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1、 Foseco Non-Ferrous Foundrymans Handbook Foseco Non-Ferrous Foundrymans Handbook Eleventh edition Revised and edited by John R. Brown OXFORDAUCKLANDBOSTONJOHANNESBURGMELBOURNENEW DELHI Preface The last edition of the Handbook was published in 1994 and like all the earlier editions, it aimed to provi
2、de 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
3、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-ferrousdealing with aluminium, copper and magnesium casting alloys Irondealing with grey, ductile and special purpose cast irons Ste
4、eldealing 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 chapt
5、ers 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 equi
6、valent 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 Preface Acknowledgements. 1 Tables and general data1. SI units and their relation to other units1. SI, metric, non-SI and non-met
7、ric conversions2 Conversion table of stress values5 Areas and volumes of circles, spheres, cylinders etc.6. The physical properties of metals7 The physical properties of metals (Continued)8 Densities of casting alloys9. Approximate bulk densities of common materials10. Patternmakers contraction allo
8、wances11. Volume shrinkage of principal casting alloys13. Comparison of sieve sizes14. Calculation of average grain size15 Calculation of AFS grain fineness number16 Recommended standard colours for patterns17. Dust control in foundries18 Buoyancy forces on cores18. Core print support19 Opening forc
9、es on moulds19. Dimensional tolerances and consistency achieved in castings21. 2 Aluminium casting alloys Introduction Casting alloys25 Casting processes39. The effect of alloying elements39 Heat treatment of aluminium alloys42. 3 Melting aluminium alloys. Introduction Raw materials47 Melting furnac
10、es47 Corundum growth54 Choice of melting unit55 4 Fluxes Application of COVERAL powder fluxes Granular COVERAL fluxes61 5 INSURAL refractory for ladles and metal transport. Ladle liners65 6 Treatment of aluminium alloy melts. Hydrogen gas pick-up in aluminium melts. Degassing aluminium alloys72 Grai
11、n refinement of aluminium alloys77 Modification of aluminium alloys79 Sodium modification81 Strontium modification82. Permanent modification83. Sand, gravity die and low pressure diecasting83 Medium silicon alloys, 4 7% Si84 Eutectic silicon alloys, 12% Si84. Treatment of hypereutectic Al Si alloys
12、(over 16% Si)85. Melting and treatment of aluminium magnesium alloys ( 4 10% Mg)86 Special requirements for gravity diecasting87. Treatment of alloys for pressure diecasting87. 7 Running, gating and feeding aluminium castings75 Gating without filters90 Gating with filters93. Feeding mechanisms in Al
13、 alloy and other non- ferrous castings94. Simulation modelling98. 8 Filtration of aluminium alloy castings SIVEX FC filters100. Use of filters in conventional running systems101 Direct pouring of aluminium alloy castings104 KALPUR combined sleeve and SIVEX FC filter for aluminium castings105 Direct
14、pouring into metal dies107 9 Pressure diecasting of aluminium alloys. Die design Process control111 Modification of the diecasting process113. Applications of diecastings114 The diecasting foundry114 Die coating116. 10 Low pressure and gravity diecasting. Low pressure diecasting Gravity diecasting12
15、4 Die coatings for gravity and low pressure diecasting127 11 Sand casting processes. Green sand136 Moulding machines137 Core assembly sand processes140 The Lost Foam process144. 12 Sands and sand bonding systems Properties of silica sand for foundry use. Typical silica foundry sand properties151. Sa
