Modernization and

Mechanization of foundries
 Need for modernisation and mechanisation

• To change picture of foundry from dark, dirty place

dotted with mounds of sand, coal, ashes and metal.
Atmosphere filled with smoke ; and enclosure where workers
breath noxious fumes.
• To improve working conditions in the shop ensuring a
safe healthy and happy life for worker
• To meet the ever changing needs of customers.
• To reduce production cost and material handling
cost.
• The efficiency of a manufacturing system is dependent upon
the ability to move the parts/materials effectively, timely and
rapidly.
Note: For small orders as well as production of large sized
castings, mechanisation is uneconomical and unpractical. On
other hand complete mechanisation is profitable for mass
production. Eg. Automobile parts, electric motors, sewing
machine.
 Advantages
• Increased production from a given floor area and higher
productivity.
• Higher degree of accuracy, closer tolerances and better
surface finish.
• Minimum casting defects.
• Reduced number of labours. Elimination of time consuming
manual operations such as mixing and preparing sands,
preparing moulds and handling various foundry materials.
• Better working conditions and improved job satisfaction.
• Reduced cost of production and higher profits.
 Disadvantages

• It is not adaptable for small jobbing foundries.

• Rise to unemployment.
• Gradual disappearance of skillful art of hand moulding.
 Handling of Sand
• About 4-5 tonnes of sand is prepared and handled per tonne
of metal poured in typical ferrous foundries.
• Sand greatly influences the quality of castings
 TYPES OF CONVEYORS
1) HANDLING SAND
• Belt Conveyor: It consists of
Endless belt (made of cotton plys made of
rubber),
Two pulleys,
Rollers or idlers for carrying loaded belt
Belt tightening mechanisms
Belt cleaners
• Bucket Elevator
It consists of two pulleys (one at top and other at bottom)
which carry an endless belt having number of buckets arround.
• Apron Conveyor
Consists of overlapping steel plates hinged at the ends and when
assembles it works as a belt.
Advantage: it transports material which are too hot for belt
conveyor.
Disadvantage: lower speed of movement, spillage and leakage
of the sand through the plates, Higher initial as well
maintenance cost
• Flight Conveyor: It consists of two endless chains moving on
sprockets fixed at both ends and carry steel plates (known as
flights) at certain intervals.

This type of conveyor is usually employed for distributing

sand to workstations from an overhead through.
• Oscillating Conveyor :

– This is made of two steel plates which are fastened

together and secured by two beams.

– The oscillating action is produced by means of an

eccentric.

– This type of conveyor may be used for transporting hot

sand and castings.
• Monorail Conveyor:

It consist of buckets or containers of the drop bottom

type which are run on an overhead monorail.
It is used for carrying sand and other materials.

• Crane:
The sand is filled in bottom discharge type bucket which
is transferred with the help of crane.
 2) Handling mould

Storage
Mould
(Stationary for Shakeout
Production pouring or pored Section
section in motion)

Empty flasks,
moulding
boards

In mechanized foundries all these transportation

conducted on conveyor system
• Roller conveyor:

It has two beams fixed on trestles of suitable height and

supporting latterly arranged rollers above.

It may be either of the gravity or power driven type

Gravity type: There is no power supply. Mould needs to be

pushed by workers. The beams may be fixed at slight inclination
to facilitate the mould movement by gravity.

Power driven: Variable speed electric motor is used for motion

of rollers. These are expensive. Worthwhile only in mass
production system.
• Pallet or car type conveyor:

It has pallets made of cast iron or steel plates mounted on

wheels which can roll along narrow gauge track.

The moulds are placed on the pallet and pushed manually. In

case of continuous drives, however pallets may be connected by
chainand driven from one end by power.
Overhead conveyor
Sometimes an overhead conveyor of monorail type is employed
for transporting moulds.

The completed moulds are placed on the platform of conveyor

and platform is carried to pouring area by overhead monorail.

After the casting has solidified the same carrier is moved to

shakeout section.
 Handling molten metal
Two systems are commonly followed

1) Where continuous conveyor is not used, the moulds after

completion are carried on roller conveyor to the storage area.
The molten metal is transferred in laddles to this area with the
help of travelling crane or hoist is poured into the stored
moulds.

