Basic fundamental of Foundry practices manual

The purpose of this manual is to introduce the basic concepts of the foundry applications and good practices in the foundry operation to achieve acceptable as-cast casting quality.

1. Pattern & Core boxes preparation.

2. Mold and core making practices.

3. Mold and Core wash coating application .

4. Mold assembly practices.

5. Melting and tapping practices.

6. Fettling practices.

Basic fundamental of foundry practices and examples are as follow:-

Basic fundamental of foundry practices manual –

铸造厂基本操作指南

Core making practices - 制芯的操作

Mold making practices

造型的操作

Mold assembly Practices

合箱的操作

Chills method 安置冷铁

的方法

Core repair Practices修补型芯

的操作

Melting Practices

熔炼的操作

Core dressing修饰型芯

的操作

Casting cleaning

and inspection铸件的清理

和检查

Motor bracket good practice马达架的操作

Pattern & Core boxes preparation. 木型和芯盒的准备工作。

Pattern not maintained and strip coated leading to casting surface irregularly & dimension inaccuracy defects.

木型没有维护以及脱模剂剥落导致：铸件表面出现瑕疵，表面不规则，尺寸不标准。

Pattern is regularly maintained and spry coated.

维持木型的保养：修补损坏的部位，并且经常涂上脱模剂，以保持木型的寿命和铸件的外观尺寸标准。

Good practices 优良的操作 Bad practices 不良的操作

Core box not maintained and strip coated leading to casting surface irregularly & dimension inaccuracy defects.

芯盒没有维护以及脱模剂剥落导致铸件表面出现瑕疵。

例如：表面不规则，尺寸不标准。

Core box is regularly maintained and spray coated.

维持芯盒的保养：修补损坏的部位并且经常涂上脱模剂以保持芯盒的寿命和铸件的尺寸标准。

Good practices 优良的操作 Bad practices 不良的操作

Pattern & Core boxes preparation. 木型和芯盒的准备工作。

Down gates are secured and aligned with metal rod to prevent sagging.

用金属棒巩固内浇道管以防止下垂。

Securing and positioning of down gates. 内浇道的巩固和安置。

Good practices 优良的操作 Bad practices 不良的操作Down gates are not properly aligned will cause interrupted metal flow leading to casting misruns, blow holes and inclusions defects.

内浇道管未适当地被排列，将导致铁水流程不流通造成铸件瑕疵。例如：浇不足 ， 气孔，夹杂物等。

Down gate locating pad practices. 塑料衬垫的应用

Good practices 优良的操作 Bad practices 不良的操作

Locating pads are in used to prevent sand from entering, casting break-in.

放置塑料衬垫于陶瓷管与木型的交界处能防止在填砂时砂子的进入， 以及清理时毁坏铸件。

No locating pads been used will results in casting sand inclusions and break-in defects.

没有安置塑料衬垫将导致铸件瑕疵。

例如：砂眼，铸件表面破损。

Tools for removal of loose piece. 撤去活块的工具

Bad practices 不良的操作Good practices 优良的操作Loose piece is fixed with a puller plate to be

attached by a traded stripping tool for removal of loose to prevent damaged.

在活块装置螺栓，在起模后拆除时就不会造成损坏。

Screw type stripping tools will damaged the loose piece.

用螺丝钉拆除木型的活块，将损坏活块。

Down gate was taped to prevent movement during mold filling.

在填砂期间，用胶带粘住内浇道管以防止移动。

Down gates are not properly secured will result in misplacement during mold filling leading to casting misruns, blow holes and inclusions defects.

在填砂期间，内浇道管未适当地被巩固，将导致移位造成铸件瑕疵。例如：浇不足 ， 气孔，夹杂物等。

Good practices 优良的操作 Bad practices 不良的操作

Securing of down gate practices. 巩固内浇道管的操作

Good practices 优良的操作 Bad practices 不良的操作

Down sprue are secured with sprue guide to prevent movement during mold filling and misalignment with pouring basin sprue.

在填砂期间，用直浇道管导标巩固直浇道，以防止移位而不能和浇口杯吻合。

Down sprue is no secured which will cause misalignment with pouring basin sprue causing chocking during pouring leading to casting blow holes, slag inclusions, misruns & etc defects.

不适当的安置直浇道管将导致和浇口杯不能吻合，浇口杯阻塞造成铸件瑕疵。例如：气孔，夹渣，浇不足等等。

Down sprue guide. 直浇道管导标

Good practices 优良的操作Bad practices 不良的操作

Core is well strengthen with sufficient reinforcement of gagger placement to prevent core breakage and sagging.

安置铁骨能充足的支撑芯子以防止芯子破损和下垂。

Insufficient reinforcement of gagger placement in the core resulting weak core and strength leading to casting warped, dimension inaccuracy, core dropped & etc defects.

