Caritas

university
Foundry study

NAME:AGUNWA IFEANYI HILLARY

COURSE: FOUNDRY
DATE:04-07-2024
DEPT: MECHANICAL ENGINEER
100LEVEL
 What are the concept of foundry
A foundry is a facility that produces metal castings through a
process known as founding. It involves melting metal, pouring it
into a mold, and allowing it to solidify and take the shape of the
desired product.

The concept of a foundry includes:

1. Melting: Metal is melted in a furnace to create a liquid molten
metal.

2. Mold-making: A mold is created with a cavity in the shape of

the desired product.

3. Pouring: The molten metal is poured into the mold.

4. Solidification: The metal is allowed to cool and solidify in the

mold.

5. Finishing: The solidified metal is removed from the mold and

undergoes additional processing, such as cleaning, machining,
and heat treatment.

Foundries produce a wide range of products, including engine

blocks, cylinder heads, gears, bearings, and other metal
components for various industries, such as automotive,
aerospace, and construction.

What are the historical development of foundry?

 some historical developments in foundries ¹ ²:

- 300-645 BC: The oldest relics of metal casting were found, with
most of them in Mesopotamia

- 4000 years ago: The technique of melting and casting metal was
established in Britain, with Cornwall being one of the few
European sources of tin for making bronze.

- Mid-first millennium BC: Wrought iron working followed.

- 15th century: Production of cast iron began.

- 18th and 19th centuries: Technical breakthroughs enabled cast

iron and steel production in large quantities at a lower cost than
wrought iron, leading to their use in the industrial age.

- Early 20th century: The industry expanded as engineering

requirements increased and motorized vehicles were developed.

- 1907: The first student chapter of the American Foundry Society

(AFS) was established in Minnesota, where a patent for high-
pressure die casting machinery was also issued in the same year.

- 1940s: The Ministry of Supply set up 36 specialized foundries,

mostly for production of bombs and track links.

- 1950s: The larger and strategically important iron and steel

foundries were nationalized under the British Steel Company.

- 1960s: The production of iron, copper-based, and zinc castings

remained strong, but the whole sector entered a decline in the
following decade.

- 1980s: Production of iron and steel castings had fallen to 40% of

their previous peak levels.

- Late 20th century: The UK industry declined as heavy

manufacturing in the UK began to collapse.

: The importance of foundry manufacturing criteria for choice of

foundry processes

Foundry manufacturing involves several key criteria for choosing

the appropriate foundry process, including:

1. *Material*: Different metals and alloys require specific foundry

processes (e.g., ferrous, non-ferrous, aluminum, copper).

2. *Size and weight*: Larger or heavier parts may require

specialized equipment and processes.

3. *Complexity*: Intricate designs or complex geometries may

require advanced processes like investment casting or 3D printing.

4. *Tolerance and precision*: Tight tolerances or high precision

requirements may necessitate specific processes like die casting
or sand casting.

5. *Surface finish*: Desired surface finish and texture influence

the choice of process (e.g., rough, smooth, machined).

6. *Production volume*: High-volume production may require

automated processes like die casting or low-pressure die casting.

7. *Cost*: Economic considerations can influence the choice of

process, with some methods being more cost-effective than
others.
 8. *Lead time*: Urgent production needs may require faster
processes like rapid prototyping or 3D printing.

9. *Environmental impact*: Some foundry processes have a

higher environmental impact than others, and eco-friendly options
may be preferred.

10. *Industry standards and regulations*: Compliance with

industry-specific standards and regulations (e.g., aerospace,
automotive) may dictate the choice of foundry process.

Considering these criteria helps foundries select the most

appropriate process to produce high-quality castings efficiently
and effectively.

Define foundry and casting and it's difference's

: *Foundry*: A foundry is a facility that produces metal castings

through a process known as founding. It's a industrial operation
that involves:

- Melting metal

- Pouring it into a mold

- Allowing it to solidify

- Producing a desired shape or product

*Casting*: Casting is the process of creating a metal object by

pouring molten metal into a mold. It's a manufacturing technique
used to produce a wide range of metal products, from small parts
to large machinery.
 *Key differences*:

- *Foundry* refers to the facility or operation where casting takes

place.

- *Casting* refers to the process of creating a metal object itself.

- A foundry can produce multiple castings, but a casting is a

single output of the foundry process.

- Foundry is a broader term that encompasses the entire

production process, while casting is a specific step within that
process.

To illustrate:
- A foundry might produce 100 castings (e.g., engine blocks) per
day.

- Each of those 100 engine blocks is a individual casting.

- The foundry is the facility where the casting process takes place.

What's the departments in typical foundry

workshop
A typical foundry workshop consists of various departments that
work together to produce metal castings. Here are some common
departments found in a foundry:

1. *Pattern Shop*: Creates patterns, molds, and cores used to

produce castings.
 2. *Melting Department*: Responsible for melting metal in
furnaces to produce molten metal

3. *Molding Department*: Prepares molds and cores for casting,

and pours molten metal into them.

4. *Casting Department*: Oversees the casting process, including

pouring, solidification, and extraction of castings from molds.