2) Where moulds are constantly moving, the metal is brought on

monorail conveyor and poured into the moving moulds.
 Handling of casting

Shakeout
Station Inspection
Clearing and
(Removal of Section
Fettling Section
Casting from
mould)
 Types of conveyor used
• Plate band conveyor
• Roller type conveyor
• Oscillating conveyor
• Overhead conveyor
 Sand Reclamation
• Reclamation- Treatment of ‘used’ moulding sand to regain its
original condition to use it again and again with minimum
addition of new sand.

• Sand associated with new sand, its transportation makes the

reclamation economical. Also, it is environment friendly.

• Reclamation process consist of

– Crushing of sand lumps
– Removal of bond from grain surface
The type of facilities or equipment required may depend on

1. Quality of sand to be handled.

2. Kind of binder and its quality eg. Synthetic, organic,
inorganic, cement etc.
3. Extent of mechanization used in foundry.
4. Overall economics of sand recycling.
 Sand Preparation Equipment
1) Magnetic Separator

• The moulding sand coming from shake out station must be freed of
iron particles and foreign matter before being put to reuse.
• The magnetic separator consists of magnetized pulley over which flat
rubber or canvas belt rolls.
• As the belt rolls over pulley, the sand and non magnetic particles falls
freely .
• The ferrous objects on other hand tend to cling the belt due to
magnetization effect and drop off only when the belt has left the
pulley.
• The pulley may be permanent magnet type or electromagnet type
carrying DC magnetizing coils.
2) Riddle-
• After separation of iron pieces, the sand usually passed
through screen or riddle.
• Pieces of dry sand cores, hard lumps of sand are eliminated
• Mechanical riddles can screen much faster than hand riddles.
• There are two types of riddles available
– Operated by compressed air
– Operated by electric motors
3) Muller-
• The function of muller is to condition the moulding sand for
reuse.
• Mulling is process of distributing the ingredients into
homogeneous mixture.
4) Aerator:

• After the sand is conditioned in muller, it is sent to an aerator

where sand grains are separated and each grain is made to
flow freely and smoothly.
• The capacity of moulding sand to flow freely around the
pattern and get packed is termed as flowability.
• Mechanical aerating accomplished by an impeller or rotating
paddles whirling the sand at high speed towards the inner
wall of casting. The rotating paddle consists of set of rods
each having number of combing fingers arranged radially.
 Moulding Processes
According to method of preparation

• The processes conducted with hand tools known as Hand

Moulding.

• The processes conducted with machine known as Machine

Moulding

• Moulding done on foundry floor known as Floor moulding

• Moulding done on working bench known as Bench moulding.

 Floor moulding
• Open sand moulding: The mould cavity is prepared
on the floor and molten metal directly poured in the
cavity.
• These type of casting do not require good surface
finish on the upper face and are unsophisticated
Eg. Weights, manhole covers, drain covers.
• One box moulding: In this one part of the flask is
placed atop the floor mould. The flask acts as a cope
and carries sprue and risers
 Bench Moulding
It is preferred for small sized castings
Two box casting:
• It makes use of pair of moulding boxes, upper part being
called cope and lower part is drag.
• The two parts are fitted with suitable clamping and
locating arrangement.
• The clamping required to prevent the cope from lifting
due to the pressure of molten metal.
• The locating device is essential for the two parts to
maintain proper alignment all the times.
Three box moulding
• Sometimes it is difficult to prepare mould with two boxes ,
then the mould can be made in three boxes.

• The additional box in the middle is called “cheek”.

• During pouring all three boxes are clamped.

 Moulding with False Cheek
• If the three piece set of boxes is not available or is not
convenient to use, the mould may be prepared in two parts
with green sand core, often referred to as “false cheek”.
 Stake Moulding

