Dross is a mass of solid impurities floating on a molten metal.

It appears usually on the

melting of low melting point metals or alloys such as tin, lead, zinc or aluminium, or by
oxidation of the metal(s). It can also consist of impurities such as paint leftovers. It can
easily be skimmed off the surface before pouring the metal into a mold or casting flask.

Molding is the process of manufacturing by shaping pliable raw material using a rigid
frame or model called a mold.

A mold or mould is a hollowed-out block that is filled with a liquid like plastic, glass,
metal, or ceramic raw materials. The liquid hardens or sets inside the mold, adopting its
shape. A mold is the opposite of a cast (see casting). The manufacturer who makes the
molds is called moldmaker. A release agent is typically used to make removal of the
hardened/set substance from the mold easier.

Slag is the by-product of smelting ore to purify metals. They can be considered to be a
mixture of metal oxides; however, they can contain metal sulfides (see also matte) and
metal atoms in the elemental form. While slags are generally used as a waste removal
mechanism in metal smelting, they can also serve other purposes, such as assisting in
smelt temperature control and minimizing re-oxidation of the final liquid metal product
before casting.

Die casting is the process of forcing molten metal under high pressure into mold cavities
(which are machined into dies). Most die castings are made from nonferrous metals,
specifically zinc, copper, aluminum, magnesium, lead, and tin based alloys[1], but ferrous
metal die castings are possible.[2] The die casting method is especially suited for
applications where a large quantity of small to medium sized parts are needed with good
detail, a fine surface quality and dimensional consistency.[2]

Coal
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Coal

Example chemical structure of coal

Coal is a fossil fuel formed in ecosystems where plant remains were preserved by water
and mud from oxidization and biodegradation, thus sequestering atmospheric carbon.
Coal is a readily combustible black or brownish-black rock. It is a sedimentary rock, but
the harder forms, such as anthracite coal, can be regarded as metamorphic rocks because
of later exposure to elevated temperature and pressure. It is composed primarily of carbon
and hydrogen along with small quantities of other elements, notably sulfur. It is the
largest source of fuel for generation of electricity world-wide, as well as the largest
world-wide source of carbon dioxide emissions, which according to the IPCC, contribute
to climate change and global warming. In terms of carbon dioxide emissions, coal is
slightly ahead of petroleum and about double that of natural gas.[1] Coal is extracted from
the ground by coal mining, either underground mining or open pit mining (surface
mining).

Molding sand
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Molding sand, foundry sand, or green sand is sand that when moistened or oiled tends to
pack well and hold its shape. It is used in the process of sand casting.

[edit] Green sand

Green sand is an aggregate of sand, bentonite clay, pulverized coal and water. Its
principal use is in making molds for the casting of metals. The largest portion of the
aggregate is always sand, which can be either silica or olivine. There are many recipes for
the proportion of clay, but they all strike different balances between moldability, surface
finish, and ability of the hot molten metal to degas. The coal, typically referred to in
foundries as sea-coal, which is present at a ratio of less than 5%, partially combusts in the
presence of the molten metal leading to offgassing of organic vapors.

Sand casting is one of the earliest forms of casting practiced due to the simplicity of
materials involved. It still remains one of the cheapest ways to cast metals because of that
same simplicity. Other methods of casting, such as those using shell molds boast higher
quality of surface finish, but higher cost.

Green sand (and other casting sands) is usually housed in what casters refer to as flasks
which are nothing other than boxes without a bottom or lid. The box is split into two
halves which are stacked together in use. The halves are referred to as the top (cope) and
bottom (drag) flask respectively.

Green sand is not green in color, but "green" in the sense that it is used in a wet state.
According to the Cast Metals Federation website, an alternative casting method is to heat-
dry the molded sand before pouring the molten metal. This dry sand casting process
results in a more rigid mold better suited to heavier castings.

[edit] See also

• DISAMATIC
• Foundry
• Casting
• Sand casting
• Cope and drag
• Hand mould