1: Introduction History of Casting; Foundry Industry 2: Patterns Introduction to Patternmaking; Types of Patterns; Pattern Allowances; Function of Patterns; Core Boxes; Rapid Prototyping; Application of CAD to Pattern and Core Making 3: Casting Processes Reusable Molds; Molds that are destroyed after making castings; Green Sand Process; Cores 4: Solidification of Metals Freezing of Pure Materials; Freezing of Alloys; Other Properties Related to Solidification 5: Gating & Risering of Castings Gating System; Design of Gating System; Risers 6: Casting Process Solidification Casting Process Simulation 7: Aluminum & Aluminum Alloys Physical Metallurgy; Melting & Melt Handling; Casting Characteristics; Heat Treatment; Mechanical and Physical Properties; Post Casting Operations Ch. 8: Copper & Copper Alloys Physical Metallurgy; Melting & Melt Handling; Heat Treatment; Mechanical & Physical Properties; Post Casting Ops Ch. 9: Magnesium & Magnesium Alloys Physical Metallurgy; Melting & Melt Handling; Heat Treatment; Mechanical and Physical Properties Ch. 10: Zinc & Zinc Alloys Physical Metallurgy; Melting & Melt Handling; Mechanical/ Physical Properties Ch. 11: Cast Iron Melting and Melt Handling; Change Materials; Pouring Practices; Solid State Transformation; Post Casting Foundry Operations; Mechanical and Physical Properties; Casting Design Considerations Ch. 12: Steel Castings Physical Metallurgy; Melting & Pouring of Steel; Heat Treatment; Post Casting Operations; Machining and Welding; Nondestructive Examinations; Troubleshooting Ch. 13: Cleaning and Inspection Cleaning Operations & Equipment; Inspection of Castings Ch. 14: Casting Defects Defect Analysis; Processing Cycle and Defect Formation; Root Cause Evaluation; Corrective Actions; Scrap Reporting; Typical Defect Analysis Charts
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.