• It is used when large number of small size components is to

be cast.
• A common passage of molten metal runs through the stakes
of intermediate boxes.
 Odd side moulding
• In case where the solid pattern does not have a flat face to
rest on the moulding board, an odd side is first prepared by
moulding in one of the moulding boxes.
• The sand is pressed hard arround the pattern by hand and is
rammed.
 Machine Moulding
Mould is made with the aid of some moulding machine.
Advantages
• It affords great saving time, especially when a large number of
similar castings in small size are required.
• When number of castings are substantial, the additional cost
of metallic patterns and other equipment are compensated by
the high rate of production.
• The casting obtained are more uniform in size and shape also
more accurate than hand moulding.
• Semi skilled worker can do the machine job.
 Hand operated moulding machines
• One or more operation such as ramming, pattern
drawing are performed by machine which is
manually operated either by a hand lever or pedal
control.
• Depending on the type of operation performed,
hand moulding machines may be of pattern draw
type or pattern draw and squeeze type.
 Power operated moulding machine
• The power operated moulding machines makes use of
hydraulic or pneumatic action to perform various operations
during moulding processes.
• Three principle methods are employed to for ramming the
sand.
– Squeezing
– Jolting
– Slinging
 Squeezing
• The flask is filled with the moulding sand and sand is squeezed
against a pressure board pneumatically or hydraulically until
mould attains desired density.

• Limitation: the sand is packed more densely at the top and

density decreases uniformly with the depth.

• The squeeze method is therefore restricted to moulds not

more than 150mm in depth.
 Jolting
• The flask is first filled with the sand and then the table
supporting the flask is mechanically raised and dropped in
succession.
• Due to sudden change in inertia at the end of each fall the
sand gets packed and rammed.
• The density and hardness of mould can be controlled by
varying the height of stroke, the amount of sand heaped
above the mould and number of strokes.
• The drawback is sand remains less dense at the top layers of
the mould.
• It is generally actuated by pneumatic principles (Compressed
air)
 Jolt and Squeeze
• In order to overcome the drawbacks of both the squeeze and
jolt principles of ramming and to achieve uniform density and
hardness in all portions of the mould.
• The machine that brings about this combined action are
referred to as jolt squeeze moulding machine
 Slinging
• The consolidation and ramming of sand is achieved by means
of impact with the pattern.
• Sand slingers are equipped for throwing a stream of sand
downwards through a slinging head, onto the pattern at high
velocity.
• Due to rapid ejection sand particles settle down instantly and
get rammed.
• The design of sand slinger incorporates a high speed rotary
impeller, pipes, band conveyor, injecting head etc.
• The ejecting head can be moved anywhere in the mould to
attain uniform density in the mould.
 High pressure moulding
• This is used for production of green sand mould. Then force of
compaction required much higher (5-10 times) than
conventional moulding machine.
• The squeeze force applied hydraulically as this enables high
production rate and noise less operation.
• The range of pressure used in conventional jolt squeeze
machine is from 1.5 Kg/cm2 to 5 kg/cm2 . In high pressure
moulding however pressure vary from 7 Kg/cm2 to 28 Kg/cm2
and may be as high as 40 Kg/cm2.
 Core sands and core making
Core is the portion of mould which forms the hollow interior of the casting or
a hole through the casting.

Characteristics of cores and core sands

• Cores should have sufficient hardness as well as strength to support its
own weight and withstand the force of molten metal.
• Core should be able to withstand high temperatures of molten metal.
• Core should produce minimum amount of gas when in contact with
molten metal.
• when casting is prepared the core should be collapsible i.e. they should
disintegrate and collapse after the metal solidifies.
 Types of Cores
• The cores used in foundries are named according to their shape and
position in the mould.

When casting is to have opening only at one side, and only one core print is
available on the pattern, a balanced core is suitable.
• The core prints in such cases should be sufficiently large to
support the weight of core which extends in mould cavity, and
it should be able to withstand force of buoyancy of molten
metal surrounded by it.
• To support the core in mould cavity, chaplets are often
inserted.
 B) Cover Core

When entire pattern is rammed in the drag and the core is

required to be suspended from the top of mould a “cover core”
may be employed.
 c) Hanging Core

• If the core hangs from the cope and does not have any
support at the bottom in drag, it is referred to as
hanging core.
• In this case it is necessary to fasten the core with the
wire or rod, which extends through the cope to a
fastening top side of the cope.
 d) Wing core

• Wing core may be used when a hole or recess is to be obtained in the casting
either above or below the parting line.

