E-CONTENT PREPARED BY: BARUN BIKASH DE

MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG

MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD

 CASTING:

Casting is a manufacturing process in which a molten metal is

usually poured into a previously made cavity or called as mould,
which contains the desired shape & size , and then allowed to
solidify. The solidified part is also known as a casting, which is
ejected or broken out of the mould to complete the process.

 Sand casting, also ` as sand moulded casting, is a metal casting process characterized by

using sand as the mould material.

MOULDING

SAND MOULD

Inspection
Melting Pouring into Casting Heat Cleaning & testing
of metal mould treatment and finishing

Furnace
solidification shakeout – additional heat treatment
(removal of risers and gates)
Outline of production steps in a typical sand casting operation
 Typical sand mould Sectional view:
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
What is Mould?
A  mould is a block with internal channel & cavity that is filled with a molten liquid metal that
hardens or sets inside the mould, adopting its shape thus produce the final object. A mould is the
counterpart to a cast.

 Moulding:

Moulding is nothing but the mould preparation activities for receiving molten metal.
Moulding usually involves: (i) preparing the consolidated sand mould around a pattern held within a
supporting metal frame, (ii) removing the pattern to leave the mould cavity with cores.
 Mould cavity is the primary cavity
 The mould cavity contains the liquid metal and it acts as a replica of the
desired product.
 The mould also contains secondary cavities for pouring and channellings

 Nomenclature of a Casting Mould:
Flask: A metal or wood frame, without fixed top or bottom, in which the mould is formed.
Depending
upon the position of the flask in the moulding
structure, it is referred to by various names such as
drag – lower moulding flask, cope – upper
moulding flask, cheek – intermediate moulding
flask used in
three piece moulding.
Pattern: It is the replica of the final object to be
made. The mould cavity is made with the help of
pattern.
Parting line: This is the dividing line between the
two moulding flasks that makes up the mould.

Moulding sand: Sand, which binds strongly without losing its permeability to air or gases. It is a
mixture of silica sand, clay, and moisture in appropriate proportions.
Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the
mould
cavity to give a better surface finish to the castings.
Core: A separate part of the mould, made of sand and
generally baked, which is used to create openings and
various shaped cavities in the castings.
Pouring basin: A small funnel shaped cavity at the top
of the mould into which the molten metal is poured.
Sprue: The passage through which the molten metal,
from the pouring basin, reaches the mould cavity. In
many cases it controls the flow of metal into the mould.
Runner: The channel through which the molten metal is
carried from the sprue to the gate.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
Gate: A channel through which the molten metal enters the mould cavity.

Chaplets: Chaplets are used to support the cores inside the mould cavity to take care of its own
weight and overcome the metallostatic force.
Riser: A column of molten metal placed in the mould to feed the castings as it shrinks and
solidifies. Also known as “feed head”.
Vent: Small opening in the mould to facilitate escape of air and gases.

MOULDING MATERIAL:

high silica sand generally used as the principal moulding material. The sand mixture is prepared by
adding binder i.e. bentonite, coal dust as additive and water . The sand is prepared by hand mixing.
After preparation of moulding sand, the mould is prepared by ramming the sand in the mould box. .
The general composition of green sand mixture is given as High Silica Sand : 86% Bentonite
(Binder) : 8 % Coal Dust (Additive) : 1 % Moisture (Water) : 5 %

 Terminology of foundry Sand: foundry sand in different conditions have different names
depending upon their uses as follows
 Green sand :it is well prepared foundry sand with moisture content just enough to make it suitable
for making moulds .the moulds prepared by this sand are called green sand moulds.
 Dry sand: when a green sand mould is dried its excess moisture evaporates.
 Facing sand: this sand forms the face of the mould to some depth beyond which floor sand is
packed . thus the sand in contact with the molten metal is well tempered foundry sand.
 Parting sand: it is the dry dry silica or burnt sand which is sprinkled on on the pattern and the
parting surface so that the cope sand does not get stick to drag sand .
 Floor ,backing sand are terms used to denote the used sand .
 Core sand : it carries high silica containing binder ,oil sand, and molasses sand carry oil and
molasses respectively as binders.
 Sand grain may be rounded or angular .angular grain give more strength.


Natural and Synthetic moulding sand

 Natural moulding sand:

 This is ready for use as it is dug from the ground. Good natural moulding sand are
obtained from Albany, New york etc.
 The following average compositions are seen in natural moulding sand:65.5% silica grains, 21.7%
clay content, 12.8% undesirable impurities.
 Too much clay content and other impurities fill up the gaps between the sand grains. This will hinder

 the necessary passage of steam and other gases during pouring of the mould.

