MODERN CASTING
CROSSWORD PUZZLE In the melt department:
ACROSS: 2. Molten metal.
3. Often consists of some scrap.
4. When molten metal is transferred seamlessly to the molding department, that’s ________.
5. Furnace type that can be channel or coreless.
9. Withdrawing molten metal from the furnace.
DOWN: 1. A pot made of refractory materials.
3. Assure melt parameters and metal chemistry specs are met.
6. Automating this ensures consistent yield and mold fi ll.
7. Types include straight-sided, tapered, buggy, truck and teapot.
8. Action to improve melt quality.
10. Perform this regularly to prevent long work stoppages in your melt department.
Work the rest of the crossword puzzle at
www.moderncasting.com. POLL QUESTION
The April website question asked:
What is your company’s casting capacity situation?
20.4% Near
capacity
This month’s question is available at
www.moderncasting.com.
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9.3% Over
capacity
Too much open capacity
53.6%
5.6% 11.1%
Needs new work Ideal capacity
“Because cast iron is used as the die ma- terial in gravity casting and the frequency of shots is not the same as diecasting. I have used water cooling in a gravity casting on certain areas of the die, especially where the section thickness of the casting is heaviest. I have also used it in core inserts. ” —Pravin Patel, Woodward Inc.
“Having run intake manifolds, structural parts and knuckles in gravity permanent mold and low pressure permanent mold, I would say the original barriers to using wa- ter cooling were: (1) air is easier to plumb and maintain, (2) air is less severe, and (3) especially with cast-iron tools, there is less of an issue with mold cracking, etc. That being said, water is less effective. Also, when you look at the cost of compressed air, it might not be the most effective approach. But when using water, you need to decide how to apply built-in lines cross- drilled in the mold or bubblers. ” —Thomas Prucha, American Foundry Society
“One of the advantages of permanent mold is the [slower] progressive solidifi - cation because it allows the solidifying casting to draw liquid metal from the gate and sprue as the skin solidifi es, reducing shrink voids and porosity. This is especially helpful in thick sections. As a result, the mold doesn’t need to have heat drawn out quite as fast, so air works just fi ne. ” —John Murane, OEM
Editor’s Note: MODERN CASTING does not necessarily endorse the views expressed in this discussion. Visit
www.moderncasting.com for a link to the Foundry and Diecaster Network.
May 2012 MODERN CASTING | 3
.com LINKEDIN DISCUSSION
On the Foundry and Diecaster Network on LinkedIn, a member asked, “I am wondering why in gravity permanent mold casting pressed air cooling is most often used and not water cooling, as in high pressure diecasting?” Below are excerpts of some of the discussion points:
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