WELCOME

Foundry
Foundry - An Industry manufacturing of casting by meting the metal.

Metals are processed by melting, pouring, and casting. A foundry can be produce castings of metal -ferrous or non-ferrous.

Advantages of Castings
Advantages of casting Process 1. Any complex shape, Any Grade 2. Any size and height 3. Any Special requirement.

Types of Moulding process

Sand casting Shell moulding Pressure Die casting Investment castings Plaster mould castings Centrifugal casting Gravity die casting.

Foundry Process

Enquiry Capability, Difficulty Pattern Development Drawing, Lay out, Pattern making ,methoding Mould & Core making Melting & Pouring Knock out Gas cutting Fettling Inspection

Foundry Process - Enquiry

Capability Size ,Weight ,Shape etc

Difficulty Mould & Core making, Handling, Fettling

Foundry Process Pattern

A master of the object to be produced called as pattern - Negative image of job to be produce. The size of pattern is slightly larger than the finished product..
An appropriately scaled oversize rulercalled a shrink rule -specific to the type of metal to be cast.

Pattern

Shrinkage 2% for CS, 2.5 % for SS Types of Pattern: Wood or Aluminum and Single or Multi pattern

Pattern

Advantages of pattern
Wood Small Qty, Big Size Aluminium Huge Volume, Small Size, Low weight.

Pattern

Methoding: Making a path for metal flow and feeding the metal to all parts of job.
Riser, runner, Chill, Padding ,Gatting, Vent are arranged in a specific way in methoding.

Pattern mounting / storage

Foundry Process Mould Making Process

Molding boxes are Made in segments that may be Latched to each other and To end closures. will be filled with prepared Casting sand or Green sanda slightly moist mixture of sand and clay. The sand is packed in through a vibratory Process called ramming.

Mould Making Process

Types: Co2 process, No bake,

Resin, Ecolotec etc

The Excess & ,un wanted Sand in the Mould are

Removed.
A coating is applied on the mould to act as refectory And to get better surface Finish in casting.

Mould Making Process

Core Making Process

To produce cavity within the casting prepared Casting sand negative forms are used to produce cores. Usually sand-molded, cores are placed into the mould box after removal of the pattern. Whenever possible, designs are made that avoid the use of cores, due to the additional set-up time and thus

greater cost.

Mould Making Process

Foundry Process Melting Process

The process of creating of molten metal in furnace is called as Melting. Type of furnace : 1.Induction 2.Electric 3.Copula

Melting Process Various level

Tapping of metal

Temperature measurement

Ferrous Alloy Addition

Preheating of laddle

The molten metal after reaching desired temperature ( 1550- 1620), addition of alloy & Oxidization, It is tranferred to Laddle. The laddle is one which is used to take the molten metal and pouring the metal in mould

Types of Pouring Process

Molten metal is poured in the readily available mould. It may be Bottom Pouring or Top Pouring

Pouring Process

Foundry Process Pouring

Bottom Pouring Process

Test Bar Pouring

Mould for pouring

When making the mould and core Chill, Kalpad & Sleeves are placed. The mould boxes (Normally - Bottom & Top) are locked after placing the core inside. The runner with pouring cup is available in Top mould . Before closing the top & bottom mould both are heated to remove the available moisture in the mould/ sand.

Knock out
Knock out is the process of separating the Castings from mould.
It is done after 6 -8 Hrs from the pouring time. This time to cool the molten metal to Solid form. If knock out is carried out before sufficient time the castings may having the defect like Warpage, Hot tear, Crack

Gas Cutting
After knock out the Sand and castings seperated by chipping, hammering or Deburring. This is the process of removing the riser , Runner , Ingate and other un necessary part which is required for molten metal flow to form Job.

Fettling
All the riser and runner after gas cutting, it is fettled in Swing grinding process. After that Final fettling is carried out by Hand wheel grinding to remove the Extra Material, Chill, welded area etc

Foundry Process Heat treatment

It shall be carried out heat wise or combination two or three heats.
Done as per the Ref STD/SPEC.

Purpose :
Relief Internal stress developed during casting, forging. Change the grain size, Homogenize the structure to remove segregation. Harden and strengthen the metals Improve machinability

Heat treatment

Foundry Process Inspection

It is in 3 Stage .
First stage Inspection is During gas cutting Second stage is after fettling Final is after heat treatment and final fettling.

II stage Inspection
This is the main One. Visual, MPI/DP, RT will be carried out at this stage. Necessary Welding are carried out and before doing the heat treatment

Final Inspection
In Final Inspection Dimension , Visual , NDT (if required )is carried out .

Investment Casting process

Investment Casting

Used to make a part which can difficult to produce by sand castings.

Eg :such as turbine blade, impeller, Pump cashing, air plane parts etc.

Foundry Process Investment Casting

Die Development Drawing, Lay out, Die Wax Injection Assembly Shell building Dewaxing Pouring Knock out Gas cutting Fettling Inspection

Foundry Process Investment Casting

Wax injection Wax is injected into the cavity to create a wax component. The dies are generally automatic and the injection process is similar to plastic injection

Assembly
The waxes are produced With feeder (through which molten Metal flow). This feeder are then secured to a wax tree to create Wax mould assembly.

Shell Building
The wax mould assembly is now ready to be invested into various slurries and refractories to create a ceramic mould, Strong enough to Withstand molten metal. Slurry is nothing but mixture of plaster of Paris, powered silica, refractory and water.