• This type of core is necessitated when it is not possible to place the pattern in
the mould such that the recess can be cored directly.
 E) Ram up core

Sometimes, the core is set with the pattern in the mould before the mould is rammed.
Such a core is called “ram up core”.
 F) Kiss Core

• When the pattern is not provided with core prints and no seat
is available as a rest of the core , the core is held in position
between the cope and drag simply by the pressure of the cope.
Such core are termed “Kiss core”.
• They are excellent when number of holes required are required
in casting and where dimensional accuracy with regard to the
relative location of holes is not important.
Rapid Prototyping and Tooling
Laminated Object Manufacturing (LOM)
• Solid physical model made by stacking layers of sheet
stock, each an outline of the cross-sectional shape of
a CAD model that is sliced into layers Starting sheet
stock includes paper, plastic, cellulose, metals, or
fiber-reinforced materials

• The sheet is usually supplied with adhesive backing

as rolls that are spooled between two reels.

• After cutting, excess material in the layer remains in

place to support the part during building
 Advantages
• Ability to produce larger-scaled models
• Uses very inexpensive paper
• Fast and accurate
• Good handling strength
• Environmentally friendly
 Disadvantages

• Need for decubing, which requires a lot of

labor
• Finish and stability of paper objects
• Not as good as materials used with other RP
methods
 Typical Uses

• Investment casting patterns

• Concept verification
• Fit-check
• Direct use
 Fused Deposition Modeling
• FDM works on an "additive"
principle by laying down material
in layers; a plastic filament or
metal wire is unwound from a coil
and supplies material to produce
a part.
• FDM uses a heating chamber to liquefy polymer that is fed
into the system as a filament.
• The filament is pushed into the chamber by a tractor wheel
arrangement and it is this pushing that generates the
extrusion pressure.
• The major strength of FDM is in the range of materials and the
effective mechanical properties of resulting parts made using
this technology.
• Parts made using FDM are amongst the strongest for any
polymerbased additive manufacturing process.
Process
• FDM begins with a software process which processes an STL file
(stereolithography file format), mathematically slicing and orienting
the model for the build process.
• If required, support structures may be generated.
• A plastic filament or metal wire is unwound from a coil and supplies
material to an extrusion nozzle which can turn the flow on and off.
There is a drive that pushes the filament into the nozzle at a
controlled rate.
• The nozzle is heated to melt the material.
• The nozzle can be moved in both horizontal and vertical directions
by a numerically controlled mechanism. The nozzle follows a tool-
path controlled by a computer-aided manufacturing (CAM)
software package, and the part is built from the bottom up, one
layer at a time. Stepper motors or servo motors are typically
employed to move the extrusion head.
 Materials
• The most popular material is the ABSplus
material, which can be used on all current FDM
machines.
• Some machines also have an option for ABS
blended with Polycarbonate.
 Limitations of FDM
• Sharp features or corners not possible to get;
Part strength is weak perpendicular to build
axis;
• More area in slices requires longer build
times;
• Temperature fluctuations during production
could lead to delamination.
 Stereolithography
• Stereolithography is a form of 3-D printing technology used for
creating models, prototypes, patterns, and production parts in a layer
by layer fashion using photopolymerization, a process by which light
causes chains of molecules to link, forming polymers.
• Stereolithography is an additive manufacturing process that works by
focusing an ultraviolet (UV) laser on to a vat of photopolymer resin.
• Photopolymers are photosensitive under ultraviolet light, the resin is
solidified and forms a single layer of the desired 3D object.
• An elevator platform descends a distance equal to the thickness of a single
layer of the design (typically 0.05 mm to 0.15 mm) into the photopolymer
vat.
• The subsequent layer is traced, joining the previous layer. A complete 3D
object can be formed using this process. Designs are then immersed in a
chemical bath in order to remove any excess resin.
• Stereolithography requires the use of supporting structures which attach to
the elevator platform to prevent deflection due to gravity and to hold cross
sections in place in order to newly created sections during the "vat rocking"
of bottom-up printing. Supports are created automatically during the
preparation of 3D Computer Aided Design models and can also be made
manually.
• The length of time it takes to produce a single part depends upon the
design and the size. Printing time can last anywhere from hours to
more than a day.
• Many 3D printers can produce parts with a maximum size of
approximately 50×50×60 cm (20×20×24 in) and some printers, such
as the Mammoth stereolithography machine (which has a build
platform of 210×70×80 cm), are capable of producing single parts
more than 2 meters in length.
• 3D printed prototypes and designs are strong enough to
be machined and can also be used to make master patterns
for injection molding, thermoforming, blow molding, and various metal
casting processes.
• Although stereolithography can be used to produce virtually any
synthetic design, it is often costly; common photopolymers can cost
about $800 per gallon.
 SLS - Selective Laser Sintering