5. *Cleaning and Finishing Department*: Cleans, trims, and

finishes castings to remove excess material and imperfections.

6. *Heat Treatment Department*: Subjects castings to various

heat treatments to achieve desired properties (e.g., annealing,
hardening).

7. *Quality Control Department*: Inspects castings for defects,

tests mechanical properties, and ensures compliance with
specifications.

8. *Maintenance Department*: Responsible for maintaining

equipment, furnaces, and facilities to ensure smooth operations.

9. *Tool Room*: Produces and maintains tools, dies, and

equipment used in the foundry.

10. *Laboratory*: Conducts chemical analysis, metallography, and

other tests to ensure material quality and process control.

11. *Administration*: Oversees management, sales, and logistics.

These departments work together to transform raw materials into
high-quality castings. The specific departments and their
functions may vary depending on the foundry's size, type, and
production requirements.

Safety measures in foundry workshop

: Foundry workshops can be hazardous, so implementing safety

measures is crucial to prevent injuries and ensure a safe working
environment. Some essential safety measures in a foundry
workshop include:

1. _Personal Protective Equipment (PPE)_: Provide and ensure the

use of PPE like hard hats, safety glasses, earplugs, gloves, and
steel-toed shoes.

2. _Respiratory Protection_: Use respirators or masks to prevent

inhalation of dust, fumes, and gases.

3. _Fire Safety_: Install fire extinguishers, ensure proper storage of

flammable materials, and have a fire evacuation plan.

4. _Heat Stress Prevention_: Provide hydration stations, regular

breaks, and monitor temperatures to prevent heat-related
illnesses.

5. _Proper Ventilation_: Ensure adequate ventilation to remove

dust, fumes, and gases.

6. _Machine Guarding_: Install guards on machinery to prevent

accidental contact.

7. _Lockout/Tagout_: Ensure proper lockout and tagout

procedures for equipment maintenance.

8. _Regular Maintenance_: Regularly inspect and maintain

equipment to prevent accidents.

9. _Training and Education_: Provide regular training on safety

procedures, first aid, and emergency response.

10. _Emergency Preparedness_: Develop an emergency response

plan, including evacuation procedures and first aid kits.

11. _Proper Storage_: Store chemicals, fuels, and other hazardous

materials properly.

12. _Electrical Safety_: Ensure proper electrical installations,

wiring, and equipment maintenance.

Remember, safety is everyone's responsibility in a foundry

workshop. Encourage a safety-first culture and regularly review

and update safety measures to ensure a safe working

environment.

Typical flow chart of foundry processes

Here is a typical flow chart of foundry processes ¹:

- Scrap acquisition
- Sorting

- Bailing

- Weighing

- Charge mixing

- Melting and holding

- Casting

- Cold rolling

- Embossing and slitting

- Weighing and sales

- Charging preparation

- Melting

- Casting operations

- Machining of the particular product is outsourced

Other activities that are included in the process map include:

- The study of the flow of processes

- The identification of waste/defects

- A consideration of whether the process can be rearranged in a

more efficient sequence

- A consideration of a better flow pattern, involving different flow

layout or transport routing

- A consideration of whether everything that is being done at each

stage is really necessary and what would happen if superfluous
tasks were removed

Casting techniques and procedures

Some common casting techniques and procedures:

1. *Sand Casting*: Creating a mold from sand and pouring molten

metal into it.

2. *Investment Casting* (Lost-Wax Casting): Creating a wax

pattern, surrounding it with a refractory material, and melting out
the wax to create a cavity for the metal.

3. *Die Casting*: Forcing molten metal into a metal mold (die)

under high pressure.

4. *Centrifugal Casting*: Rotating a mold at high speed to

distribute molten metal evenly.

5. *Vacuum Casting*: Pouring molten metal into a mold in a

vacuum environment.

6. *Lost-Foam Casting*: Creating a foam pattern, surrounding it

with sand, and pouring molten metal into it.

7. *Shell Molding*: Creating a mold from a resin-coated sand

mixture and pouring molten metal into it.

8. *Plaster Molding*: Creating a mold from plaster and pouring

molten metal into it.

9. *Squeeze Casting*: Forcing molten metal into a mold using a

hydraulic press.

10. *Gravity Die Casting*: Pouring molten metal into a metal mold
under gravity.

11. *Low-Pressure Die Casting*: Pouring molten metal into a

metal mold under low pressure.

12. *Ceramic Molding*: Creating a mold from ceramic materials

and pouring molten metal into it.

These techniques and procedures are used to produce various

castings, including engine blocks, cylinder heads, gears, bearings,
and other metal components for various industries.

Casting defect

Casting defects are irregularities or imperfections that occur

during the casting process, resulting in a faulty or unusable
casting. Here are some common casting defects:

1. *Porosity*: Holes or voids in the casting, often due to gas

entrainment or solidification shrinkage.

2. *Shrinkage*: Cavities or shrinkage holes that form as the metal

solidifies and contracts.

3. *Inclusions*: Foreign particles or impurities trapped in the

casting, such as sand, slag, or metal oxides.

