Raw Materials Pre-treatment
- Water - Glass binder: water - glass, sodium silicate is a binder. Concentration up to as much as modulus is also critical. A typical range is 2.2 - 3.0, concentration varying as a matter of requirement in a cast.
Molding Process
- Pattern making: Wooden or metal pattern is made as per design of the component of the heavy machinery. The pattern is made with ideal dimensions as much as a surface quality in order to achieve high quality in cast.
- Molding sand preparation: The water - glass binder is mixed with the molding sand. The water - glass : sand ratio is generally in between 3% - 8% on a weight basis. Additives are also present in order to enhance desirable properties in the sand, i. e., collapsibility, as well as its fluidity.
- Mold Assembly: The patterned moulding sand is packed around the pattern in the mould box in order to form a mould cavity. Cores, as required, are placed into the mould in order to create internal features.
Melting and pouring
- Melting: The molten metal is melted in a furnace, i.e., electric arc furnace or induction furnace. Melting is necessary to be monitored in a systematic way in order to have a suitable chemical composition as well as suitable molten metal temperature. For example, the melting point is around 1450 - 1550°C in case of steel.
- Pouring: The hot metal is poured into a mould cavity once melted at its suitable temperature. The rate at which pouring is conducted as well as pouring temperature are critical. Slow pouring rate can cause cold shuts, whereas defects in terms of porosity are triggered by unsuitable pouring temperature.
Solidification and Cooling
- Solidification: The metal is solidified in a mould once cast. The duration will be a matter of both form as also cast dimensions. The metal is in a state of transition from fluid into solid as it solidifies with its metal form development.
- Cooling: Slow cooling is achieved in a manner that will not cause it to crack as a byproduct. The casting can be allowed cool in mould over a given time, or heat treated after casting in an effort to eliminate stresses.
Post - Processing
- Shakeout: The cast is shaken out from cast in a shakeout once cooled. The shakeout is a procedure which is removing casting from moulding sand.
- Finishing Operations: The cast is then treated with a series of ending operations that entail cutting gates and risers as well as machining. The activities are conducted in a bid to attain the final dimensions as well as surface quality that is necessary in application in heavy - machinery.
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