Professional Documents
Culture Documents
The purpose of this manual is to introduce the basic concepts of the foundry applications and good practices in the foundry operation to achieve acceptable as-cast casting quality. Basic fundamental of foundry practices and examples are as follow:1. Pattern & Core boxes preparation. 2. Mold and core making practices. 3. Mold and Core wash coating application . 4. Mold assembly practices. 5. Melting and tapping practices. 6. Fettling practices.
Melting Practices
Core dressing
Chills method
Good practices
Pattern is regularly maintained and spry coated.
Bad practices
Pattern not maintained and strip coated leading to casting surface irregularly & dimension inaccuracy defects.
Good practices
Core box is regularly maintained and spray coated.
Bad practices
Core box not maintained and strip coated leading to casting surface irregularly & dimension inaccuracy defects.
Good practices
Down gates are secured and aligned with metal rod to prevent sagging.
Bad practices
Down gates are not properly aligned will cause interrupted metal flow leading to casting misruns, blow holes and inclusions defects.
Good practices
Locating pads are in used to prevent sand from entering, casting break-in.
Bad practices
No locating pads been used will results in casting sand inclusions and break-in defects.
Good practices
Loose piece is fixed with a puller plate to be attached by a traded stripping tool for removal of loose to prevent damaged.
Bad practices
Screw type stripping tools will damaged the loose piece.
Good practices
Down gate was taped to prevent movement during mold filling.
Bad practices
Down gates are not properly secured will result in misplacement during mold filling leading to casting misruns, blow holes and inclusions defects.
Good practices
Down sprue are secured with sprue guide to prevent movement during mold filling and misalignment with pouring basin sprue.
Bad practices
Down sprue is no secured which will cause misalignment with pouring basin sprue causing chocking during pouring leading to casting blow holes, slag inclusions, misruns & etc defects.
Hook guide.
Good practices Core hooks are properly position with hook guide to prevent movement during core making.
Bad practices No hook guide to position core hook will cause core off centering for handling and assembly results in casting defect caused by sand dropped.
Good practices
Text vents are extensively used and neatly laid through core prints.
Bad practices
Insufficient text vents for gas venting leading to casting blow holes defects.
Good practices
Hook and chain are used for better core handling.
Bad practices
Rope go through the core rib will damage core surface result in casting appearance imperfection & sand dropped defects.
Good practices
Core surface, corner and radius are well defined.
Bad practices
Core surface, corner and radius are not well defined result in casting appearance imperfection defects.
Good practices
Clean chaplet used
Bad practices
Rusty chaplet is not acceptable will cause blow holes in casting.
Good practices
Correct way of securing the chaplet with the plate bended.
Bad practices
Wrong way of chaplets placement as the plate is not bended will results in casting chaplet dropped defects.
Good practices
Always used single chaplet with the correct size.
Bad practices
Wrong way of chaplets placement. Different chaplets size used instead of single chaplet leading to casting chaplet dropped defects.
Good practices
Chaplets placed at the bottom are nailed.
Bad practices
Chaplets are not nailed and secured will results in casting chaplet dropped defects.
Good practices
Used furan sand for patching and torching.
Bad practices
Wrong way of repairing core by using mold wash material for repairing, with the risk that casting will contain blow holes defects.
Good practices
Broken core was glued and secured with nails.
Bad practices
Broken core was not properly secured and exposed core glue will results in casting sand dropped, bad appearance and blow holes defects.
Good practices
Always check core height using a straight rule.
Bad practices
Cores height are not checked will results in casting dimension deviations defects.
Good practices
Torching the core after mold washing to ensure it is thoroughly dried.
Bad practices
Core was not torched after recoating with mold wash still damped will lead to casting blow holes and inclusions defects.
Good practices Good compaction of sand at down gate areas to prevent loose sand.
Bad practices Poorly compact sand at down gate area causes loose sand results in casting sand dropped and metal penetration defects.
Core appearance.
Good practices
Ribs are well molded and defined.
Bad practices
Ribs are badly molded with core fins will results in casting appearance imperfection and fine crack lines defects.
Good practices
Cores are neatly arranged and displayed.
Bad practices
Poor placement of cores on base board with sand on it. Loose sand will stick to the core during mold washing will results in casting sand dropped defects.
Good practices
Applied sufficient amount core glue.
Bad practices
Excessive core glue been used and if its not completely dried, with the risk that casting will contain blow holes defects.
Good practices
Using a cast sand core about 5 7mm for chills placement so that the thickness is controlled.
Bad practices
Inconsistent of sand thickness for this type of indirect chills placement will results in casting microstructure problem and low hardness defects.
7mm
Good practices
The operator used cardboard to step while mold washing.
Bad practices
No cardboard been used as the shoes will damage the mold surface leading to bad casting appearance defects.
Good practices
Fine stones about 5 to 10mm in size used for filling the gas vent channels thus allowing core gases to disperse freely and speedily through the cope vent for better permeability.
Bad practices
Poor permeability due to gas vent channels are filled with fine sands which prevented the gases to disperse freely and speedily through the cope vent, with the risk that casting contain blow holes defects.
10mm
Good practices
Fine stones about 5 to 10mm in size used for filling the core gas vent thus allowing core gases to disperse freely and speedily through the cope vent for better permeability.
Bad practices
Poor permeability due to core gas vent routes are filled with fine sands which prevented the gases to disperse freely and speedily through the cope vent, with the risk that casting contain blow holes defects.
10mm
Good practices
Applied sufficient amount of core glue.
Bad practices
Excessive core glue been used and if its not completely dried, with the risk that casting will contain blow holes defects.
Good practices
No excessive glue was squeezed out from the core.
Bad practices
Excessive glue was squeezed out from core, with the risk that casting will contain blow holes defects.
Good practices
Downgates are checked by blowing with the compress air to ensure no blockage and loose sand in it.
Bad practices
Downgate not check with loose sand in it, with the risk that casting will contain sand inclusions, blow holes and cold shut defects.
Good practices
Core is properly support with fixture.
Bad practices
Wrong way of placement and supporting the core will results core sagging, with the risk that casting will contain dimension deviation defects.
Good practices
Ceramic fiber cloth is in used to seal undersize core print to prevent thick fins.
Bad practices
Gap at core print not properly sealed will results thick fins thus grinding will be difficult.
Good practices
Core are designed with prints so that cope rope can be easily laid and gas venting are properly been sealed between core and cope vents.
Bad practices
Core with no prints designed will have difficulty in laying cope rope and sealing of gas venting, with the risk that casting will contain blow holes and inclusions defects.
Chaplet appearances
-1
Good practices
Chaplet has been ground flat
Bad practices
Chaplets mark and nails have not been ground result in bad appearance on casting.
Remedies
Chaplet appearances
-2
Good practices
Nail on the chaplet has been ground.
Bad practices
Nail on the chaplet has not been removed. Bed appearance on casting
Remedies
Good practices
Good casting appearance, no veining defects.
Bad practices
Bad casting appearance, veining defect has not been removed.
Remedies
Check core ramming, coating drying and ensure pouring after 24hrs.
24
Good practices
Good casting appearance, core hole free from fins
Bad practices
Bad casting appearance, core hole fins has not been removed.
Remedies
Good practices
Good casting appearance, paint without sand defect.
Bad practices
Bad casting appearance, paint with sand defect. Due to sand not been removed before pray painting.
Remedies
Good practices
Good casting appearance, no core fins on the rib.
Bad practices
Bad casting appearance, rib with core fins not repair.
Remedies : Check core box condition and inspection casting before spray painting.