4. *Misrun*: A casting that fails to fill completely, often due to

inadequate melting or pouring techniques.

5. *Cold Shut*: A defect that occurs when two streams of metal

fail to fuse properly, resulting in a weak spot.

6. *Hot Tears*: Cracks that form in the casting as it cools and

contracts.

7. *Warpage*: Distortion or warping of the casting due to uneven

cooling or shrinkage.

8. *Surface defects*: Imperfections on the casting surface, such

as cracks, scales, or rough spots.

9. *Core shift*: Movement of the core during casting, resulting in a

defective casting.

10. *Mold damage*: Damage to the mold or pattern, affecting the

casting's accuracy or surface finish.

These defects can be caused by various factors, including:

- Poor mold design or preparation

- Inadequate melting or pouring techniques

- Incorrect metal composition or temperature

- Insufficient core support or shifting

- Inadequate cooling or solidification rates

By understanding the causes of these defects, foundries can
implement measures to prevent or minimize them, ensuring the
production of high-quality castings.

: The preventing and curative measures to defect

some preventing and curative measures for common casting

defects:

*Preventing Measures:*

1. *Proper mold design* and construction to avoid mold damage

and core shift.

2. *Accurate metal composition* and temperature control to

prevent porosity, shrinkage, and inclusions.

3. *Effective pouring techniques* to minimize turbulence and

prevent misruns and cold shuts.

4. *Adequate core support* and secure core placement to prevent

core shift and mold damage.

5. *Proper cooling and solidification rates* to prevent warpage,

hot tears, and shrinkage.

6. *Regular maintenance* of equipment and molds to prevent

damage and ensure proper functioning.

7. *Quality control measures* to detect and correct defects early

in the process.

*Curative Measures:*

1. *Repairing or replacing* damaged molds or cores.

2. *Re-melting and re-casting* defective castings.

3. *Welding or brazing* to repair cracks or holes.

4. *Machining or grinding* to remove surface defects or

imperfections.

5. *Heat treatment* to relieve stresses and improve

microstructure.

6. *Chemical treatment* to remove impurities or inclusions.

7. *Inspection and testing* to identify and rectify defects.

By implementing these preventing and curative measures,

foundries can minimize the occurrence of casting defects, reduce

scrap rates, and produce high-quality castings consistently.

Different types of casting pattern

There are several types of casting patterns, including:

1. _Solid Pattern_: A single, solid piece that is used to create a
mold.

2. _Hollow Pattern_: A pattern with a hollow interior, used to

create a casting with a hollow core.

3. _Split Pattern_: A pattern divided into two or more parts, used

to create a mold with multiple pieces.

4. _Segmented Pattern_: A pattern made up of multiple segments,

used to create a large or complex casting.

5. _Shell Pattern_: A thin, shell-like pattern used to create a

casting with a thin wall.

6. _Skeleton Pattern_: A pattern with a skeletal structure, used to

create a casting with a complex internal shape.

7. _Loose Piece Pattern_: A pattern made up of individual pieces

that are not attached, used to create a casting with multiple parts.

8. _Gated Pattern_: A pattern with a gate (a channel) that

connects the pattern to the sprue (a channel that leads to the
mold cavity).

9. _Riser Pattern_: A pattern with a riser (a channel that allows

molten metal to flow into the mold cavity).

10. _Match Plate Pattern_: A pattern made up of two plates that

match each other, used to create a casting with a symmetrical
shape.
These patterns are used in various casting processes, including
sand casting, investment casting, and die casting, to produce
different types of castings. The choice of pattern type depends on
the specific requirements of the casting, such as its size, shape,
and complexity.

Construction of patterns

The construction of patterns involves several steps and

considerations:

1. *Design*: Create a design or blueprint for the pattern,

considering the casting's shape, size, and tolerances.

2. *Material selection*: Choose a material for the pattern, such as

wood, metal, or plastic, depending on the casting process and
desired durability.

3. *Fabrication*: Cut, shape, and assemble the pattern pieces

using various techniques, like machining, carving, or gluing.

4. *Joinery*: Use joints or fasteners to secure the pattern pieces

together, ensuring accuracy and stability.

5. *Surface finish*: Apply a finish to the pattern surface, such as

sanding or coating, to achieve the desired texture and durability.

6. *Core boxes*: Create core boxes or inserts to produce cores or

internal features in the casting.

7. *Gates and risers*: Add gates and risers to the pattern to

facilitate during casting.
8. *Inspection and testing*: Verify the pattern's accuracy and
integrity through inspection and testing.

Some common pattern construction techniques include:

- *Carpentry*: Building patterns using wood and traditional

woodworking joints.

- *Metalworking*: Fabricating patterns using metal sheets, plates,

or bars, and techniques like welding or machining.

- *Model making*: Creating precise patterns using specialized

materials and techniques, like stereolithography (SLA) or selective
laser sintering (SLS).

- *3D printing*: Building patterns using additive manufacturing

technologies, like fused deposition modeling (FDM) or selective
laser sintering (SLS).

The chosen construction method depends on the specific

requirements of the casting, the pattern material, and the
available resources.