• File type ‘.stl’ used

• Finished sample cools for 12-24 hrs then pulled out of Powder
• Powder
– Nylon-11
• For High Strength and Elasticity
– Nylon-12
• Finer Surface Quality but lower elasticity
– Elastomer
• Simulate Rubber-Like Products
• The powder is metered in precise amounts and is
spread by a counter rotating roller on table.
• High power laser beam selectively melts and fuses
powdered material spread on a layer.
• The table is lowered through a distance
corresponding to the layer thickness before the
roller spreads the next layer of powder on the
previously build layer.
• The unsintered powder serves as support for
overhanging portions, if any in the subsequent
layers.
 Direct metal laser sintering
• The DMLS process involves use of a 3D CAD model and
converted into .stl format.
• Once this "build file" has been completed, it is "sliced" into
the layer thickness the machine will build in and
downloaded to the DMLS machine allowing the build to
begin.
• The technology fuses metal powder into a solid part by
melting it locally using the focused laser beam
• Parts are built up additively layer by layer, typically using
layers 20 micrometers thick.
Advantages

• This process allows for highly complex geometries to be

created directly from the 3D CAD data, fully automatically,
in a relatively short time and without any tooling.
• It produces parts with high accuracy and detail resolution,
good surface quality and better mechanical properties.
• It allows to make alloys.

Limitations
• Wastage of powder.
 Advantages of additive manufacturing
• Complexity is free: It actually costs less to print a complex part
instead of a simple cube of the same size. The more complex (or,
the less solid the object is), the faster and cheaper it can be
made through additive manufacturing.

• Variety is free: If a part needs to be changed, the change can

simply be made on the original CAD file, and the new product
can be printed right away.

• No assembly required: Moving parts such as hinges and bicycle

chains can be printed in metal directly into the product, which
can significantly reduce the part numbers.

• Little lead time: Engineers can create a prototype with a 3-D

printer immediately after finishing the part’s stereo lithography
(STL) file. As soon as the part has printed, engineers may then
begin testing its properties instead of waiting weeks or months
for a prototype or part to come in.
• Little-skill manufacturing: While complicated parts with
specific parameters and high-tech applications ought to be left
to the professionals, even children in elementary school have
created their own figures using 3-D printing processes.

• Few constraints: Anything you can dream up and design in the

CAD software, you can create with additive manufacturing.

• Less waste: Because only the material that is needed is used,

there is very little (if any) material wasted.

• Infinite shades of materials: Engineers can program parts to

have specific colors in their CAD files, and printers can use
materials of any color to print them.
 Disadvantages of additive
manufacturing
• Slow build rates: Many printers lay down material at a
speed of one to five cubic inches per hour. Depending on
the part needed, other manufacturing processes may be
significantly faster.
• High production costs: Sometimes, parts can be made
faster using techniques other than additive manufacturing,
so the extra time can lead to higher costs. Additionally,
high-quality additive manufacturing machines can cost
anywhere from $300,000 to $1.5 million, and materials can
cost $100 to $150 per pound.
• Considerable effort in application design and setting
process parameters: Extensive knowledge of material
design and the additive manufacturing machine itself is
required to make quality parts.
• Requires post-processing: The surface finish and
dimensional accuracy may be lower quality than other
manufacturing methods.

• Discontinuous production process: Parts can only be

printed one at a time, preventing economics of scale.

• Limited component size/small build volume: In most

cases, polymer products are about 1 cubic yard in size,
while metal parts may only be one cubic foot. While larger
machines are available, they will come at a cost.

• Poor mechanical properties: Layering and multiple

interfaces can cause defects in the product.
 Fettling and Repair of Casting
1) Shaking of Moulds
• Casting is knocked out by breaking the mould after metal
has solidified.

• It is essential to ensure that the castings are removed from

the mould as early as possible for economical reasons.

• Premature withdrawal may give rise to distortion, cracks

and chilling effect and cause rejection.

