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Foseco Non-Ferrous
Foundryman\u2019s Handbook
Eleventh edition
Revised and edited by
John R. Brown
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
Preface
The last edition of theHandbook was published in 1994 and like all the earlier e
ditions, it aimed to provide a practical reference book for all those involved i
n making castings in any of the commonly used alloys by any of the usual mouldin
g methods. In order to keep theHandbook to a reasonable size, it was not possibl
e to deal with all the common casting alloys in detail. Since 1994 the technolog
y of casting has continued to develop and has become more specialised so that it
has been decided to publish the 11th edition of the
Handbookin three separate volumes:
Non-ferrous dealing with aluminium, copper and magnesium casting
alloys
Iron
dealing with grey, ductile and special purpose cast
irons
Steel
dealing with carbon, low alloy and high alloy steels
Certain chapters (with slight modifications) are common to all three volumes: th
ese chapters include tables and general data, sands and sand bonding systems, re
sin bonded sand, sodium silicate bonded sand and feeding systems. The remaining
chapters have been written specifically for each volume.
TheHandbook refers to many Foseco products. Not all of the products are availabl
e in every country and in a few cases, product names may vary. Users should alwa
ys contact their local Foseco company to check whether a particular product or i
ts equivalent is available.
The Foseco logo and all product names appearing in capital letters are
trademarks of the Foseco group of companies, used under licence.
John R. Brown
Preface
The last edition of theHandbook was published in 1994 and like all the earlier e
ditions, it aimed to provide a practical reference book for all those involved i
n making castings in any of the commonly used alloys by any of the usual mouldin
g methods. In order to keep theHandbook to a reasonable size, it was not possibl
e to deal with all the common casting alloys in detail. Since 1994 the technolog

y of casting has continued to develop and has become more specialised so that it
has been decided to publish the 11th edition of the
Handbookin three separate volumes:
Non-ferrous dealing with aluminium, copper and magnesium casting
alloys
Iron
dealing with grey, ductile and special purpose cast
irons
Steel
dealing with carbon, low alloy and high alloy steels
Certain chapters (with slight modifications) are common to all three volumes: th
ese chapters include tables and general data, sands and sand bonding systems, re
sin bonded sand, sodium silicate bonded sand and feeding systems. The remaining
chapters have been written specifically for each volume.
TheHandbook refers to many Foseco products. Not all of the products are availabl
e in every country and in a few cases, product names may vary. Users should alwa
ys contact their local Foseco company to check whether a particular product or i
ts equivalent is available.
The Foseco logo and all product names appearing in capital letters are
trademarks of the Foseco group of companies, used under licence.
John R. Brown
Preface
.......................
Acknowledgements
............................................
1 Tables and general data
1
.........................................
SI units and their relation to other units
1
...................................
SI, metric, non-SI and non-metric conversions
2
........................
Conversion table of stress values
5
............................................
Areas and volumes of circles, spheres, cylinders etc.
6
.............
The physical properties of metals
7
............................................
The physical properties of metals (Continued)
8
........................
Densities of casting alloys
9
.......................................................
Approximate bulk densities of common materials
10
...................
Patternmakers contraction allowances
11
...................................
Volume shrinkage of principal casting alloys
13
...........................

Comparison of sieve sizes

14
.......................................................
Calculation of average grain size
15
............................................
Calculation of AFS grain fineness number
16
..............................
Recommended standard colours for patterns
17
.........................
Dust control in foundries
18
..........................................................
Buoyancy forces on cores
18
.......................................................
Core print support
19
....................................................................
Opening forces on moulds
19
.......................................................
Dimensional tolerances and consistency achieved in
castings
21
................................................................................
...
2 Aluminium casting alloys
......................................
Introduction
.......................................
Casting alloys
25
..........................................................................
Casting processes
39
...................................................................
The effect of alloying elements
39
................................................
Heat treatment of aluminium alloys
42
.........................................
3 Melting aluminium alloys
.......................................
Introduction
.......................................
Raw materials
47
..........................................................................
Melting furnaces
47
......................................................................
Corundum growth
54
....................................................................
Choice of melting unit
55

