pouring materials. Aluminium alloy casting has
melting temperature of 660C [4] with its corresponding pouring temperature
range to be between 700C-750C. It was also stated by Lindberg [5] that this
melting temperature may be as low as 649C.
Green sand
There are three types of sand molds are green-sand, cold-box, and no-bake
molds. Green sand molding is the most common material that consists of a
mixture of sand, clay, and water which has to be moist while the metal is
being poured into it. This is the least expensive method of making molds.
In the cold-box mold process, various organic and inorganic binders
are blended into the sand to bond the grains chemically for greater strength.
These are dimensionally more accurate than green-sand molds but are more
expensive.
The no-bake mold process is a synthetic liquid resin, which is mixed
with the sand so that the mixture can be hardened at room temperature.
Some major components of sand molds are:
The mold itself, which is supported by a flask. The flask consists of
two pieces of molds that are known as the cope located on the top and a drag
on the bottom.
A pouring basin, into which the molten metal is poured.
A sprue, the part where molten metal flows through.
 A riser, the section that supplies additional metal to the casting while
the metal shrinks in the solidification stage.

Vents are placed in molds for the main purpose of releasing existing
gases when the molten metal comes into contact with the sand. They also
exhaust air from the mold cavity as the molten metal flows into the mold.
Parting agent
The parting agent is used to release cope from drag and over pattern
preventing the molding sand from sticking and ruin the mould finshing. Talc
powder can be used too and will be as effective.

4.2 HAND TOOLS

When working with casting sand the caster needs a few basic tools to achieve
good casting results. Casting tools can be expensive, the hobby metal caster
can use home objects or tools which are as good as professionals ones.

Metal wire: can be used to create the gas vent holes.

Molder Trowel: could be replaced with a pointy block layer finishing trowel.
Slick: this could be replaced with a simple small kitchen spoon to create for
example the pouring basin or runner or to clear off unwanted sand particles
etc'.
Sand Sifter: A sifting tool is used for spreading very fine textured sand
directly into contact with the pattern to get the best finishing results. Mesh size
will determine how fine sand grain is sifted. I used a simple garden mesh with
a deep wooden frame to prevent sand falling out of the sifting mesh.
Sprue and Riser: To create the Sprue and Riser can be done simply by cutting
timber to fit the work flask. For example I used a rounded timber toy to create
the Sprue adding the casting sand around it.
4.3 MACHINE AND EQUIPMENT

Furnace
A furnace is a device used for heating. The name derives from Latin fornax. In
my blog I will introduce my home made furnace for melting aluminum. In
order to Heat this DIY type of furnace it could be achieved by using charcoal,
propane gas, waste oil or electric heating element.

Sand Rammer
This is used to pack all the sand into the flask eliminating air pockets and lose
sand that might ruin the final mould after pouring the molten metal. The
rammer comes in different sizes. Most rammers are made of wood or
aluminum, one side flat the other side narrow to fit into the flask corners. For
bigger jobs and more commercial use the electric hand rammer is ideal. If one
does not have a sand rammer a simple block of timber will do to pack the sand
well into the flask.
Sand muller
A sand muller is a machine that mixes and restores the "ready-to-use" texture
of molding sand.
Sand separator
The machine is used to separate the sand blob into a fine grain sand.
Flask
Some flasks are used to form a mold and they are removed before pouring the
casting so another mold can be made. Other flasks are designed to contain the
mold through the pouring operation, and then the casting is shaken out of the
mold.
Figure 4.3.1: Sand Rammer Figure 4.3.2: Sand Muller

Figure 4.3.3: Sand separator Figure 4.3.4: Furnace