Shell Building
After the mould buildup is complete (min 6 8 mm thickness), it is then placed inside a stream autoclave which releases the wax from the mould.

Dewaxing
Once the ceramic is dry, the wax is melted to creating a negative impression of the assembly within the shell. This molten metal fired in a furnace at around 1000 C resulting in a high integrity ceramic mould.

Pouring
In the Conventional process the shell is filled with molten metal. As the metal cools, the parts and gates, spure and pouring cup become one solid casting.

Knock out
The mould then solidifies and the ceramic shell is broken off by any Mechanical method. The individual component are removed by cutting through the feeders. The feeders are then dressed back up by finishing and the Components will ready after heat treatment And inspection.

Advantages of investment castings

Freedom of choice in design Suited for Complex and precision component Excellent Surface finish Close tolerance levels Reduced machining cost Cost effective production process Unlimited choice of alloys.

Casting defects

1. Visual defects 2. Surface defects 3. Sub surface defects 4. Volumetric defects 5. Dimensional In accuracy

Visual Defects
The defects which is able to identify with eye and no need any instrument, equipment are required.
Eg : Not formed, poor formation, Rough surface.

Visual Defects

Surface defects
Surface defect : Defect which is open to surface is this category. This can detectable by visually or MPI,DPI.

Eg: Hot tear , Crack, gas hole, Cold shut etc

Sub surface defects

The defects which is not able to identify with eye and can be detectable with any kind of equipments are under this category.
It can be detectable by MPI,RT UT Eg : Gas Cavity, Crack Shrinkage, Inclusion etc

Volumetric Defects
The defects which is observed in center portion of job. It can be detectable by RT, UT Eg : Shrinkage, Void etc

Foundry Process Dimensional Issue Because various operation/parameter in foundry process the dimensional deviation will be there in all casting. Either accept or rework or reject is parameter.
Normal deviation in Foundry is Mismatch, Excess / less fettling, Core movement/ hanging, Contraction problem, Less wall thickness, warpage.

Un acceptable Defects
This kind of defects are not at all Acceptable.
Eg:

Foundry Process Defects

Remedy for defects

Hot tear / Crack It may be because Melt
tepmerature, poor methoding, Heat treatment, Mould harness etc. It can eliminated by Maintaining of Melt temperature, mould hardness providing Chill or Fin, good methoding, Proper Heat treatment.

Remedy for defects

Gas hole/blow hole It may be Because Gating/riser, Poor venting, Moulding.
It can avoided by providing sufficient Vent Size, Proper gating / riser, by Maintaining the Mould parameter.

Remedy for defects

Inclusion It is because low hardness Mould, Gating. It can be Controlled by Maintaining of Mould harness , removing sharp Corners moulds, proper gatting. Pin holes It is because gas absorbed by molten metal, moisture in mould sand. It can be eliminated by Molten metal Property, Good heating in mould / sand to remove moisture.

Remedy for defects

Shrinkage : It may be because Insufficient riser or poor methoding, Mould metal temperature. It can eliminated by Maintaining of Melt temperature, Sufficient feeder in Hot spot / Methoding.

Remedy for defects

Dimension in accuracy: Main cause is Pattern & Fettling. It can be controlled by Maintaining pattern quality ( Finish, dimension, Type of pattern), Controlling of Fettling process.

Remedy for defects

War page / open out: It may be in sufficient strength, HT process, Pattern Proper handling. It can be controlled by Proper reinforcement, Proper handling, Maintaining of pattern.

Grade used in AIL

Carbon steel : WCB,WCC,LCB,LCC No alloy elements Low alloy steel : WC9, WC6
Alloy Elements - 0-5% of alloy elements

Medium alloy steel : C5, C12, CA15...

Alloy Elements 5-10% of alloy elements

Stainless steel : CF8M,CF3M,CF8,CF3

Cr > 11% , Alloy more than 10%

Castings STD
A216 WCB,WCC
A217 WC6,WC9,C5,C12, C12A (9Cr-1Mo- V),CA15 A351 - F8,CF8M,CF3,CF3M,CD3McuN,CF8c A352 LCC,LCB,LC1 A995 4A : 22Cr-5Ni-Mo-N or CD3MN 5A : 25Cr-7Ni-Mo-N or CE3MN

Crack
18 300 WCB Body leak MPK Because of crack

Crack
10 33 Plug valve Body - Crack

Crack
12 33 Plug valve Body - Crack

Crack
24 150 TMBV Connector- Crack

Crack
24 150 TMBV Body - Crack

Blow hole / Gas hole

Blow Hole in 24 600 WCB Body

Blow hole / Gas hole

Blow Hole in 24 600 WCB Body

Blow hole / Gas hole 16 1500 DISC

Blow hole / Gas hole

16 1500 Bracket

Blow Hole/ inclusion

4 900 Check valve cover

Gas hole / Inclusion

6 1500 TMBV Seat ring GrA

Shrinkage cavity

Quality Issues Excess Fettling

8 150 Plug. 24 measure 10 12 mm

Quality Issues Under cut

Bonnet under cut

Excess Material
Gate Ext Bonnet -- Excess Material

Material Identification NIL/ Grounded 4 33 Lower bonnet with out any identification

Core movement
18 300 Ext Bonnet Uneven thickness upto 8 mm