..............................................................
Preface
.......................
Acknowledgements
............................................
1 Tables and general data
1
.........................................
SI units and their relation to other units
1
...................................
SI, metric, non-SI and non-metric conversions
2
........................
Conversion table of stress values
5
............................................
Areas and volumes of circles, spheres, cylinders etc.
6
.............
The physical properties of metals
7
............................................
The physical properties of metals (Continued)
8
........................
Densities of casting alloys
9
.......................................................
Approximate bulk densities of common materials
10
...................
Patternmakers contraction allowances
11
...................................
Volume shrinkage of principal casting alloys
13
...........................
Comparison of sieve sizes
14
.......................................................
Calculation of average grain size
15
............................................
Calculation of AFS grain fineness number
16
..............................
Recommended standard colours for patterns
17
.........................
Dust control in foundries
18
..........................................................
Buoyancy forces on cores
18
.......................................................
Core print support
19
....................................................................
Opening forces on moulds

19
.......................................................
Dimensional tolerances and consistency achieved in
castings
21
................................................................................
...
2 Aluminium casting alloys
......................................
Introduction
.......................................
Casting alloys
25
..........................................................................
Casting processes
39
...................................................................
The effect of alloying elements
39
................................................
Heat treatment of aluminium alloys
42
.........................................
3 Melting aluminium alloys
.......................................
Introduction
.......................................
Raw materials
47
..........................................................................
Melting furnaces
47
......................................................................
Corundum growth
54
....................................................................
Choice of melting unit
55
..............................................................
4 Fluxes
.........................
Application of COVERAL powder fluxes
..................................
Granular COVERAL fluxes
61
......................................................
5 INSURAL refractory for ladles and metal
transport
..........................
Ladle liners
65
..............................................................................
6 Treatment of aluminium alloy melts
.....................
Hydrogen gas pick-up in aluminium melts
...............................
Degassing aluminium alloys
72
....................................................
Grain refinement of aluminium alloys

77
......................................
Modification of aluminium alloys
79
..............................................
Sodium modification
81
................................................................
Strontium modification
82
.............................................................
Permanent modification
83
...........................................................
Sand, gravity die and low pressure diecasting
83
........................
Medium silicon alloys, 4 7% Si
84
................................................
Eutectic silicon alloys, 12% Si
84
.................................................
Treatment of hypereutectic Al Si alloys (over 16% Si)
85
...........
Melting and treatment of aluminium magnesium alloys (
4 10% Mg)
86
..............................................................................
Special requirements for gravity diecasting
87
.............................
Treatment of alloys for pressure diecasting
87
.............................
7 Running, gating and feeding aluminium
castings
75
......................................................................
Gating without filters
90
................................................................
Gating with filters
93
.....................................................................
Feeding mechanisms in Al alloy and other non- ferrous
castings
94
................................................................................
...
Simulation modelling
98
...............................................................
8 Filtration of aluminium alloy castings
..................
SIVEX FC filters
100
.......................................................................
Use of filters in conventional running systems

101
........................
Direct pouring of aluminium alloy castings
104
..............................
KALPUR combined sleeve and SIVEX FC filter for
aluminium castings
105
..................................................................
Direct pouring into metal dies
107
..................................................
4 Fluxes
.........................
Application of COVERAL powder fluxes
..................................
Granular COVERAL fluxes
61
......................................................
5 INSURAL refractory for ladles and metal
transport
..........................
Ladle liners
65
..............................................................................
6 Treatment of aluminium alloy melts
.....................
Hydrogen gas pick-up in aluminium melts
...............................
Degassing aluminium alloys
72
....................................................
Grain refinement of aluminium alloys
77
......................................
Modification of aluminium alloys
79
..............................................
Sodium modification
81
................................................................
Strontium modification
82
.............................................................
Permanent modification
83
...........................................................
Sand, gravity die and low pressure diecasting
83
........................
Medium silicon alloys, 4 7% Si
84
................................................
Eutectic silicon alloys, 12% Si
84
.................................................
Treatment of hypereutectic Al Si alloys (over 16% Si)
85
...........
Melting and treatment of aluminium magnesium alloys (