 Synthetic molding sand

 Synthetic moulding sand is made by mixing together specially selected high quality
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
clay free silica, with about 5% of clay . They are tailor made to give most desirable
results.
 Some of the advantages of synthetic moulding sand are:
1. Refractory grain sizes are more uniform,
2. Higher refractoriness (= 3000 0F),
3. less bonding agent is required (about 1/3rd of the clay percentage found in natural moulding sand),
4. More suitable for use with mechanical equipment
 Advantages of natural moulding sand: 1. moisture content range is wide, 2. moulds can be
repaired easily
 Properties (characteristics ) of moulding sands:

 Refractoriness: ability to withstand very high temperature without fusing. The sand posses this
due to presence of quartz or silica sio2 . large grain lead to high refractoriness.
 Permeability: also called porosity, allow gases and steam to escape out through sand moulds. if gas
do no get easy exit they may cause defect in casting. Round grain and venting increase permeability
and hard ramming reduce it.
 Flow ability : allow sand to pack uniformly around the pattern to assume he desired shape and
distributions.
 Cohesiveness: ability of the sand particle to remain bonded together ,the mould faces develop
sufficient strength to withstand the pressure of flowing metal. This property in green state called
green strength. When mould face dried in oven or molten metal is poured into the mould
cohesiveness is still needed to keep the mould shape intact. This property in dry state called dry
strength.
 Collapsibility: is the property of the mould or core to allow it to automatically or easily collapse
after casting. To permit free contraction of the casting .hindered contraction may cause tears and
cracks in castings.

 Ingredients used in sand for making moulds/cores:

 Refractory sand grains : silica, zircon( has chilling properties),olivine, magnesite, carbon ,coke
etc.
 Binders Used in Sand Casting for Moulds, Cores :
 Clays: Fire clay (kaolinite) bentonite (calcium montmorillonite)
 Oils : Vegetables (e.g. linseed oil) ,Marine animal (e.g., whale oil)
 Synthetic resins, thermosetting :Urea formaldehyde ,Phenol Formaldehyde
 Cereal binders made from corn: Gelatinized starch, Gelatinized corn flour ,Dextrin
 Wood –product binders: Natural resin (e.g., rosin, thermoplastic) Sulphite binders (contain Other
binders :Portland cement ,Pitch (a coal-tar product),Molasses (usually applied in water as a
spray),Cements (e.g., rubber cement),Sodium silicate CO2 hardening binders)

 Facing material: sea coal, pitch(dry powder), graphite, coke, silica flower
 Cushion material : wood flower ,cereal, cellulose, sea coal ,coke.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
Types of sand mould

sand moulds are characterized by the types of sand and bonding agent that comprise mould .

 There are three basic types of sand moulds: green sand, cold box, no bake moulds.
 Green sand mould: prepared by mixture of sand , clay and water . the term green refers to the
fact that the sand in the mould is in moist or damp while metal is being poured into it. Advantage
is that used sand is reclaimed.
 Skin dry mould: the mould surface are dried either by drying it with torches or can be made by
making mould by green sand and spraying a coating of binder such as linseed oil, molasses,
gelatinized starch that harden when heat is applied .this improves the surface quality and
dimensional accuracy of the casting. Generally used for large casting.
 Dry sand moulds: are made by made as same as skin dry mould using coarse sand and binder
which are completely dried. .surface finish are improved but because of high strength it reduce
collapsibility of the mould and cause hot tearing metals. It needs more energy ,equipment.
 Loam sand moulds: used for large castings are built with bricks or large iron parts plastered with
thick loam mortar ,sweep or skeleton pattern gives shape, dried thoroughly. Such moulds take
long time to dry and not used thoroughly.
 Cold box mould : various organic and inorganic binders are blended into the sands to bond the
grains chemically for greater strength. these moulds are dimensionally more accurate than green
sand moulds but are more expensive.
 No bake mould: synthetic liquid resin is mixed with the sand ,the mixture hardens at room
temperature .because bonding of the mould in this and in the cold box process takes place without
heat, they are called cold setting process.

Methods of making moulds:

Bench moulding: used for small works.it carried out on bench of convenient height using small
mould box and common moulding tools.
Floor moulding: used on floor for moulds of size in convenient to handle on the bench. Medium
and large size moulds are prepared on floor.

