Alloy — A substance containing two or more chemical
elements, at least one of which is metal. The substance
usually has metallic properties and possesses qualities
different from those of the individual components.
AOD — A
refining treatment used to control the carbon content
of steel.
Binders — Binders are added to mold materials
in order to create a mold of sufficient hardness. Binders
can be
either organic or inorganic materials.
CAD — Computer
Aided Design.
CAM — Computer Aided Manufacturing.
Captive Foundry — A
foundry operation that is wholly incorporated into a larger
manufacturing operation. A
captive foundry only produces castings for the operation
that it
is a part of.
Casting — A process used to form solid
metal shapes out of molten metal. The molten metal is
poured into a
cavity or a mold.
Charge — Metal and alloy materials
that make up the composition of a melt.
Cope — The top
half of a horizontally parted mold.
Core — The part
of a mold used in the casting process that forms the internal
shapes of a casting.
Crucible Furnace — A furnace that melts
metals in a refractory crucible. The furnace is typically
fueled
with coke, oil, gas or electricity.
Cupola Furnace — The traditional furnace
used for melting metal. The furnace is typically fueled
with
coke.
Direct-Arc Furnace — An electric arc furnace in
which the metal being melted is one of the poles.
Draft — Taper on the vertical sides of a pattern
or corebox that permits the core or pattern to be removed
without distorting or tearing of the sand.
Drag — The bottom half of a horizontally parted
mold.
Ferrous Metal — An alloy that has iron
as the predominant metal.
Flash — A thin section of metal formed at the
mold, core, die joint or parting in a casting. Flash
usually forms when the cope and drag do not match completely
or when the core and the coreprint do not match.
Gas Porosity — A condition in a casting
that occurs when gas is trapped in molten metal or as
a result of
mold gasses that evolved when the casting was poured.
Gating Systems — The channel(s) that allow
the molten metal to enter the mold cavity.
Green Sand — Moist sand that is bonded
by a mixture that contains silica, bentonite clay, carbonaceous
material,
and water.
Gross Weight of Casting — The weight of
the casting which includes the actual product plus the
metal in
the gating system as poured.
Hot Isostatic Pressing (HIP) — The process
of using high hydrostatic pressure and high temperature
to compress fine particles into coherent parts.
Impurity — An element that is allowed into a metal
or alloy. Impurities slightly change the properties
of the material in some circumstances and can completely
damage it in others.
Inclusion — Nonmetallic materials that become
part of a metal matrix usually through reoxidation,
refractories, slag, and deoxidization products.
Indirect-Arc Furnace — An alternating current
electric-arc furnace. The metal being melted is not
one of the poles.
Induction Furnace — An alternating current melting
furnace that uses the heat of electrical induction.
Investment Casting — A casting process that uses
a wax or thermoplastic pattern and is surrounded in
a refractory slurry to form a mold. Once the refractory
slurry is dry, the wax or plastic is melted out and
the mold is formed. Molten metal is then poured in to
fill the area that was previously filled with wax.
Jobbing Foundry — A foundry that creates a wide
variety of castings, in small quantities for a range
of customers.
Ladle — The name for a variety of receptacles
used to move and pour molten metal during the casting
process.
Lining — The refractory layer of firebrick, clay,
sand or other materials that coat the inside of a furnace
or ladle.
Lost Foam Process — A casting process that uses
foam to form the pattern. The foam is eventually melted
out of the mold when the molten metal is poured in.
Metal Yield — The difference between the
weight of a finished casting and the total weight of
the metal
poured.
Mold — The cavity that the molten metal is poured
in to form the final shape. A mold usually consists
of a top and bottom piece made of sand or ceramic material.
Net Weight of Casting — The final weight
of a casting that is determined once all of the excess
metal
from the gating system has been removed.
Non-ferrous Metal — An alloy that doesn’t
have iron as the predominant metal.
Oxidation Losses — The loss of metal or
alloy through the process of oxidation.
Oxidizing Atmosphere — Furnace atmosphere
which gives off oxygen under certain conditions or where
there
is an excess of oxygen in the product of combustion,
or the products of combustion are oxidizing to the metal
being heated.
Pattern — The wood, metal, foam or plastic replica
of the final product to be made. Patterns usually include
gating systems.
Pattern Draft — The taper allowed on the
vertical faces of a pattern to enable removal of the
mold or
die.
Pigging — Pouring molten metal back into lined
containers so that it can be returned to the furnace.
Rapid Prototyping — The computerized equipment
that builds a three-dimensional model of a casting from
a CAD drawing.
Reducing atmosphere — Furnace atmosphere which
absorbs oxygen under suitable conditions or in which
there is insufficient air to completely burn the fuel,
or the product of combustion is reducing to the metal
being heated.
Sand Casting — Producing metal castings out of
sand molds.
Sand Reclamation — Processing used sand grains
into usable forms so that they can be used in the casting
process as a replacement for new sand.
Scrap — All non-product metal produced during
the casting process.
Shell Molding — Bringing a resin-bonded
sand mixture into contact with a pre-heated metal pattern
to form
a mold.
Shell Process — The process in which clay-free
silica sand coated with a thermostatic resin or mixed
with resin is placed on a heated metal pattern for a
short period of time to form a partially hardened shell.
The bulk of the sand mixture inside the resulting shell
is removed for further use. The pattern and shell are
heated further to harden or polymerize the resin-sand
mix, and the shell is removed from the pattern. Frequently,
shell cores are made using this process.
Shotblasting — A process for cleaning castings
that involves using a metal abrasive that is propelled
by centrifugal or air force.
Shrinkage — The reduction in the volume of metal
that occurs as it solidifies.
Shrink Hole — A cavity that forms in a metal part
when there was not enough source metal fed into the
mold during the casting process.
Slag — A film that forms on top of molten metal
as a result of impurities. Slag is composed of non-metal
elements.
Slag Inclusions — Imperfections of the
surface of metal caused by slag (impurities in the molten
mix).
Slurry — The watery mixture such as the gypsum
mixture for plaster molding, the molding medium used
for investment casting, core dips, and mold washes.
Sprue — The opening in the mold where the metal
is first poured.
V-process — A molding process, developed in Japan,
in which the mold is formed by stretching a sheet of
mylar plastic over a heated metal pattern so that it
conforms to the shape of the pattern. A box of loose
sand is placed over the pattern, and a vacuum is applied
to the sand, which then conforms to the shape of the
mylar film. Thus supported, the sand-backed film is
removed from the pattern and is used as one part of
mold. When the metal is poured, the vacuum is released,
and the loose sand falls away from the casting.
Vacuum Casting — The process of casting that uses
a vacuum to draw molten metal into a mold that is placed
into it.
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