pouring basin sprue
UFUT test bars—0.47-in. diameter castings
gate well
Fig. 5. Cut off sprues, runners and gates are saved as foundry returns to be remelted for more castings.
consisting of two parts, a cope and drag.
Floor molding Used when pattern sizes prohibit the use of a molding machine; the pattern is bolted to the floor, and the assembled mold is moved by crane.
Fluxing Applying a solid or gaseous material to molten metal in order to remove oxides and other foreign material.
Foundry returns Metal (of known composition) in the form of gates, sprues, runners, risers and scrapped castings returned to the furnace for remelting (Fig. 5).
Furan Generic term for a family of chemical compounds, includ- ing furfural and furfuryl alcohol, used as binders for core sands.
Gage A device for determining the dimensional size of an object (also spelled gauge). Galvanize To coat iron or steel with zinc. Gas porosity A condition existing in a casting caused by the trapping of gas in the molten metal or by mold gases evolved during the pouring of the casting.
Gate (ingate) The portion of the runner where the molten metal enters the mold cavity (Fig. 6).
Grain An individual crystal in a metal or alloy. Also an individual component of aggregate when referring to metalcasting sands.
Grain fineness number (GFN) A system for expressing the average grain size of a given sand. Graphite One of the soft, crystal forms of carbon. Green sand Moist, clay-bonded molding sand. Heat A single furnace charge of metal. Heat treatment A combination of heating and cooling opera- tions timed and applied to a metal or alloy in the solid state in a manner that will produce desired mechanical properties.
High pressure mold A strong, high-density mold made by air or hydraulic pressure or another squeeze process. Holding furnace A furnace for maintaining molten metal supplied from a larger melting furnace at the proper pour- ing temperature.
Hotbox process A resin-based process that uses heated metal coreboxes to produce cores.
Hot isostatic pressing (HIP) A process used to improve the internal soundness, increase the density and improve the properties of a casting. Castings are placed in an inert atmosphere in a pressure vessel, where the temperature is raised to near the solidus. The pressure is increased in
2010 Casting sourCe DireCtory runner
Fig. 6. The gating system, which brings the molten metal to the mold cavity, is illustrated in its simplest form. The design of this system is critical in the introduction of clean metal to the mold cavity.
UFT
the vessel, causing plastic deformation that collapses the internal porosity.
Hot tear Irregularly shaped fracture in a casting resulting from stresses set up by steep thermal gradients within the casting during solidification. Impregnation Treatment of castings with a sealing medium to stop pressure leaks. Inclusions Particles of slag, refractory materials, sand or deoxidation products trapped in the casting during pour- ing solidification.
Ingot A mass of metal cast to a convenient size and shape for remelting or hot working. Injection molding The injection of molten metal under pressure into molds. Inoculation Addition to molten metal of substances de- signed to change the physical and mechanical properties of the structure.
Inserts Parts formed from a secondary material and placed in the mold to function as integral structural parts of the casting. Investment casting A pattern casting process in which a wax or thermoplastic pattern is used. The pattern is invested (surrounded) by a refractory slurry. After the mold is dry, the pattern is melted or burned out of the mold cavity, and molten metal is poured into the resulting cavity.
Fig. 7. Molten metal is poured from a ladle into a mold. Metal Casting Design & PurChasing 45
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