Foundry (rv)

• What is Foundry?

  a work area (factory) that produces metal casting.
• What is "casting"?

  Processing of molding
• What are the 2 most common metals being cast?

  aluminum and cast iron
• Metal casting enables the production of simple to complex parts that meet a variety of needs
• The process of metal casting consists of pouring molten metal into a mold containing a cavity of the desired shape.
• Typically, casting are further processed by machining, which involves smoothing surface, drilling holes, cutting threads for fasteners, and other steps necessary for incorporation into an assembly.
• Reasons why metal casting is important?

  1. Because cast metal products are found in almost every sector of the economy.
  2. Almost 90% of all manufactured products contain 1 or more metal castings.
  3. Cast manufactured components include automotive parts such as engine blocks, transmission housings and suspension parts.
  4. it is also used in parts for pumps and compressors, pipes and fittings, mining and oiled field equipment, recreational equipment, surgical equipment, and in many other areas.
• What is the process of fusing two or more metal parts using heat, pressure, or both?

  Welding
• What is the process in which metal stock is passed through one or more pairs of rolls to reduce thickness, to make thickness uniform, and/or to impart a desired mechanical property?

  Rolling
• What is the manufacturing process used to convert flat metal sheets into specific shapes?

  Stamping
• What is the process used to remove material, typically metal, to create parts for machines, tools, transportation, and more. (Use of lathes, mills, and drill press)

  Machining
• What is the process in which metal is forced through a die to reduce its cross section or convert it into desired shape?

  Extruding
• What is the process of making or shaping a metal by heating it in a fire or furnace and beating or hammering it?

  Forging
• Advantages of MC: The most complex of external and internal shapes may be cast. As a result, many other operations can be reduced or eliminated.
• Advantages of MC: Because of their physical properties, some metals can only be cast since they cannot be hot-worked into rods, bars, plates, or other shapes from ingot.
• Advantages of MC: Assembly effort may be reduced, as objects can be cast in a single piece which would otherwise require assembly of a number of parts and fasteners.
• Advantages of MC: Metal casting is well suitable for mass production, because large numbers of a casting may be produced rapidly.
• Advantages of MC: Uncommonly large and massive metal objects may be cast when they would be difficult or even impossible to produce otherwise (example: housing of a power turbine).
• Advantages of MC: Some mechanical properties are achieved better in castings than in machined parts.

  EXAMPLE:

  1. Uniformity (from a directional standpoint)
  2. Strength in certain alloys
• What are 4 most common metals in metal casting?

  1. cast iron
  2. steel
  3. aluminum
  4. copper
• What is a "cast material"?

  material (typically metal) used for casting
• What is the number 1 most commonly cast metal in the foundry industry?

  Iron
• Cast iron and steel are alloys of the metallic element iron although they differ in many ways.
• Cast iron contains over 2% by weight carbon.
• Cast iron has lower melting point than Steel, and requires less refining.
• Cast Iron can be produced less costly than steel casting because it requires less specialized equipment.
• Cast Iron shrinks less when solidifying, thus it can be cast into more complex shapes.
• Cast Iron does not have sufficient ductility to be rolled or forged.
• Metal foundries produce molten iron by melting scrap iron, pig iron, and scrap steel in a traditional coke-fired cupola furnace, or in electric induction or electric arc furnaces. 


  molten iron = scrap iron + pig iron + scrap steel
• Molten Iron is refined by adding alloying metals into either the furnace or a ladle. It is then moved to a pouring station for pouring into molds. The molten iron then takes the shape of the mold as it solidifies during cooling.
• Steel castings are produced in a wide range of chemical compositions and physical properties.
• Steel Castings are, in general, of higher strength and ductility than cast iron.
• Castings of Alloy Steel = High strength

  Castings of Stainless Steel = Highly resistant to corrosion
• Aluminum-alloy castings contain varying amounts of silicon, copper, magnesium, tin, and zinc.
• The strength-to-weight ratio of Aluminum is among the highest of all metals. This means that lighter-weight aluminum can find niche in almost every segment of the transportation industry - particularly in the aerospace where aluminum castings are used in engine and airframe parts.
• What is the meaning of strength-to-weight ratio?

  strength of the material over its weight. A high stw ratio means high strength with relatively low weight
• Copper castings include those of copper-based alloys, such as brass and bronze.

  Brass = copper + zinc (primary alloying metal)

  Bronze = large fam of copper + tin, aluminum, manganese, etc
• Copper castings have:

  -high corrosion resistance

  -good electrical and thermal conductivity (esp pure or near pure copper castings)

  -good tensile and comprehensive strength (certain metals are nearly as strong as many stainless steel alloys)

  -non-sparking

  -exhibit low friction (when in contact w/ other metals)

  -good wear resistance (when in contact w/ other metals)
• Copper castings maintain its many properties at extremely low temperatures.
• Copper castings are especially amenable (open) to post-casting operations such as machining, brazing, soldering, polishing and plating.