4 10% Mg)
86
..............................................................................
Special requirements for gravity diecasting
87
.............................
Treatment of alloys for pressure diecasting
87
.............................
7 Running, gating and feeding aluminium
castings
75
......................................................................
Gating without filters
90
................................................................
Gating with filters
93
.....................................................................
Feeding mechanisms in Al alloy and other non- ferrous
castings
94
................................................................................
...
Simulation modelling
98
...............................................................
8 Filtration of aluminium alloy castings
..................
SIVEX FC filters
100
.......................................................................
Use of filters in conventional running systems
101
........................
Direct pouring of aluminium alloy castings
104
..............................
KALPUR combined sleeve and SIVEX FC filter for
aluminium castings
105
..................................................................
Direct pouring into metal dies
107
..................................................
9 Pressure diecasting of aluminium alloys
.............
Die design
.....................................Process control
111
........................................................................
Modification of the diecasting process
113
.....................................
Applications of diecastings
114
......................................................
The diecasting foundry
114
............................................................

Die coating
116
...............................................................................
10 Low pressure and gravity diecasting
.................
Low pressure diecasting
..........................................................
Gravity diecasting
124
....................................................................
Die coatings for gravity and low pressure diecasting
127
..............
11 Sand casting processes
.......................................
Green sand
136
..............................................................................
Moulding machines
137
..................................................................
Core assembly sand processes
140
..............................................
The Lost Foam process
144
...........................................................
12 Sands and sand bonding systems
......................
Properties of silica sand for foundry use
.................................
Typical silica foundry sand properties
151
.....................................
Safe handling of silica sand
152
.....................................................
Segregation of sand
153
................................................................
Measurement of sand properties
153
.............................................
Thermal characteristics of silica sand
153
......................................
Zircon, ZrSiO4
154
.........................................................................
Chromite, FeCr2O4
156
.................................................................
Olivine, Mg2SiO4
156
.....................................................................
Green sand additives
157
...............................................................
The green sand system
160

...........................................................
Green sand properties
163
.............................................................
Control of green sand systems
164
................................................
Sand testing
165
.............................................................................
Control graphs
165
.........................................................................
Parting agents
166
.........................................................................
Special moulding materials, LUTRON
166
.....................................
13 Resin bonded sand
...............................................
9 Pressure diecasting of aluminium alloys
.............
Die design
.....................................Process control
111
........................................................................
Modification of the diecasting process
113
.....................................
Applications of diecastings
114
......................................................
The diecasting foundry
114
............................................................
Die coating
116
...............................................................................
10 Low pressure and gravity diecasting
.................
Low pressure diecasting
..........................................................
Gravity diecasting
124
....................................................................
Die coatings for gravity and low pressure diecasting
127
..............
11 Sand casting processes
.......................................
Green sand
136
..............................................................................
Moulding machines
137
..................................................................
Core assembly sand processes
140
..............................................

The Lost Foam process

144
...........................................................
12 Sands and sand bonding systems
......................
Properties of silica sand for foundry use
.................................
Typical silica foundry sand properties
151
.....................................
Safe handling of silica sand
152
.....................................................
Segregation of sand
153
................................................................
Measurement of sand properties
153
.............................................
Thermal characteristics of silica sand
153
......................................
Zircon, ZrSiO4
154
.........................................................................
Chromite, FeCr2O4
156
.................................................................
Olivine, Mg2SiO4
156
.....................................................................
Green sand additives
157
...............................................................
The green sand system
160
...........................................................
Green sand properties
163
.............................................................
Control of green sand systems
164
................................................
Sand testing
165
.............................................................................
Control graphs
165
.........................................................................
Parting agents
166
.........................................................................
Special moulding materials, LUTRON
166
.....................................
13 Resin bonded sand
...............................................
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BROWN, J. R. (1999). Foseco Non-Ferrous Foundryman's Handbook (11th ed.)
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416 p.
CHILDS, T. (2000). Metal Machining - Theory and Applications
371 p.
BROWN, J. R. (2000). Foseco Ferrous Foundryman's Handbook
309 p.
BROWN, J. R. (1999). Foseco Non-Ferrous Foundryman's Handbook (11th...
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