16、fe handling of silica sand152. Segregation of sand153 Measurement of sand properties153. Thermal characteristics of silica sand153 Zircon, ZrSiO4154. Chromite, FeCr2O4156. Olivine, Mg2SiO4156. Green sand additives157. The green sand system160. Green sand properties163. Control of green sand systems1
17、64 Sand testing165. Control graphs165. Parting agents166. Special moulding materials, LUTRON166. 13 Resin bonded sand. Chemically bonded sand. Self-hardening process (also known as self-set, no- bake or cold- setting process) Testing chemically bonded, self-hardening sands169. Mixers171 Sand quality
18、172. Pattern equipment172. Curing temperature173 Design of moulds using self-hardening sand173. Foundry layout173. Sand reclamation175. Typical usage of sand reclamation178 Furanes180. Phenolic-isocyanates (phenolic-urethanes)182. Alkaline phenolic resin, ester hardened183. Heat triggered processes1
19、85 Gas triggered systems186. The shell or Croning process187. Hot-box process189 Warm-box process190 Oil sand191. Phenolic-urethane-amine gassed (cold-box) process193. ECOLOTEC process (alkaline phenolic resin gassed with CO2)195 The SO2 process196. SO2- cured epoxy resin198. Ester-cured alkaline ph
20、enolic system198 Review of resin core-making processes199 14 Sodium silicate bonded sand Sodium silicate CO2 silicate process ( basic process)205. Gassing CO2 cores and moulds207 Improvements to the CO2 silicate process208 The CARSIL range of silicate binders209. SOLOSIL209. Self-setting sodium sili
21、cate processes210. Ester silicate process210. Adhesives and sealants215. CORSEAL sealants215. TAK sealant215. 15 Magnesium casting Casting alloys The melting, treatment and casting of magnesium alloys218. 16 Copper and copper alloy castings The main copper alloys and their applications Specification
22、s for copper-based alloys226 Colour code for ingots227. Melting copper and copper-based alloys232. Melting and treatment of high conductivity copper238 Copper-silver242. Copper cadmium243 Copper chromium243. Commercial copper243. Melting and treatment of brasses, copper zinc alloys244. Melting bronz
23、es and gunmetals248. Melting aluminium bronze250 Melting manganese bronze250. Melting high lead bronze250. Melting copper nickel alloys251 Filtration of copper-based alloys251 17 Feeding systems. Natural feeders Aided feeders253 Feeding systems254. The calculation of feeder dimensions257 Steel, mall
24、eable iron, white irons, light alloys and copper- based alloy castings262 Grey and ductile irons266 Introduction268 Range of feeder products269 Breaker cores279 The application of feeder sleeves280 Williams Cores283. FERRUX anti-piping compounds for iron and steel castings284. Metal-producing top su
25、rface covers285 FEEDOL anti-piping compounds for all non-ferrous alloys286 Aids ot the calculation of FEEDER requirements286 Nomograms287. FEEDERCALC287 Calculating feeder sizes for aluminium alloy castings288. Index. Acknowledgements The following Organisations have generously permitted the use of
26、their material in the Handbook: The American Foundrymens Society, Inc., 505 State Street, Des Plaines, Illinois 60016-8399, USA. The Association of Light Alloy Founders (ALARS), Broadway House, Calthorpe Road, Five Ways, Birmingham, B15 1TN. BSI, Extracts from British Standards are reproduced with t