Pit moulding:
Large castings are made in pits in foundry
floor. Reinforced concrete is used to make
sides and bottom of pits.
• a bed of charcoal is used at the bottom of a pit
to aid the escape of gases.
• bedding-in technique may be used since
rolling over of drag is not possible.
• appropriate placing of pattern is done.
• several cores can be used for making delicate
shapes.
• Pit moulding may take few days to weeks for
completion, and hence binders are added to the
moulding sand which harden when air-dried.
• sometimes, the mould cavity is heated to
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
harden with time, by placing a stove down into the mould cavity and covering the entire mould to
keep the heat inside the cavity. slow cooling of molten metal is allowed so that
the internal stresses can be minimized.

Machine moulding:

Conventionally moulding is done by compacting the sand by hand ramming (tamping) or ramming it around
pattern .but in modern operation moulding is done by machine, these machine eliminate arduous labour ,offer
high quality casting by improving the application and distribution of forces ,manipulate mould carefully
controlled manner ,and increase production rate.
The moulding machine operate on one or more of the principle explained:
Mechanisation of moulding process can be assist further by jolting , squeezing or sand slinging .

Jolting(jolt ramming): the flask ,moulding sand ,and pattern are first placed on a pattern plate mounted on an
anvil ,then jolted upward by air pressure at rapid interval . the internal forces compact the sand around the
pattern. Jolting produce the highest compaction at the horizontal parting line.

Sqeezing: it is found satisfactory for shallow flask as it gives more density to mould top region . The pattern
plate is clamped on the machine table, and a flask is put into position. A sand frame is placed on the flask, and
both are then filled with sand from a hopper .Next, the machine table travels upward to squeeze the sand
between the pattern plate and a stationary squeeze head. The squeeze head enters into the sand frame and
compacts the sand so that it is level with the edge of the flask. These machines rammed the sand harder at the
back of the mould and softer on the pattern face. Squeezer machines are very useful for shallow patterns.

Sand slinger: The working principle of a sand slinger machine is moulding sand is fed into a
housing containing an impeller that rotates rapidly around a horizontal axis. Sand particles are picked
up by the rotating blades and thrown at a high speed through an opening onto the pattern, which is

positioned in the flask. This type of machine is employed in moulding sand in flasks of any size,
whether for mass production of moulds or individual mould.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
Fig: Principle of machine moulding operation

 Green sand mould making procedure:

There are number of steps and enormous effort involved in making the sand mould intended for casting.

Below picture depicts sequence of operation for sand moulding.

These moulding is for elbow joint of pipe.

a) A mechanical drawing of the component is used to generate a design for the pattern. While
making pattern shrinkage and draft allowance must be considered.
b) Split pattern is being mounted on cope side of the metal plate with pin for alignment.
c) Other side of the pattern is being mounted on drag side of plate. also there is a provision of core
print to hold the core in place.
d) A core box is prepared to produce the core .
e) the core sand is packed in core box which
produce the core which is pasted together .the
core will be used to produce the hollow area in
the casting.
f) The cope half of the mould is assembled by
securing the cope pattern plate to the flask with
alignment pin, attaching inserts to form the
sprue and risers.
g) The flask is rammed with sand appropriately
and the plate and inserts are removed.
h) The drag half is produced by same manner, a
bottom board is placed below drag and
alignment with pin .drag half of the pattern is
placed in box. then the drag half of the mould is
filled with rammed in the same manner as done
during cope.
i) The pattern, flask ,and bottom board are
inverted and the pattern is withdrawn ,leaving the appropriate imprint .all gating parts are cut or
imprinted on face of the drag side of mould thus creating gating design.
j) The core is set in place within drag cavity.

k) The mould is closed by placing the cope upside down on drag side and securing assembly with
pins .mould is ready for pouring .molten metal poured into to mould cavity through internal
channels.
l) After metal solidifies the casting is removed from mould .
m) The sprue and risers are cut off from casted object which are recycled.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
n) The casting is the cleaned ,inspected, and heat treated.

Schematic illustration of sequence of the sand moulding

 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD

FURNACE

 What is furnace ?
 Heating media or device .
 Used for heating or melting .
 For providing heat to chemical reaction for processes like cracking .
 The furnace may be heated by fuel as in many furnaces coke is used as fuel .
Some are operated by electrical energy e.g. electric arc furnace
 FURNACES FOR CASTING PROCESSES :-
 Furnaces most commonly used in foundries :-
1. Cupola furnace
2. Blast furnace
3. LD converter
4. Electric-arc furnaces
5. Induction furnaces

Cupola furnace :
1. Cupola furnace was made by Rene – Antoine around 1720.
2. Cupola is a melting device.
3. Used in foundries for production of cast iron .
4. Used for making bronzes .
5. Its charge is coke , metal , flux .
6. Scrap of blast furnace is re melted in cupola .
7. Large cupolas may produce up to 100 ton /hour of hot iron.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD

 Parts of cupola :-
 Spark arrester ,Charging door, Air box, Tuyers, Tap hole , Slag hole.

