Table of Contents

1: IntroductionHistory of Casting; Foundry Industry2: PatternsIntroduction to Patternmaking; Types of Patterns; Pattern Allowances; Function of Patterns; Core Boxes; Rapid Prototyping; Application of CAD to Pattern and Core Making3: Casting ProcessesReusable Molds; Molds that are destroyed after making castings; Green Sand Process; Cores4: Solidification of MetalsFreezing of Pure Materials; Freezing of Alloys; Other Properties Related to Solidification5: Gating & Risering of CastingsGating System; Design of Gating System; Risers6: Casting Process SolidificationCasting Process Simulation7: Aluminum & Aluminum AlloysPhysical Metallurgy; Melting & Melt Handling; Casting Characteristics; Heat Treatment; Mechanical and Physical Properties; Post Casting OperationsCh. 8: Copper & Copper AlloysPhysical Metallurgy; Melting & Melt Handling; Heat Treatment; Mechanical & Physical Properties; Post Casting OpsCh. 9: Magnesium & Magnesium AlloysPhysical Metallurgy; Melting & Melt Handling; Heat Treatment; Mechanical and Physical PropertiesCh. 10: Zinc & Zinc AlloysPhysical Metallurgy; Melting & Melt Handling; Mechanical/ Physical PropertiesCh. 11: Cast IronMelting and Melt Handling; Change Materials; Pouring Practices; Solid State Transformation; Post Casting Foundry Operations; Mechanical and Physical Properties; Casting Design ConsiderationsCh. 12: Steel CastingsPhysical Metallurgy; Melting & Pouring of Steel; Heat Treatment; Post Casting Operations; Machining and Welding; Nondestructive Examinations; TroubleshootingCh. 13: Cleaning and InspectionCleaning Operations & Equipment; Inspection of CastingsCh. 14: Casting DefectsDefect Analysis; Processing Cycle and Defect Formation; Root Cause Evaluation; Corrective Actions; Scrap Reporting; Typical Defect Analysis Charts

About the Author

Mahi Sahoo (Ottawa, Ontario, Canada) is a research scientist at Casting Technology Scientiste en Recherche, techniques de moulage. He is the author of two metals titles with American Foundry Society.

Sam Sahu (Waukesha, WI) is manager of metallurgy and technical services at the Waukesha Foundry Co., Inc.