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Glossary of Metalcasting Terms


Acceptable quality level (AQL) A quality level estab- lished on a prearranged system of inspecting randomly selected samples.


Age hardening After rapid cooling or cold working, the process of increasing hardness and strength and decreasing ductility through aging.


Aging A change in a metal’s physical properties that results when an alloy recovers from an unstable condition.


Alloy A substance composed of two or more elements, at least one of which is metal, created to improve the material’s prop- erties or lower its cost.


Angularity The angular relationship of one surface to another; specifically, as it relates to the dimensional tolerance of such features on a casting. Annealing A ferrous heat treatment that softens metals by heating above the critical temperature and slow cooling. Many types exist, but the process generally reduces hardness and improves machinability.


Arc furnace Used to melt metal either directly by an electric arc between an electrode and the work or indirectly between two electrodes.


As-cast A casting condition without subsequent finishing, including heat treatment. Attrition Wearing away by friction; abrasion. Austempered ductile iron (ADI) Ductile iron that has been austenitized, quenched and tempered for increased strength, ductility, wear resistance, design flexibility and low manufacturing cost.


Austenitizing Heating to and holding within the temperature range where austenite is stable in ferrous alloys.


Autoclave A vessel that uses super-heated steam under pres- sure to remove wax from invested shells and to carry out chemical reactions.


Backing sand The bulk of the sand in the flask; the sand compacted on top of the facing sand that covers the pattern.


Base metal The principal metallic material used in an alloy. Bath The molten metal on the hearth of a furnace, in a crucible or in the ladle (Fig. 1).


Bentonite A colloidal, clay-like substance used as a binder in metalcasting sand mixtures where extra green or hot strength is required.


Binder The bonding agent used as an additive to mold or core sand to impart strength or plasticity in a dry state.


Blast cleaning Projecting sand, metal shot or grit under pres- sure to remove sand or oxide scale from castings.


Bottom pouring Filling a mold cavity from a low point through gates from the runner.


Brinell hardness A test for determining the hardness of a material by forcing a ball of specified diameter into it under a specified load; results in the Brinell hardness number (Bhn).


Bull ladle A large container for transporting and pouring molten metal. Frequently used to designate a transfer ladle.


Burn-on sand Sand adhering to the surface of the casting that is extremely difficult to remove.


Captive foundry A division of a larger manufacturing estab- lishment that produces parts for the parent company.


Case hardening Making the surface layer of a ferrous alloy substantially harder than the interior.


Castability A combination of liquid metal properties and solidification characteristics that promotes accurate and sound castings; the ease with which a metal flows through a mold or die.


Chaplet A small metal insert or spacer used in molds to provide core support during the casting process.


Charge A given weight of metal introduced into the furnace. Chill A metal insert in the sand mold used to produce local rapid heat loss and equalizes the rate of solidification throughout the casting.


Clamp A device for holding together parts of a mold, flask or corebox. Cleaning Removal of runners, risers, flash, surplus metal and sand from a casting.


Cold shut A surface imperfection due to unsatisfactory fu- sion of metal.


Fig. 1. Molten metal in a furnace, crucible or ladle is referred to as “the bath.”


2011 CASTING SOURCE DIRECTORY


Fig. 2. These drawings illustrate the role of the core in the mold to form the internal cavities of the casting.


METAL CASTING DESIGN & PURCHASING 43


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