:-
 Charging of cupola furnace

 Before the blower is started , the furnace is uniformly preheated and the metal , flux and coke
charges , lying in alternate layers , are sufficiently heated up .
 The cover plate are positioned are suitably and the blower is started .
 The height of coke charge in the cupola in each layer varies generally from 10 to 15 cm. The
requirements of flux to the metal charge depends upon the quality of the charge metal and
scrap ,the composition of the coke and the amount of ash content present in the coke .

 Working of cupola furnace :-

 Its charge consists of scrap, coke and flux .

 The charge is placed layer by layer .
 The first layer is coke , second is flux and third metal.
 Air enter through the bottom tuyeres .
 This increases the energy efficiency of the furnace .
 Coke is consumed .
 The hot exhaust gases rise up through the charge , preheating it.
 The charge is melted .
 As the material is consumed, additional charges can be added to the furnace.
 A continuous flow of iron emerges from the bottom of the furnace .
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD

 Operation of cupola :-
 Preparation of cupola .
 Firing the cupola.
 Soaking of iron.
 Opening of air blast.
 Pouring the molten metal.
 Closing the furnace.

Zones within furnace

Well:

 The space between the bottom of the tuyers and the

sand bed.
 Molten metal collected in this portion.
Combustion zone
 Also known as oxidizing zone .
 Combustion takes place in this zone .
 It is located between well and melting zone.
 Height of this zone is normally 15cm to 30cm
 In this zone the temperature is 1540 degree to 1870
degree centigrade .
 The exothermic reaction takes place in this zone these
are following :
 C +O2 CO2 + heat
 Si + O2 SiO2 + heat
 2Mn + O2 2MnO + heat
Reducing zone
 Locate between upper level of combustion zone and
upper level of coke bed.
 In this zone temperature is about 1200 degree
centigrade.
 In this zone CO2 changes into CO .
CO2 + C (coke) 2CO

Melting zone

 In this zone melting is done.

 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
 It is located between preheating zone and combustion zone.
 The following reaction takes place in this zone
 3Fe + 2CO Fe3C + CO2
Preheating zone
 This zone is starts from the upper end of the melting zone and continuous up to the bottom level
of the charging door.
 Objective of this zone is preheat the charges from the room temperature to about 1090 degree
centigrade before entering the metal charge to the melting zone. . Zones are shown in
given figure

Stack
The empty portion of cupola above the preheating zone is called as stack . it provides the passage
to hot gasses to go to atmosphere from the cupola furnace .

Advantages
 It is simple and economical to operate .
 Cupolas can refines the metal charge , removing impurities out of the slag.
 High melt rates.
 Ease of operation.
 Adequate temperature control.
 Chemical composition control.
 Efficiency of cupola varies from 39% to 50% .

Disadvantages

 Since molten iron and coke are in contact with each other , certain elements like Si , Mn are
lost and others like sulphur are picked up . This changes the final analysis of the molten metal.
Closed temperature control is difficult to maintain

 Electric Arc Furnace

 An Electric arc furnace (EAF) is a  steel
making furnace which uses high-voltage
electric current to heat and melt the steel scrap
by means of electric arcs striking between the
furnace electrodes and the metal bath .and
convert it into liquid steel of a specified
chemical composition and temperature. It is
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
first introduced in U.S in 1906.

 capacity :
Industrial arc furnaces range in size from small units of approximately one ton capacity
used in foundries for producing cast iron products) up to about 400 ton units used for
secondary steelmaking. industrial electric arc furnace temperatures can reach 1,800 °C
(3,272 °F), while laboratory units can exceed 3,000 °C (5,432 °F).
 Three-phase AC Electric Arc Furnaces with graphite electrodes are commonly used in steel
making.

