Metal Casting

by Hurst, Steve

• ISBN13: 9781853391972
• ISBN10: 1853391972
• Format: Paperback
• Copyright: 1996-05-01
• Publisher: Practical Action Pub

Summary

An introduction to small-scale non-ferrous casting. Includes step-by- step instructions on how to make equipment using local materials; and provides information on moulding techniques, pattern making, core making, the use of wax and metal preparation.

Table of Contents

Preface	ix
Acknowledgements	x
Introduction	1	(9)
Making a choice of production method	1	(3)
Advantages and disadvantages of each process	4	(4)
Examples	8	(2)
Setting up the workshop	10	(5)
The small workshop or sand foundry	11	(1)
The workshop for a lost-wax foundry	12	(1)
Examples of foundry designs	13	(2)
Pattern making	15	(10)
Materials	15	(3)
Skills	18	(1)
Designing the pattern	18	(5)
Storing patterns	23	(2)
Flexible moulds for the mass-production of wax patterns	25	(13)
Making the case for a flexible mould	26	(2)
Making a rubber mould	28	(4)
Gelatine moulding	32	(3)
Mixing plaster	35	(1)
Summary	36	(2)
Sand casting	38	(22)
Essential moulding equipment	39	(1)
Making a simple, solid casting	40	(7)
Making a simple casting using a split pattern	47	(2)
Hollow casting	49	(5)
The nature of moulding sand	54	(4)
Other sand processes	58	(2)
Lost-wax casting	60	(25)
Waxes	62	(3)
Moulding the wax	65	(2)
The block investment process	67	(9)
Kiln firing (de-waxing)	76	(2)
The clay slurry investment method	78	(5)
Inca silver	83	(2)
The ceramic shell process	85	(17)
Equipment	86	(1)
The ceramic shell process in outline	87	(1)
The process in detail	87	(15)
Die casting	102	(5)
Examples of the technique	102	(2)
Finding and correcting faults in the castings	104	(3)
Melting and pouring metal	107	(4)
Summary	107	(3)
Safety precautions	110	(1)
Metallurgy and the low budget foundry	111	(15)
The structure of metals	111	(3)
Selection of scrap metals for casting	114	(3)
Alloying	117	(2)
Metal melting	119	(3)
Metal flow and solidification	122	(4)
Kilns and furnaces	126	(21)
The furnace drum	127	(8)
Kilns	135	(6)
Crucibles	141	(5)
Conclusion	146	(1)
Faults, fettling and finishing	147	(48)
Common faults in castings	147	(4)
Fettling and finishing	151	(6)
Appendices
A Newar Casting in Patan, Nepal	157	(6)
B Bamoum lost-wax casting, western Cameroon	163	(8)
C The Dedza crucible	171	(4)
D Sand conditioning and testing	175	(6)
E Other sand processes	181	(4)
F Summary of ceramic shell investment processes	185	(10)
Further reading	195	(4)
Glossary	199