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Foseco Ferrous Foundryman’s Handbook
Foseco Ferrous
Foundryman’s Handbook
Edited by
John R. Brown
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
85268333.001.png
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 01801-2041
A division of Reed Educational and Professional Publishing Ltd
A member of the Reed Elsevier plc group
First published 2000
© Foseco International Ltd 2000
All rights reserved. No part of this publication
may be reproduced in any material form (including
photocopying or storing in any medium by electronic
means and whether or not transiently or incidentally
to some other use of this publication) without the
written permission of the copyright holder except
in accordance with the provisions of the Copyright,
Designs and Patents Act 1988 or under the terms of a
licence issued by the Copyright Licensing Agency Ltd,
90 Tottenham Court Road, London, England W1P 9HE.
Applications for the copyright holder’s written permission
to reproduce any part of this publication should be
addressed to the publishers
British Library Cataloguing in Publication Data
Brown, John R.
Foseco ferrous foundryman’s handbook.
1. Founding – Handbooks, manuals, etc.
I Title II Foseco International III Foundryman’s handbook
671.2
Library of Congress Cataloguing in Publication Data
Foseco ferrous foundryman’s handbook/revised and edited by John R. Brown.
p. cm.
Includes index.
ISBN 0 7506 4284 X
1 Founding – Handbooks, manuals, etc.
2 Iron founding – Handbooks,
manuals, etc.
3 Cast-iron – Handbooks, manuals, etc.
I Title: Ferrous
foundryman’s handbook II Brown John R.
TS235 F35 2000
672.2–dc21
00-033679
ISBN 0 7506 4284 X
Typeset at Replika Press Pvt Ltd, Delhi 110 040, India
Printed and bound in Great Britain
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Contents
Preface
xi
Acknowledgements
xii
Chapter 1 Tables and general data
1
SI units and their relation to other units
1
SI, metric, non-SI and non-metric conversions
2
Conversion table of stress values
5
Areas and volumes of circles, spheres, cylinders etc.
6
The physical properties of metals
7
Densities of casting alloys
9
Approximate bulk densities of common materials
10
Patternmakers’ contraction allowances
11
Volume shrinkage of principal casting alloys
13
Comparison of sieve sizes
14
Calculation of average grain size
15
Calculation of AFS grain fineness number
16
Recommended standard colours for patterns
17
Dust control in foundries
18
Buoyancy forces on cores
18
Opening forces on moulds
19
Dimensional tolerances and consistency achieved in castings
21
Chapter 2 Types of cast iron
23
Introduction
23
Physical properties of cast irons
27
Iron casting processes
28
Chapter 3 Grey cast iron
30
Specifications
30
Relationship between composition, strength and structure of
grey cast iron
32
Applications of grey iron castings
37
The production of grey irons
37
vi Contents
Chapter 4 Melting cast iron
40
Introduction
40
Cupola melting
40
Electric melting
53
Shop floor control of metal composition
60
Chapter 5 Inoculation of grey cast iron
62
Introduction
62
Ladle inoculation
64
Late stream inoculation
66
Mould inoculation
69
Chapter 6 Ductile iron
70
Production of ductile iron
70
Melting ductile iron base
74
Cupola melting and duplexing
74
Induction furnace melting
75
Use of the tundish cover ladle
75
Sandwich treatment
77
NODULANT
77
Pure magnesium converter process
77
Cored wire treatment
78
In-the-mould treatment
78
Inhibiting elements
78
Inoculation and fading
79
Specifications for ductile cast iron
79
Heat treatment of ductile iron
82
Casting ductile iron
84
Compacted graphite irons
84
Chapter 7 Malleable cast iron
90
Introduction
90
Whiteheart malleable
90
Blackheart malleable iron
92
Chapter 8 Special purpose cast irons
95
Heat resisting alloys
95
Corrosion resistant cast irons
101
Wear resistant cast irons
102

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