• Therefore it is advisable to establish temperatures at which

casting of each type, alloy composition and complexity are
to be withdrawn from moulds and sent for shakeout.
Suggested temperatures at which steel castings can be
withdrawn from moulds are shown below.

i. Simple castings of uncritical nature and uniform sections:

900°C.
ii. Parts with uneven wall thickness; cast with chills: 600°C.
iii. Casting with critical shapes, prone to warping or cold
cracking; subjected to variable impact loads: 300°C.
iv. Thin walled castings having abrupt changes in sections:
100°C
• Moulds may either be broken manually on pouring floor
itself or transferred to a separate shakeout station.

• In case of separate shake out station, mould is dumped on

the shakeout where it is rapidly shaken out so that sand
falls through the grate or screen. Mechanical shakeouts
used for large scale work.

• Mechanical units consists of a perforated plate or heavy

meshed screen fixed to vibrating frame.
 2. Cleaning of Casting
The operation of cutting off the unwanted parts, and cleaning
and finishing the casting known as fettling.

Fettling operation may be divided into different stages

1. Knocking out of dry sand cores.
2. Removal of gates and risers.
3. Removal of fins and unwanted projections.
4. Cleaning and smoothening of the surface.
5. Repairing the castings.
 Knocking out of dry sand cores
• Dry cores may be removed by knocking or rapping with an
iron bar.
• For quick knocking hydraulic or pneumatic devices may be
employed.
 Removal of gates and risers
The choice of method for removing gates and risers from
casting depends on the size and the shape of casting and the
type of metal. The options for such work are:
• Knocking off or braking with hammer, which is particularly
suited in case of gray iron castings and other brittle metals.
• Sawing with a metal cutting saw, which may be a band saw,
a circular saw or power hacksaw (for steel malleable iron
and non ferrous castings)
• Flame cutting with oxyacetylene gas is generally adopted
for ferrous metals. Specially for large sized castings where
the risers and gates are very heavy.
• Employing abrasive cut off machines, which can work with
all metals but are specially designed for hard metals, which
are difficult to saw or shear.

• Plasma arc cutting is now being increasingly used to cut

sprue and risers of plate shaped castings with a view to
eliminate the manual operation of burning off and to make
work fast, clean and accurate, by using the programmable
robot for holding and manipulating the casting.
 Removal of fins and unwanted projections.
Operation of removing unwanted metal fins, projections etc.
from the surface of the casting is called snagging.

Methods of snagging include:

i. Using grinders of pedestal, bench, flexible shaft or swing

frame type.

ii. Chipping with hands or pneumatic tools.

iii. Flame cutting

iv. Removing metal by arc air equipment.

v. Filing
 Cleaning and Smoothening of the Surface
Castings often have sand particles adhering to their
surface in fused form also scale will form on the surface. In
order that casting surface be clean and smooth, the adhering
sand particles has to be removed. The various methods are

i. Tumbling
ii. Tumbling with hydroblast
iii. Cleaning with compressed air impact (Sand blasting)
iv. Cleaning with mechanical impact (Shot blasting)
v. Arc air process
vi. Pickling
I. Tumbling:

The castings to be cleaned are put in large steel shell or

barrel. Barrel is supported on horizontal trunnions and is
rotated at a speed varying from 25-50rpm.

Along with castings, small pieces of white iron called “stars”

are also charged.

When barrel is rotated it causes rubbing and peening action

against each other, Thus not only the casting gets cleaned and
polished but also the sharp edges and fins get eliminated.
 Repairing the Castings
Sometimes the castings get broken, bent or deformed during
shakeout or because of rough handling. They are repaired by
suitable means and put to use due to economical reasons unless
the defects are such that they can not be remedied.

The methods of repair are as follows:

• Metal Arc Welding:
A.C. metal arc welding is often selected for welding steel
castings.
D.C. welding is preferred for welding cast irons and non ferrous
metals.
• Oxyacetylene (02-C2H2) Gas Welding
It is least expensive method and easily portable. It is suitable where
sections to be welded are not too heavy.

The flame temperatures are lower than that of the arc, so cooling
rates are slow. Hence process is preferable where slow cooling
rates are required.

Oxidizing flames is used for brasses and bronzes.

Reducing or carburizing flame for high carbon and alloy steel,
nickel alloys and other hard facing materials.
Neutral flame for low carbon steels.

