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Comprehensive Overview of Casting Practices in Foundries

This chapter explores the essential processes in casting production and scrap metal recycling. It details methods for refining molten metals, such as protective flux coverings, bubbling gases, and vacuum degassing. Various molding techniques, including sand molds, investment casting for precision shapes, and the use of permanent molds, are discussed. The chapter also differentiates between coreless and channel induction furnaces, addresses solidification shrinkage issues, and emphasizes the importance of riser placement for successful filling and solidification. Proper design considerations are also highlighted to optimize casting characteristics.

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Comprehensive Overview of Casting Practices in Foundries

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  1. Chapter 25 Casting Casting Practice • Casting Quality

  2. The foundry flowsheet indicates the steps performed to produce castings and recycle scrap metal.

  3. Methods of refining molten metals include protective flux coverings, bubbling insoluble gases through the melt, and vacuum degassing.

  4. A sand mold is complex and consists of several components.

  5. Investment casting is used to produce small, precision shapes and is achieved using a wax pattern.

  6. Permanent mold casting requires a metal mold that may be reused many times.

  7. The basic types of induction furnaces are the coreless and the channel (core) types.

  8. The crucible furnace is extremely versatile and is generally used to handle small charges.

  9. Three stages of shrinkage occur during the solidification of a casting.

  10. Solidification shrinkage leads to voids and microporosityunless the casting is properly fed.

  11. Alloys may have short or long freezing ranges, which influences the way they solidify.

  12. Risers must be located so that the casting is completely filled and solidified.

  13. Castings must be properly designed to take advantage of their unique characteristics.

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