Precision Casting Processes

A. J. CLEGG
Loughborough University of Technology, Leicestershire, UK

PERGAMON PRESS
OXFORD • NEW YORK • BEIJING • FRANKFURT
SEOUL • SYDNEY • TOKYO
 Contents

Preface vii

Chapter 1 Introduction 1

Chapter 2 Precision Sand Casting Processes 17

(Inorganic Binders)
Introduction 17
The Green Sand Moulding Process 24
The C02/Silicate Process 42
The Alumina-Phosphate System 54

Chapter 3 Precision Sand Casting Processes 57

(Organic Binders)
The Cold Set and Cold Box Processes 57
The Cosworth Process 68
The Shell Moulding Process 73
The Colshell Process 86
The Zeus Process 86

Chapter 4 Precision Sand Casting Processes 90

(Unbonded Sands)
Introduction 90
The Evaporative Pattern Casting (EPC) Process 91
The Vacuum-Sealed (V-) Process 99

Chapter 5 The Plaster Mould Casting Process 110

Chapter 6 The Ceramic Mould Casting Processes 123

Introduction 123
The Shaw Process 131

Chapter 7 The Investment Casting Process 145

Introduction 145
Counter Gravity Investment Casting Processes 164
The Replicast Ceramic Shell (CS) Process 168
Plaster Mould Investment Casting 172

v
Chapter 8 The Die Casting Processes 176
Introduction 176
Gravity Die Casting 177
Pressure Die Casting 182
Low Pressure Die Casting 196
Squeeze Casting 200

Chapter 9 Design for Casting 211

Introduction 211
Design for Soundness 220

Chapter 10 Metal Melting and Treatment 243

Introduction 243
Metal Melting 244
Gases in Metals 249
Melt Treatments 251
Special Techniques 259

Chapter 11 Quality Control and Assurance 264

Introduction 264
Mould Materials 265
Metal Melting and Composition Control 266
Casting Evaluation 269
Statistical Process and Quality Control 277

Index 283

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