LPG or natural gas can be used in place of acetylene where broad

flame is desired.
• Carbon Arc Welding
Electrode is made of carbon which is non consumable, a
separate filler rod is fed into the arc to acquire deposition.
This is suited for welding copper base and aluminum alloys.

• Inert Gas Tungsten Arc Welding

The process uses non consumable type tungsten electrode.
Shielding provided by inert gas, such as helium. And argon
for protection of the welding zone.
It is most suitable for metals that tends to get quickly
oxidized, eg. Magnesium and magnesium alloys
• Inert Gas Metal Arc Welding
Consumable type electrode is used in this process. Electrode
wire is automatically fed and inert gas protects the metal
from oxidation. The gases used are argon nitrogen etc. It is
suitable for large sized steel castings and is economical where
high speed operation is required.
• Submerged Arc Welding
Arc produced between tip of tool and workpiece is completely
submerged inside the flux powder therefore it is called
submerged arc welding.
Some amount of flux is melting and forming a slag and
remaining slag can be reused.
• Thermit welding
The thermit mixture is filled into joint & thin layer of igniting
powder is also filled on the top. Ignition will be given
externally

Exothermic
𝐹𝑒3 𝑂4 + 𝐴𝑙 Fe + 𝐴𝑙2 𝑂3 +Heat
Reaction

Thermit
Powder
Iron : used as Filler rod material
𝑨𝒍𝟐 𝑶𝟑 : Used as slag for protecting weld bead from atmospheric
contamination.
Heat : Used for melting of parent material.
• Flow welding
• Braze welding
• Soldering
• Resin impregnation
• Epoxy Fillers
• Straightening
• Metal Spraying
 Pollution Control in Foundries
• Pollutants in foundry
- Large quantity of particulate matter are generated
when preparing mould and core sands, melting metals,
knocking out poured moulds and loading and
unloading raw materials.
- Gaseous matter like gases, vapours, fumes and smoke
are produced during melting and pouring operations.
- The basic means of controlling the emission of
pollutants are :
- Changing production process,
- supplying adequate make up air,
- proper ventilation of the shop,
- good house keeping etc.
 Emission during Melting operations

• Emissions from cupola furnace

The particulate emissions from cupola may be of three
types
1. Metallic oxides
2. Silicon and calcium oxides resulting from lining erosion
3. Combustible materials, which include coke particles or coke
dust, vaporized or partly burnt oil or grease.
• The gaseous emissions from cupola are composed of CO2, CO,
N2, and smaller amount of SO2 and H2.
providing sufficient air results in CO to convert into CO2
Sulphur is introduced in exhaust gases as the most harmful SO2
gas, because of its presence in coke and metallic charge. Low sulphur
fuels should be used to reduce content of SO2.
Gases carried in the exhaust like CO2, H2, N2 are harmless.
• Emissions from electric furnaces

– Compared to cupola and arc furnaces the emissions from

electric furnaces is small. The major pollutants from this
furnaces are dust, smoke, CO, oxides of nitrogen and
sulphur etc.
 Emissions in other areas of foundry
a) Moulding and core making section: the major pollutant is
dust.
b) Amount of dust generated in sand mixer.
c) Generation of dust in knockout section.
d) Sand handling system.
e) Amount of gases evolved when pouring moulds.
f) Fettling shop
g) Heat treatment furnaces
h) Pattern shop.
 Dust and Fume Control
1. Filter: filter serves for removing gas or air streams by
retaining it in or on the porous structure through which the
gas flows

Fig. Bag Filter

• Porous structure is usually a woven or felted fabric. Filter must
be continuously or periodically cleaned or replaced.
• Filters are commonly employed in pattern shops on various
wood working machines, such as band saw, circular saw.
• They are also used on cupola collection systems in
conjunction with other equipment, such as afterburners, gas
cooler, exhaust blower etc.
• Sand reclamation plants also use bag filters for separating
fines from sand grains.
 Cyclone
• It works on principle of centrifugal separation in which a
vortex motion of particulate matter is created within the
collector.
 Mechanical Collectors
• It collects particulate matter by gravity or centrifugal force but
do not depend upon vortex as in the case of cyclones.
Inspection and Testing Methods