芯子的铁骨安置不足会导致芯子松懈造成铸件瑕疵。例如：铸件偏倾，尺寸不准确，芯子 下坠等等。

Gagger placement practice. 安置铁骨的操作

Good practices 优良的操作 Bad practices 不良的操作

Hook guide. 吊勾的导标

Core hooks are properly position with hook guide to prevent movement during core making.

吊勾被适当地安置在吊勾的导标上。

No hook guide to position core hook will cause core off centering for handling and assembly results in casting defect caused by sand dropped.

没有在芯盒上制定吊勾的导标，吊勾随意的安置将导致芯子吊起时不能平衡，在造型时造成砂子掉落。

Mold and core making practices. 砂型和芯子的操作。

Good practices 优良的操作

Text vents are extensively used and neatly laid through core prints.

排气绳应广泛地使用和整齐的放置。

Bad practices 不良的操作

Insufficient text vents for gas venting leading to casting blow holes defects.

排气绳不足够将导致铸件瑕疵。例如：气孔。

Only one text vent

Good practices 优良的操作 Bad practices 不良的操作

Hook and chain are used for better core handling.

使用铁勾和铁链能更好的吊起芯子。

Rope go through the core rib will damage core surface result in casting appearance imperfection & sand dropped defects.

钢索穿击筋板内腔将导致铸件出现瑕疵。

例如：表面不完整和砂子掉落。

Proper ways of hooking the core. 吊芯子的正确方法

Good practices 优良的操作 Bad practices 不良的操作

Core surface, corner and radius are well defined.

Core surface, corner and radius are not well defined result in casting appearance imperfection defects.

芯子表面，边缘和角度都完整无缺。 芯子表面，边缘和角度不完整将造成铸件表面有瑕疵 。

Compaction of sand core. 制造结实的芯子

Chaplet used should be free of rust. 不可使用生锈的芯撑。

Clean chaplet used

使用干净的芯撑。

Rusty chaplet is not acceptable will cause blow holes in casting.

使用生锈的芯撑将产生气孔。

Good practices 优良的操作 Bad practices 不良的操作

Correct way of securing the chaplet with the plate bended.

弯曲芯撑的一角以牢固芯子。

Wrong way of chaplets placement as the plate is not bended will results in casting chaplet dropped defects.

没有弯曲一角的芯撑会松落，导致芯子移位。

How to secure a chaplet? 如何牢固芯撑？

Bad practices 不良的操作Good practices 优良的操作

Always used single chaplet with the correct size.

使用一个正确尺寸的芯撑。

Wrong way of chaplets placement. Different chaplets size used instead of single chaplet leading to casting chaplet dropped defects.

同时使用多个芯撑， 会造成芯撑松落，导致芯子移位。

Core chaplet placement practices . 芯撑的安置。

Good practices 优良的操作 Bad practices 不良的操作

Good practices 优良的操作 Bad practices 不良的操作

Chaplets placed at the bottom are nailed.

在底部的芯子安置铁钉式芯撑。

Chaplets are not nailed and secured will results in casting chaplet dropped defects.

不用铁钉式芯撑将导致芯撑掉落。

Placement of bottom chaplets practices. 芯撑的安置。

Used furan sand for patching and torching.

使用树脂砂修型后必须烘烤。

Correct way of patching and repairs of core. 修补芯子的正确方法。

Wrong way of repairing core by using mold wash material for repairing, with the risk that casting will contain blow holes defects.

使用砂型涂料修补芯子，将造成铸件产生气孔。

Good practices 优良的操作 Bad practices 不良的操作

Good practices 优良的操作 Bad practices 不良的操作

Broken core was glued and secured with nails.

使用封箱膏修补毁坏的芯子再用铁钉牢固芯子。

Broken core was not properly secured and exposed core glue will results in casting sand dropped, bad appearance and blow holes defects.

未适当地修补毁坏的芯子；封箱膏露出芯子外面将导致铸件瑕疵。

例如：砂子掉落，铸件表面粗劣和 产生气孔。

Securing of broken core with nails. 用钉子牢固修补后的芯子。

Always check core height using a straight rule.

每一个芯子固定后，务必使用一个平直的木板检查芯子的水平。

Good practices 优良的操作 Bad practices 不良的操作

Cores height are not checked will results in casting dimension deviations defects.

没有检查芯子的水平将导致铸件尺寸不准确。

Checking of core height. 芯子的水平检查。

Torching the core after mold washing to ensure it is thoroughly dried.

在重新涂型后必须再一次烘烤。

Core was not torched after recoating with mold wash still damped will lead to casting blow holes and inclusions defects.