 Structure of an Electric Arc Furnace

 The furnace consists of a spherical hearth (bottom), cylindrical shell and a swinging water-
cooled dome-shaped roof. The roof has three holes for consumable graphite electrodes held
by a clamping mechanism. The mechanism provides independent lifting and lowering of
each electrode
 The water-cooled electrode holders serve also as contacts for transmitting electric current
supplied by water-cooled cables (tubes). The electrode and the scrap form the star
connection of three-phase current, in which the scrap is common junction.
 The furnace is mounted on a tilting mechanism for tapping the molten steel through a tap
hole with a pour spout located on the back side of the shell.
The charge door, through which the slag components and alloying additives are charged, is
located on the front side of the furnace shell. The charge door is also used for removing the
slag (de-slagging).

 Refractory lining of an Electric Arc Furnace:

Refractory linings of Electric Arc Furnaces are made by generally of resin-bonded magnesia-carbon bricks .Fused
magnetite grains and flake graphite are used as raw materials.
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD

When the bricks are heated the bonding material is coked and turns into a carbon network binding the refractory
grains, preventing wetting by the slag and protecting the lining from erosion and chemical attack of the molten
metal and slag.

Chemical and physical Process in electric arc furnace:

Operation: steel scrap and a small amount of carbon and limestone are dropped into the electric furnace
through the open roof. electric furnace can be can be also charged with 100 0/0 scrap .the roof is then
closed and electrodes are lowered .power is turned on. and within of 2 hours ,the metal melts. the current
is then shut off ,the electrodes are raised ,the furnace is tilted, and the molten metal is poured into ladle
,which is a receptable used for transferring and and pouring the metal .

 Melting process starts at low voltage (short arc) between the electrodes and the scrap. The arc
during this period is unstable. In order to improve the arc stability small pieces of the scrap are
placed in the upper layer of the charge. The electrodes descend melting the charge and
penetrating into the scrap forming bores. The molten metal flows down to the furnace bottom.
When the electrodes reach the liquid bath the arc becomes stable and the voltage may be
increased (long arc). The electrodes are lifting together with the melt level. Most of scrap (85%)
melt during this period.

 The arc forms between the charged material and the electrode, the charge is heated both by
current passing through the charge and by the radiant energy evolved by the arc. The electric arc
temperature reaches around 3000 °C (5000 °F), thus causing the lower sections of the electrodes
to glow incandescently when in operation. The electrodes are automatically raised and lowered
by a positioning system, which may use either electric winch hoists or hydraulic cylinders. The
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
regulating system maintains approximately constant current and power input during the melting
of the charge, even though scrap may move under the electrodes as it melts.
  After all scrap charges have completely melted, refining operations take place to check and
correct the steel chemistry and superheat the melt above its freezing temperature in preparation
for tapping. More slag formers are introduced and more oxygen is blown into the bath, burning
out impurities such as silicon, sulphur, phosphorus, aluminium, manganese, and calcium, and
removing their oxides to the slag. Removal of carbon takes place after these elements have burnt
out first, as they have a greater affinity for oxygen. Metals that have a poorer affinity for oxygen
than iron, such as nickel and copper, cannot be removed through oxidation and must be
controlled through scrap chemistry alone, such as introducing the direct reduced iron and pig
iron 

 Oxidizing stage

At this stage excessive carbon, phosphorous, silicon and manganese oxidize.

slag consist of lime (CaO) and ion ore (FeO) is used during the oxidizing period.
Gaseous oxygen may be blown into the melt for additional oxidizing.
Iron oxide causes increase of Oxygen content in the molten steel according to the reaction:
(square brackets [ ] - signify solution in steel, round brackets ( ) - in slag, curly brackets {} - in
gas)

(FeO)=[Fe]+[O]

Oxygen dissolved in the melt oxidizes carbon, phosphorous, silicon and manganese:

[C] + [O] = {CO}

[Si] + {O2} = (SiO2)

[Mn] + 1/2{O2} = (MnO)

2[P] + 5/2{O2} = (P2O5)

Carbon monoxide partially burns in the atmosphere:

{CO} + {O2} = {CO2}

The formed oxides are absorbed by the slag. CO bubbles floating up through the melt result in
refining of the steel from non-metallic inclusions and hydrogen removal.

Gaseous products CO and CO2 are removed by the exhausting system. Oxidizing potential of the
atmosphere is characterized by the post-combustion ratio: {CO2}/({CO2}+{CO}).

The oxidizing slag enriched with phosphorous and other oxides formed during this period is
removed from the furnace to a slag pot (de-slagging).
 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
 Reducing stage

New slag composed mainly of lime (CaO), CaF2 (as slag fluidizer) is added at this stage for
formation of basic reducing conditions.

