福士科(Foseco)公司有色金属铸造手册(上).pdf
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1、 Foseco Non-Ferrous Foundrymans Handbook Foseco Non-Ferrous Foundrymans Handbook Eleventh edition Revised and edited by John R. Brown OXFORDAUCKLANDBOSTONJOHANNESBURGMELBOURNENEW DELHI Preface The last edition of the Handbook was published in 1994 and like all the earlier editions, it aimed to provi
2、de a practical reference book for all those involved in making castings in any of the commonly used alloys by any of the usual moulding methods. In order to keep the Handbook to a reasonable size, it was not possible to deal with all the common casting alloys in detail. Since 1994 the technology of
3、casting has continued to develop and has become more specialised so that it has been decided to publish the 11th edition of the Handbook in three separate volumes: Non-ferrousdealing with aluminium, copper and magnesium casting alloys Irondealing with grey, ductile and special purpose cast irons Ste
4、eldealing with carbon, low alloy and high alloy steels Certain chapters (with slight modifications) are common to all three volumes: these chapters include tables and general data, sands and sand bonding systems, resin bonded sand, sodium silicate bonded sand and feeding systems. The remaining chapt
5、ers have been written specifically for each volume. The Handbook refers to many Foseco products. Not all of the products are available in every country and in a few cases, product names may vary. Users should always contact their local Foseco company to check whether a particular product or its equi
6、valent is available. The Foseco logo and all product names appearing in capital letters are trademarks of the Foseco group of companies, used under licence. John R. Brown Preface Acknowledgements. 1 Tables and general data1. SI units and their relation to other units1. SI, metric, non-SI and non-met
7、ric conversions2 Conversion table of stress values5 Areas and volumes of circles, spheres, cylinders etc.6. The physical properties of metals7 The physical properties of metals (Continued)8 Densities of casting alloys9. Approximate bulk densities of common materials10. Patternmakers contraction allo
8、wances11. Volume shrinkage of principal casting alloys13. Comparison of sieve sizes14. Calculation of average grain size15 Calculation of AFS grain fineness number16 Recommended standard colours for patterns17. Dust control in foundries18 Buoyancy forces on cores18. Core print support19 Opening forc
9、es on moulds19. Dimensional tolerances and consistency achieved in castings21. 2 Aluminium casting alloys Introduction Casting alloys25 Casting processes39. The effect of alloying elements39 Heat treatment of aluminium alloys42. 3 Melting aluminium alloys. Introduction Raw materials47 Melting furnac
10、es47 Corundum growth54 Choice of melting unit55 4 Fluxes Application of COVERAL powder fluxes Granular COVERAL fluxes61 5 INSURAL refractory for ladles and metal transport. Ladle liners65 6 Treatment of aluminium alloy melts. Hydrogen gas pick-up in aluminium melts. Degassing aluminium alloys72 Grai
11、n refinement of aluminium alloys77 Modification of aluminium alloys79 Sodium modification81 Strontium modification82. Permanent modification83. Sand, gravity die and low pressure diecasting83 Medium silicon alloys, 4 7% Si84 Eutectic silicon alloys, 12% Si84. Treatment of hypereutectic Al Si alloys
12、(over 16% Si)85. Melting and treatment of aluminium magnesium alloys ( 4 10% Mg)86 Special requirements for gravity diecasting87. Treatment of alloys for pressure diecasting87. 7 Running, gating and feeding aluminium castings75 Gating without filters90 Gating with filters93. Feeding mechanisms in Al
13、 alloy and other non- ferrous castings94. Simulation modelling98. 8 Filtration of aluminium alloy castings SIVEX FC filters100. Use of filters in conventional running systems101 Direct pouring of aluminium alloy castings104 KALPUR combined sleeve and SIVEX FC filter for aluminium castings105 Direct
14、pouring into metal dies107 9 Pressure diecasting of aluminium alloys. Die design Process control111 Modification of the diecasting process113. Applications of diecastings114 The diecasting foundry114 Die coating116. 10 Low pressure and gravity diecasting. Low pressure diecasting Gravity diecasting12
15、4 Die coatings for gravity and low pressure diecasting127 11 Sand casting processes. Green sand136 Moulding machines137 Core assembly sand processes140 The Lost Foam process144. 12 Sands and sand bonding systems Properties of silica sand for foundry use. Typical silica foundry sand properties151. Sa
16、fe handling of silica sand152. Segregation of sand153 Measurement of sand properties153. Thermal characteristics of silica sand153 Zircon, ZrSiO4154. Chromite, FeCr2O4156. Olivine, Mg2SiO4156. Green sand additives157. The green sand system160. Green sand properties163. Control of green sand systems1
17、64 Sand testing165. Control graphs165. Parting agents166. Special moulding materials, LUTRON166. 13 Resin bonded sand. Chemically bonded sand. Self-hardening process (also known as self-set, no- bake or cold- setting process) Testing chemically bonded, self-hardening sands169. Mixers171 Sand quality
18、172. Pattern equipment172. Curing temperature173 Design of moulds using self-hardening sand173. Foundry layout173. Sand reclamation175. Typical usage of sand reclamation178 Furanes180. Phenolic-isocyanates (phenolic-urethanes)182. Alkaline phenolic resin, ester hardened183. Heat triggered processes1
19、85 Gas triggered systems186. The shell or Croning process187. Hot-box process189 Warm-box process190 Oil sand191. Phenolic-urethane-amine gassed (cold-box) process193. ECOLOTEC process (alkaline phenolic resin gassed with CO2)195 The SO2 process196. SO2- cured epoxy resin198. Ester-cured alkaline ph
20、enolic system198 Review of resin core-making processes199 14 Sodium silicate bonded sand Sodium silicate CO2 silicate process ( basic process)205. Gassing CO2 cores and moulds207 Improvements to the CO2 silicate process208 The CARSIL range of silicate binders209. SOLOSIL209. Self-setting sodium sili
21、cate processes210. Ester silicate process210. Adhesives and sealants215. CORSEAL sealants215. TAK sealant215. 15 Magnesium casting Casting alloys The melting, treatment and casting of magnesium alloys218. 16 Copper and copper alloy castings The main copper alloys and their applications Specification
22、s for copper-based alloys226 Colour code for ingots227. Melting copper and copper-based alloys232. Melting and treatment of high conductivity copper238 Copper-silver242. Copper cadmium243 Copper chromium243. Commercial copper243. Melting and treatment of brasses, copper zinc alloys244. Melting bronz
23、es and gunmetals248. Melting aluminium bronze250 Melting manganese bronze250. Melting high lead bronze250. Melting copper nickel alloys251 Filtration of copper-based alloys251 17 Feeding systems. Natural feeders Aided feeders253 Feeding systems254. The calculation of feeder dimensions257 Steel, mall
24、eable iron, white irons, light alloys and copper- based alloy castings262 Grey and ductile irons266 Introduction268 Range of feeder products269 Breaker cores279 The application of feeder sleeves280 Williams Cores283. FERRUX anti-piping compounds for iron and steel castings284. Metal-producing top su
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