在重新涂型后未再一次烘烤芯子，芯子也许仍然有湿气。

Bad practices 不良的操作

Good practices 优良的操作

Torching of core after recoating practices. 重新涂型后的烘烤。

Good practices 优良的操作 Bad practices 不良的操作

Compaction of sand at down tube area . 在内浇道部位紧实地舂砂。

Good compaction of sand at down gate areas to prevent loose sand.

在内浇道部位紧实地舂砂以防止砂子脱落。

Poorly compact sand at down gate area causes loose sand results in casting sand dropped and metal penetration defects.

砂子不紧实将造成砂子脱落以及铸件粘砂。

Bad practices 不良的操作

Good practices 优良的操作

Ribs are well molded and defined.

芯筋内腔部位塑造得完整无缺。

Ribs are badly molded with core fins will results in casting appearance imperfection and fine crack lines defects.

芯筋内腔不完整将导致铸件不完整和裂缝。

Core appearance. 芯子的外观。

Bad practices 不良的操作Good practices 优良的操作

Cores are neatly arranged and displayed.

整齐的排列芯子在底板上。

Poor placement of cores on base board with sand on it.

Loose sand will stick to the core during mold washing will results in casting sand dropped defects.

安置芯子在附有砂子的底板上，涂型料时底板上的散砂会粘着芯子导致铸件瑕疵。例如：砂子掉落。

Placement of core on base board. 在底板上安置芯子。

Applied sufficient amount core glue.

使用适当数量的封箱膏。

Excessive core glue been used and if it’s not completely dried, with the risk that casting will contain blow holes defects.

使用过量的封箱膏，由于封箱膏不完全干，可能导致气孔的产生。

Good practices 优良的操作 Bad practices 不良的操作

Gluing of loose core practices. 封箱膏的应用。

Gluing of core and right type of materials used. 使用适当足量的封箱膏（泥）。

Bad practices 不良的操作

Good practices 优良的操作Applied sufficient of core sealant.

使用适当足量的封箱膏。

Excessive core glue applied will results in casting blow holes defects. Preferable, sealant should be in used.

过量的封箱膏将导致铸件瑕疵。

例如：气孔。

Bad practices 不良的操作Good practices 优良的操作

Using a cast sand core about 5〜 7mm for chills placement so that the thickness is controlled.

用砂子制作一个大约 5 〜 7mm 的砂子底板放置冷铁，使木型与冷铁的间隙厚度一致。

Inconsistent of sand thickness for this type of indirect chills placement will results in casting microstructure problem and low hardness defects.

冷铁安置在厚度不均衡的砂子上将导致铸件瑕疵。

例如：粗分子和低硬度。

Indirect chills placement practices. 间接性的冷铁安置。

Mould coating practices. 正确的砂模涂型。

Bad practices 不良的操作Good practices 优良的操作

The operator used cardboard to step while mold washing.

用纸板铺在已经刷涂料的模型上工作。

No cardboard been used as the shoes will damage the mold surface leading to bad casting appearance defects.

鞋子跨在没有铺纸板的模型上将毁坏模型表面以导致铸件外观粗糙。

Bad practices 不良的操作Good practices 优良的操作

Filling of vent channel practice, example 1. 排气孔沟槽的填装。

Fine stones about 5 to 10mm in size used for filling the gas vent channels thus allowing core gases to disperse freely and speedily through the cope vent for better permeability.

使用大约 5到 10mm大小的石子填装在排气孔沟槽会发挥更好的透气性。

Poor permeability due to gas vent channels are filled with fine sands which prevented the gases to disperse freely and speedily through the cope vent, with the risk that casting contain blow holes defects.

用细砂子填装在芯子排气孔沟槽将使气体不能迅速通过上箱排气孔排出导致透气性不良。

Filling of vent channel practice, example 2. 排气孔沟槽的填装。

Bad practices 不良的操作Good practices 优良的操作

Fine stones about 5 to 10mm in size used for filling the core gas vent thus allowing core gases to disperse freely and speedily through the cope vent for better permeability.

使用大约 5到 10mm大小的石子填装排气孔沟槽会发挥更好的透气性。

Poor permeability due to core gas vent routes are filled with fine sands which prevented the gases to disperse freely and speedily through the cope vent, with the risk that casting contain blow holes defects. 用细砂子填装在芯子排气孔沟槽将使气体不能迅速通过上箱排气孔排出导致透气性不良。

Bad practices 不良的操作Good practices 优良的操作

Applied sufficient amount of core glue.

使用适当数量的封箱膏（泥）。Excessive core glue been used and if it’s not completely dried, with the risk that casting will contain blow holes defects.