The function of this slag is refining of the steel from sulphur and absorption of oxides, formed as a result
of deoxidation (”killing”).
The excessive oxygen dissolved in the melt during oxidizing period is removed by metallic
deoxidizers Mn, Si, Al:
[Mn] + [O] = (MnO)

[Si] + 2[O] = (SiO2)

2[Al] + 3[O] = (Al2O3)

Basic reducing slag is favourable for desulfurization in accordance to the reaction:

[S] + (CaO) = (CaS) + [O]

Oxide and sulphide non-metallic inclusions are absorbed by the slag.

Alloying elements (Cr, Ni, Mo, V, etc.) are added after deoxidation.

Advantage:
The main advantage of the Electric Arc Furnaces over the Basic Oxygen Furnaces (BOF) is their capability to
treat charges containing up to 100% of scrap. About 33% of the crude steel in the world is made in the Electric
Arc Furnaces (EAF). A current is passed from separate electrodes creating arcs of ionized gas .

Subjective questions: (each question carry 10 marks)

1) Discuss about different mould material used in sand casting .explain different moulding machine used in
practice.
2) Write down different types of sand? What are the best property of sand needed in sand casting.
3) Elaborate with net sketch the nomenclatures of a casting mould showing all parts and its purpose.
4) Explain green sand mould making procedure with sketch.
5) Demonstrate the working principle and operation of electric arc furnace or cupola furnace with net sketch.

Objective questions:

1.In green sand moulding process, uniform ramming leads to:

a)Less chance of gas porosity b)Uniform flow of molten metal into the mould cavity

c)Greater dimensional stability d)Less sand expansion type of casting defect.

 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
2.Disposable patterns are made of : a)Wood b)Rubber c)Metal d)Polystyrene

3.Ruducing atmosphere is maintained in a:

a) Calcination Kinn b)Blast furnace c) Soaking pit d) L.D Converter

4.Which of the following is not a principle constituent of moulding sand?

a) Silica b) Aluminium c) Iron oxide d) Copper

5.When the sand is its natural moist it is known as?

a) Green sand b) Facing sand c) Loam sand d) Dry sand

6.Which of the following sand is back in colour?

a) Green sand b) Facing sand c) Loam sand d) Backing sand

7.Which of the following sand is placed next to the surface and comes in contact with the molten metal?

a) Green sand b) Facing sand c) Loam sand d) Backing sand

8.Green strength of sand does not depend upon?

a) grain size b) Moisture content c) Shape and distribution of sand d) Refractoriness of the sand

9.which of the following will have better plasticity?

a) Coarse sand b) Fine grained sand c) Semi grained structure d) Plasticity does not depend on sand grain
size

10.Which of the following sand is coated with phenol or urea formaldehyde resins?

a) Shell sand b) Green sand c) Dry sand d) Facing sand

11.Which of the most thermally efficient furnace?

a) Rotary kilns b) Boiler furnace c) Reheating furnace d) Reverberator furnace

12.Pig iron is the product of :

a) Cupola furnace b) Blast furnace c) Die casting d) Moulding

13.Heat will be transferred by :

a) Convection b) Radiation c) Conduction d) All of the above

14.Which is an indirectly heated furnace?

a) Open hearth furnace b) Muffle furnace c) Soaking pit d) Reheating furnace

15.Which furnace employs an I.D fan for the removal of flue gases from the furnace?

a) Coke oven d) Blast furnace stoves c) Beehive coke oven d) High pressure boiler

16.Which of the following is a heat treatment furnace?

a) Muffle furnace b) Annealing furnace c) Reheating furnace d) Rotary kiln

 E-CONTENT PREPARED BY: BARUN BIKASH DE
MANUFACTURING PROCESS-I LECTURER IN MECHANICAL ENGG
MODULE -8 MEDINIPUR SADAR GOVT. POLYTECHNIC
CASTING
CASTING MOULD MATERIAL,FURNACE, GREEN SAND MOULD
17.Calcination of limestone to produce lime is done in a ______________ kiln.

a) Tunnel b) Rotary c) Vertical shaft d) Both a&b

18.Pot furnace which is either regenerative or recuperative, is used in the manufacture of

a) Glass b) Stainless steel c) Potteries d) Refractory bricks

19.Temperature of a furnace fired with low calorific value fuel gas can be increased by

a) Preheating the combustion air b) Oxygen enrichment of combustion air c) Preheating the fuel gas d) All
of the above

20.Size of the combustion chamber of a furnace depends the

a) Heat release b) Preheat temperature of fuel & air c) Method of mixing the fuel & air d) All of the above