Core

A core is a body of material, usually sand, used to produce a

cavity in a casting. A core must have sufficient strength to
support itself and should not fracture when liquid metal is
approaching to it.
Cores may be classified as Green-Sand and Dry-Sand
Cores. Green-sand cores are formed by the pattern and
made from the same sand as rest of the mold.
Dry-sand cores are made separately to be inserted after the
pattern is drawn but before the mold is closed. They are
usually made of clean river sand (40 parts) which is mixed
with a binder (1 part) and then baked to give the desired
shape. The box in which cores are formed to proper shape is
called a core box. Generally, perforated pipe or wire frames
are added to give sufficient strength.

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Cores are made of sand with
addition of some binder for
strength by means of core boxes:

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Characteristic of core
Green strength: a core made of green sand
should be stronger enough to retain the shape till
it goes for baking.
Dry strength: it should have adequate dry
strength ,when core is placed in mold it should be
able to resist metal pressure acting upon it.
Collapsibility: core has good collapsibility
,resistance against the shrinkage .
Smothness:surface of the core should be smooth
to provide a good surface finish casting.

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Characteristic of core
permeability: gases evolving from molten metal and
generated from the mold, some time may have to pass
through the core to escape. So core are required to have
higher permeability.
Core sand: sand mixture suitable for cores.
Core sand ingredients: sand grains, binders and other
additives .
Silica sand is the mostly sand used for core making.
Binders: binders are used to hold the sand grains together
and produce strength, resistance to erosion and to
breakage binders are classified as organic ,inorganic .

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Organic binder : core oil,cereal,resisn plastics,
pitch, dextrin molasses.
Inorganic binder: fire clay ,bentonites , silica
flour, iron oxide
Core coatings: core coatings are normally known
as core washes, core diping or facing. Core
coating may be applies as liquid by spraying, or
brushing or some times by dusting.
water,referactory material and binder.

Core making
Chaplets:

Chaplets are metallic support kept inside

the mould cavity to support the cores.
Thee are the same composition as that of
pouring metal would provide the enough
heat to completely melt them and fuse it
during solidification.

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Cores defects during casting.
blows: cores give off gases, they may cause blows
or gas cavities in casting. Core which are under
baked and have green strength produce blows.
Core rise: this defect occurs when core floats and
moves up close to cope. Touch the cope surface
and left hollow the section .a week core or one
which is not properly supported with chaplets
cause this defect. An undersize core not held
tightly by the core print may also raise.

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Cores defects during casting.
core shift: core may shift horizontally if it is not
tightly held by chaplets or prints.
Cracks of: core may be crack . A stronger core
or better support is used for core handling.
Metal penetration :this defect is very common in
large casting when core becomes heated up the
melting point of metal, metal then seeps into the
core , developing an adhering mass of metal and
sand.

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Cores defects during casting.
Crush: most commonly defect in mold ,which is
caused during core setting or closing of mold. in a
crush sand on mold cavity is displaced by the core.
some time core is over size then core stick with the
mold causing to remove the sand so overall
dimension changes.
Core wash: a core will was when surface collapses too
fast. Washes may be minimized by using a refractory
coating on the core or strengthening it by using
more binder. Silica flour or clays developed more
resistance to washing.

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Baking of cores
Core ovens
Batch type
Counties type
Horizontal
Vertical

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Core ovens

Core ovens are useful for handling a wide

variety of work in small and medium size
castings. Core oven are possible to bake the
cores of varying size and thickness. size of
core is not limited in this. large type batch
oven are fired, with gas oil or coal. for baking
core fresh air is required since oxygen is
needed for many core oils to harden.

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Finishing of cores
Cleaning
Sizing
Core assembly
Inspection