过量使用封箱膏（泥），由于封箱膏（泥）不完全干，可能导致气孔的产生。

Applying core glue practices, example 1. 封箱膏（泥）的应用。

Excessive glue was squeezed out from core, with the risk that casting will contain blow holes defects.

过量的封箱膏（泥），会造成气孔缺陷。

Bad practices 不良的操作Good practices 优良的操作

No excessive glue was squeezed out from the core.

芯子固定后，没有过量的封箱膏溢出。

Applying core glue practices, example 2. 封箱膏（泥）的应用。

Blowing of down gate clearance. 内浇道的清理。

Bad practices 不良的操作Good practices 优良的操作

Downgates are checked by blowing with the compress air to ensure no blockage and loose sand in it.

通过压缩吹气清理内浇道的砂子以防止通道堵塞。

Downgate not check with loose sand in it, with the risk that casting will contain sand inclusions, blow holes and cold shut defects.

不清理内浇道的砂子将导致铸件瑕疵。例如：内浇道堵塞，夹砂和冷隔。

Bad practices 不良的操作Good practices 优良的操作

Proper way to support core with fixture. 正确的使用固定物支持与安置芯子

Core is properly support with fixture.

以固定物支持与安置芯子。Wrong way of placement and supporting the core will results core sagging, with the risk that casting will contain dimension deviation defects.

错误地安置芯子将导致芯子下垂，铸件

尺寸不标准。

Bad practices 不良的操作Good practices 优良的操作

Ceramic fiber cloth is in used to seal undersize core print to prevent thick fins.

陶瓷纤维布料用于密封比一般小的核心印刷品防止厚实的飞翅。

Gap at core print not properly sealed will results thick fins thus grinding will be difficult.

空白在核心印刷品不适当地被密封的意志结果厚实的飞翅因而研将是困难的。

Core print gap sealing practice. 芯头间隙的封合

Bad practices 不良的操作Good practices 优良的操作

Core are designed with prints so that cope rope can be easily laid and gas venting are properly been sealed between core and cope vents.

精密的芯头设计，以使封箱绳可以顺利地被安置，并且排气绳也适当地被密封在芯子和排气孔之间。

Core with no prints designed will have difficulty in laying cope rope and sealing of gas venting, with the risk that casting will contain blow holes and inclusions defects.

没有芯头的芯子不能准确的排例封箱绳和排气绳，这将导致气孔和砂眼的产生。

Core designed practices. 芯子的设计。

Bad practices 不良的操作Good practices 优良的操作

Chaplet appearances 外观 - 1

Chaplet has been ground flat

芯撑必须被彻底磨平。

Chaplets mark and nails have not been ground result in bad appearance on casting.

芯撑与铁钉没有彻底磨平， 造成铸件外观不良。Remedies 改善 :

Inspect before pray painting.

喷漆前先检查外观。

Chaplet appearances 外观 - 2

Bad practices 不良的操作Good practices 优良的操作

Nail on the chaplet has been ground.

钉子必须被彻底磨平。

Nail on the chaplet has not been removed. Bed appearance on casting

在芯撑上的钉子没彻底磨平，造成铸件外观不良。

Inspect before pray painting.

喷漆前先检查外观。

Remedies 改善 :

Veining defects on casting

Bad practices 不良的操作Good practices 优良的操作

Good casting appearance, no veining defects.

没有披缝的良好铸件。

Bad casting appearance, veining defect has not been removed.

披缝没彻底磨平。

Check core ramming, coating drying and ensure pouring after 24hrs.

舂砂必须紧实， 砂型涂料必须干燥，在合箱后在 24 个小时以后才能浇注。

Remedies 改善 :

成脉络的瑕疵在铸件

Core hole fins defect

Bad practices 不良的操作Good practices 优良的操作

Good casting appearance, core hole free from fins

芯孔没有任何披缝。

Bad casting appearance, core hole fins has not been removed.

芯孔的披缝已完全去除。

Verify core box window print and assembly process.

检验芯盒与合箱的操作。

Remedies 改善 :

芯孔披缝的问题

Paint with sand defect

Bad practices 不良的操作Good practices 优良的操作

Good casting appearance, paint without sand defect.

油漆后的铸件没有粘砂问题。

Bad casting appearance, paint with sand defect. Due to sand not been removed before pray painting.

油漆后的铸件出现粘砂问题。

Remedies 改善 :

Inspect before pray painting.

喷漆前先检查外观。

油漆以沙子瑕疵

Bad practices 不良的操作Good practices 优良的操作

Good casting appearance, no core fins on the rib.

铸件的筋骨部位没有披缝问题。

Bad casting appearance, rib with core fins not repair.

铸件的筋骨部位不顽症。Remedies 改善 :Check core box condition and inspection casting before spray painting.

检查芯盒的状况以及在喷漆之前先检查铸件的外观。