Safety Precautions

As in all manufacturing operations, safety in foundries is an important consideration. The

methods and materials involved in any form of metal casting operation are very hazardous so
safety is particularly important in these operations because of the following factors:

1) Dust from sand and other compounds used in casting because of dust, proper ventilation
and safety equipment for the personnel is necessary.

2) Fumes from molten metals, as well as splashing of the molten metal during transfer or
pouring into molds.

3) The presence of fuels for furnaces, the control of their pressure and the proper operation
of valves.

4) The presence of water and moisture in crucibles, molds, and other locations because
since it rapidly converts to steam and creating severe danger of explosion.

5) Improper handling of fluxes, which are hygroscopic and create a danger when they
absorb moisture.

6) Inspection of crucibles, tools, and other equipment for wear and cracks.

7) Inspection of equipment, such as pyrometers, for accuracy and proper calibration.

8) Wear a proper personal safety equipment such as gloves, aprons, face shields, and shoes
Equipments and tools

1 2 3 5
6

1) Bench Rammer
2) Trowel
3) Soil Scoops
4) Strip Bar
5) Leaf & square spoons
6) Sprue
Standard Operating Procedure

1. Mixing the sand

A green sand has been put into the sand muller machine for mixing process. Then,
switch on the machine to start the mixture and add some water about 1.5L to moisture
the green sand when the mixing process is on progress.

2. Creating a mould

First of all, properly place and fix the selected pattern to the flask and make sure the
flask has been aligned using alignment pins and locks. Then, after the green sand is in
suitable form to use, take the green sand and use the sieves to separate the rough sand
with a fine sand to fill the drag side. After filling, compact it using bench rammers and
after finish compact it turn the flask to cope side by place the sprue and riser and repeat
the same concept as filling the drag side. Lastly, remove the sprue, riser and pattern and
make pouring basin and gate for metal pouring process.
3. Prepare molten metal

Use an aluminium type of metal and put in a melting furnace for melting process until
is done.

4. Pouring the melted metal

When the melted metal is done, pour the molten slowly with continuously into the
mould basin and gate until full. The person that handling the pouring the melted metal
must use an appropriate and tools for safety personal protection equipment to prevent
from any accident or danger.

5. Allow the melted metal to solidified

When poured melted metal on the mould the metal has start to cool and solidified into
the shape of the casting.

6. Remove the shape and trim excess metal

Once the part has been completely solidified and cool, break up the sand mould and
remove the shape part. For the final part, cut off the gating system and trim the shape
using cutters, grinders, and other to get the final product and observe the product for
any casting defects.