27、he permission of British Standards Institution. Complete copies can be obtained by post from Customer Services, BSI, 389 Chiswick High Road, London W4 4AL. Buhler UK Ltd, 19 Station Road, New Barnet, Herts, EN5 1NN. Butterworth-Heinemann, Linacre House, Jordan Hill, Oxford OX2 8DP. The Castings Deve
28、lopment Centre (incorporating BCIRA), Bordesley Hall, The Holloway, Alvechurch, Birmingham, B48 7QB. The Castings Development Centre (incorporating Steel Castings Research radius r, diameter d: circumference = 2?r = ?d area = ?r2= ?/4 ? d2 Sphere; radius r: surface area = 4?r2 volume = 4 3?r3 Cylind
29、er; radius of base r, height h: area of curved surface = 2?rh volume = ?r2h Cone; radius of base r, height h: volume = 1 2area of base ? height = 1 2?r2h Triangle; base b, height h: area = 1 2bh Tables and general data7 The physical properties of metals ElementSymbolAtomic weight Melting point (C) B
30、oiling point (C) Latent heat of fusion (kJ/kg) (cal/g) Mean specific heat 0100C (kJ/kgK) (cal/gC) AluminiumAl26.97660.42520386.892.40.9170.219 AntimonySb121.76630.71590101.724.30.2090.050 ArsenicAs74.93volat6160.3310.079 BariumBa137.3772921300.2850.068 BerylliumBe9.0212872470133.531.92.0520.490 Bism
31、uthBi209.0271.4156454.413.00.1250.030 CadmiumCd112.41321.176758.614.00.2330.056 CalciumCa40.088391484328.678.50.6240.149 CarbonC12.010.7030.168 CeriumCe140.1379834300.1880.045 ChromiumCr52.0118602680132.731.70.4610.110 CobaltCo58.9414942930244.558.40.4270.102 CopperCu63.5710852560180.043.00.3860.092
32、 GalliumGa69.7429.7220580.219.20.3770.090 GoldAu197.21064.4286067.416.10.1300.031 IndiumIn114.815620700.2430.058 IridiumIr193.1244743900.1310.031 IronFe55.8415362860200.547.90.4560.109 LeadPb207.22327.5175020.95.00.1300.031 LithiumLi6.941811342137.432.83.5170.840 MagnesiumMg24.326491090194.746.51.03
33、80.248 ManganeseMn54.9312442060152.836.50.4860.116 MercuryHg200.6138.935712.63.00.1380.033 MolybdenumMo96.0261546100.2510.060 NickelNi58.6914552915305.673.00.4520.108 NiobiumNb92.91246747400.2680.064 OsmiumOs190.9303050000.1300.031 PalladiumPd106.715542960150.736.00.2470.059 PhosphorusP31.0444.12792
34、0.95.00.7910.189 PlatinumPt195.2317703830113.027.00.1340.032 PotassiumK39.163.275967.016.00.7540.180 RhodiumRh102.91196637000.2430.058 SiliconSi28.314123270502.4120.00.7290.174 SilverAg107.88961.9216392.122.00.2340.055 SodiumNa23.0097.8883115.127.51.2270.293 StrontiumSr87.6377013750.7370.176 Sulphur
35、S32.0115444.532.79.00.0680.016 TantalumTa180.829805370154.937.00.1420.034 TelluriumTe127.645098831.07.40.1340.032 ThalliumTl20430414730.1300.031 TinSn118.7232262561.114.60.2260.054 TitaniumTi47.916673285376.890.00.5280.126 TungstenW184.033875555167.540.00.1380.033 UraniumU238.2113244000.1170.029 Van
36、adiumV50.9519023410334.980.00.4980.119 ZincZn65.38419.6911110.126.30.3940.094 ZirconiumZr90.6185244000.2890.069 8Foseco Non-Ferrous Foundrymans Handbook The physical properties of metals (Continued) ElementThermal conductivity (W/mK) Resistivity (?ohmcm at 20C) Vol change on melting (%) Density (g/c
37、m3) Coeff of expansion (? 106/K) Brinell hardness no Al2382.676.62.7023.517 Sb23.840.11.46.681130 As33.35.735.6 Ba603.518 Be1943.31.8512 Bi91173.39.8013.49 Cd1037.34.78.643120 Ca1253.71.542213 C16.32.307.9 Ce11.985.46.758 Cr91.313.27.106.5350 Co966.38.9012.5125 Cu3971.694.18.961748 Ga415.9118.3 Au31
38、62.25.219.314.118.5 In808.87.324.81 Ir1475.122.46.8172 Fe7810.15.57.8712.166 Pb3520.63.411.68295.5 Li769.31.50.5356 Mg1564.24.21.742625 Mn7.81607.423 Hg8.7963.7513.5561 Mo1375.710.25.1147 Ni896.98.913.380 Nb54168.67.2 Os878.822.54.6 Pd7510.812.011.050 P1.836.2 Pt7310.621.459.052 K1046.82.80.86830.04
