2 BROWN, J. R. (1999). Foseco Non-Ferrous Foundryman's Handbook (11th ed.).pdf

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Foseco Non-Ferrous Foundryman’s Handbook
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Foseco Non-Ferrous
Foundryman’s Handbook
Eleventh edition
Revised and edited by
John R. Brown
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
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Preface
The last edition of the Handbook was published in 1994 and like all the earlier
editions, it aimed to provide a practical reference book for all those involved
in making castings in any of the commonly used alloys by any of the usual
moulding methods. In order to keep the Handbook to a reasonable size, it was
not possible to deal with all the common casting alloys in detail. Since 1994
the technology of casting has continued to develop and has become more
specialised so that it has been decided to publish the 11th edition of the
Handbook in three separate volumes:
Non-ferrous dealing with aluminium, copper and magnesium casting
alloys
Iron
dealing with grey, ductile and special purpose cast
irons
Steel
dealing with carbon, low alloy and high alloy steels
Certain chapters (with slight modifications) are common to all three
volumes: these chapters include tables and general data, sands and sand
bonding systems, resin bonded sand, sodium silicate bonded sand and
feeding systems. The remaining chapters have been written specifically for
each volume.
The Handbook refers to many Foseco products. Not all of the products are
available in every country and in a few cases, product names may vary.
Users should always contact their local Foseco company to check whether a
particular product or its equivalent is available.
The Foseco logo and all product names appearing in capital letters are
trademarks of the Foseco group of companies, used under licence.
John R. Brown
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Preface
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Acknowledgements
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SI units and their relation to other units
1
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SI, metric, non-SI and non-metric conversions
1
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2
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Areas and volumes of circles, spheres, cylinders etc.
5
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6
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The physical properties of metals (Continued)
7
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8
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Approximate bulk densities of common materials
9
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10
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Volume shrinkage of principal casting alloys
11
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13
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Calculation of average grain size
14
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Calculation of AFS grain fineness number
15
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Recommended standard colours for patterns
16
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17
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Buoyancy forces on cores
18
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18
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Opening forces on moulds
19
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Dimensional tolerances and consistency achieved in
castings
19
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21
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Introduction
2 Aluminium casting alloys
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Casting alloys
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Casting processes
25
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The effect of alloying elements
39
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Heat treatment of aluminium alloys
39
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42
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Introduction
3 Melting aluminium alloys
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Raw materials
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Melting furnaces
47
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Corundum growth
47
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Choice of melting unit
54
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55
1 Tables and general data
Conversion table of stress values
The physical properties of metals
Densities of casting alloys
Patternmakers contraction allowances
Comparison of sieve sizes
Dust control in foundries
Core print support

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