39、 Rh1484.712.48.5156 Si1391031062.347.6 Ag4251.64.510.519.125 Na1284.72.50.97710.1 Sr232.6100 S2722.0770 Ta5813.516.66.540 Te3.816 ? 1056.24 Tl45.516.611.8530 Sn73.212.62.87.323.5 Ti21.6544.58.9 W1745.419.34.5 U282719.0 V31.619.66.18.3 Zn1206.06.57.143135 Zr22.6446.495.9 Tables and general data9 Dens
40、ities of casting alloys AlloyBS1490 g/mlAlloyBS1400 g/ml Aluminium alloysCopper alloys Pure Al2.70HC copperHCC18.9 AlSi5Cu3LM42.75Brass CuZn38AlDCB18.5 AlSi7MgLM252.68CuZn33Pb2SiHTB18.5 AlSi8Cu3FeLM242.79CuZn33Pb2SCB38.5 AlSi12LM62.65Phosphor bronze CuSn11PPB18.8 Cast steelsCuSn12PB28.7 Low carbon 0
41、.407.84Al bronze CuAl10Fe2AB17.5 Low alloy7.86Gunmetal Med. alloy7.78CuSnPb5Zn5LG28.8 Med./high alloy7.67Copper nickel CuNi30Cr2FeMnSiCN18.8 Stainless 13Cr7.61Cast irons 18Cr8Ni7.75Grey iron 150MPa6.87.1 2007.07.2 Other alloys2507.27.4 Zinc base3007.37.4 ZnAl4Cu16.70Whiteheart malleable7.45 Blackhea
42、rt malleable7.27 Lead baseWhite iron7.70 PbSb610.88Ductile iron (s.g.)7.27.3 Tin base (Babbit)7.34Ni-hard7.67.7 Inconel Ni76Cr188.50High silicon (15%)6.8 10Foseco Non-Ferrous Foundrymans Handbook Approximate bulk densities of common materials Materialkg/m3lb/ft3Materialkg/m3lb/ft3 Aluminium, cast256
43、0160Lead11370710 wrought2675167Limestone25302700158168 Aluminium bronze7610475 Ashes59037Magnesite2530158 Mercury13560847 Brass, rolled8390524Monel8870554 swarf2500157 Babbit metal7270454Nickel, cast8270516 Brick, common1360189085118Nickel silver8270516 fireclay1840115 Bronze8550534Phosphor bronze85
44、80536 Pig iron, mean4800300 Cast iron, solid7210450Pig iron and scrap turnings2240140(cupola charge)5400336 Cement, loose136085 Chalk2240140Sand, moulding120014407590 Charcoal, lump29018silica136014408590 Clay19002200120135Silver, cast10500656 Coal96012806080Steel7850490 Coal dust85053 Coke45028Tin7
45、260453 Concrete2240140 Copper, cast8780548Water, ice94058.7 Cupola slag2400150liquid 0C100062.4 100C95559.6 Dolomite2680167Wood, balsa10013078 oak83052 Fire clay144090pine48030 French chalk2600162teak64040 Wrought iron7700480 Glass2230139 Gold, pure192001200Zinc, cast6860428 22 carat175001090rolled7
46、180448 Graphite, powder48030 solid2200138 Tables and general data11 Patternmakers contraction allowances Castings are always smaller in dimensions than the pattern from which they are made, because as the metal cools from its solidification temperature to room temperature, thermal contraction occurs
47、. Patternmakers allow for this contraction by making patterns larger in dimensions than the required castings by an amount known as the “contraction allowance”. Originally this was done by making use of specially engraved rules, known as “contraction rules”, the dimensions of which incorporated a co
48、ntraction allowance such as 1 in 75 for aluminium alloys, or 1 in 96 for iron castings. Nowadays, most patterns and coreboxes are made using computer- controlled machine tools and it is more convenient to express the contraction as a percentage allowance. Predicting casting contraction can never be
49、precise, since many factors are involved in determining the exact amount of contraction that occurs. For example, when iron castings are made in greensand moulds, the mould walls may move under the pressure of the liquid metal, causing expansion of the mould cavity, thus compensating for some of the metal contraction. Cored castings may not contract as much as expected, because the presence of a strong core may restrict movement of the casting as