福士科(Foseco)公司钢铁铸造手册(上).pdf
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1、Foseco Ferrous Foundrymans Handbook Foseco Ferrous Foundrymans Handbook Edited by John R. Brown OXFORDAUCKLANDBOSTONJOHANNESBURGMELBOURNENEW DELHI Butterworth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn, MA 01801-2041 A division of Reed Educational and Profession
2、al Publishing Ltd A member of the Reed Elsevier plc group First published 2000 Foseco International Ltd 2000 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or
3、incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, Lo
4、ndon, England W1P 9HE. Applications for the copyright holders written permission to reproduce any part of this publication should be addressed to the publishers British Library Cataloguing in Publication Data Brown, John R. Foseco ferrous foundrymans handbook. 1. Founding Handbooks, manuals, etc. I
5、TitleII Foseco InternationalIII Foundrymans handbook 671.2 Library of Congress Cataloguing in Publication Data Foseco ferrous foundrymans handbook/revised and edited by John R. Brown. p.cm. Includes index. ISBN 0 7506 4284 X 1Founding Handbooks, manuals, etc.2Iron founding Handbooks, manuals, etc.3C
6、ast-iron Handbooks, manuals, etc.ITitle: Ferrous foundrymans handbookII Brown John R. TS235 F35 2000 672.2dc2100-033679 ISBN 0 7506 4284 X Typeset at Replika Press Pvt Ltd, Delhi 110 040, India Printed and bound in Great Britain Contents Prefacexi Acknowledgementsxii Chapter 1 Tables and general dat
7、a1 SI units and their relation to other units1 SI, metric, non-SI and non-metric conversions2 Conversion table of stress values5 Areas and volumes of circles, spheres, cylinders etc.6 The physical properties of metals7 Densities of casting alloys9 Approximate bulk densities of common materials10 Pat
8、ternmakers contraction allowances11 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 Opening for
9、ces on moulds19 Dimensional tolerances and consistency achieved in castings21 Chapter 2 Types of cast iron23 Introduction23 Physical properties of cast irons27 Iron casting processes28 Chapter 3 Grey cast iron30 Specifications30 Relationship between composition, strength and structure of grey cast i
10、ron32 Applications of grey iron castings37 The production of grey irons37 Chapter 4 Melting cast iron40 Introduction40 Cupola melting40 Electric melting53 Shop floor control of metal composition60 Chapter 5 Inoculation of grey cast iron62 Introduction62 Ladle inoculation64 Late stream inoculation66
11、Mould inoculation69 Chapter 6 Ductile iron70 Production of ductile iron70 Melting ductile iron base74 Cupola melting and duplexing74 Induction furnace melting75 Use of the tundish cover ladle75 Sandwich treatment77 NODULANT77 Pure magnesium converter process77 Cored wire treatment78 In-the-mould tre
12、atment78 Inhibiting elements78 Inoculation and fading79 Specifications for ductile cast iron79 Heat treatment of ductile iron82 Casting ductile iron84 Compacted graphite irons84 Chapter 7 Malleable cast iron90 Introduction90 Whiteheart malleable90 Blackheart malleable iron92 Chapter 8 Special purpos
13、e cast irons95 Heat resisting alloys95 Corrosion resistant cast irons101 Wear resistant cast irons102 viContents Chapter 9 Types of steel castings108 Introduction108 Specifications for steel castings109 Types of steel castings111 Carbon steels112 Low alloy and medium alloy steels112 Austenitic manga
14、nese steel114 High alloy steels114 Duplex steels117 Physical properties of steels117 Selection of suitable steel for casting117 Chapter 10 Melting and treatment of steel for casting121 Arc furnace melting121 Induction furnace melting123 AOD refining125 Melting and casting quality125 Chapter 11 Molte
15、n metal handling130 Iron foundries130 Metal handling systems130 Ladle lining130 KALTEK ladle lining system for iron foundries132 KALTEK insulating lining system for automatic pouring boxes136 Casting defects due to poor ladle maintenance137 Molten metal handling in steel foundries138 Ladle practice1
16、38 The KALTEK ladle lining system142 Pouring temperature for steels144 Chapter 12 Sands and green sand146 Silica sand146 Measurement of sand properties149 Non-silica sands151 Green sand152 Parting agents163 Special moulding materials, LUTRON163 Green sand moulding machines164 Contentsvii Chapter 13
17、Resin bonded sand167 Chemical binders167 Self-hardening process167 Sand reclamation173 Self-hardening resin binder systems180 Triggered hardening systems184 Heat triggered processes186 Gas triggered processes192 Review of resin coremaking processes198 Chapter 14 Sodium silicate bonded sand204 CO2 si
18、licate process (basic process)204 Improvements to the CO2 silicate process207 Self-setting sodium silicate processes209 Adhesives and sealants213 Chapter 15 Lost foam casting216 Principle of the process216 Patternmaking217 Assembling clusters218 Coating the patterns218 Investing in sand218 The mecha
19、nism of casting into foam patterns218 Advantages of lost foam casting221 Disadvantages222 Applications222 The future224 Chapter 16 Coatings for moulds and cores226 The need for a coating226 Choice of coating and form of supply227 Components of a coating228 Application methods for coatings230 Coating
20、s for iron and steel foundries234 Coatings for high production foundries234 Coatings for jobbing moulds and cores237 Spirit based coatings237 The TRIBONOL process240 Miscellaneous coatings241 Coatings for foundry tools243 viiiContents Chapter 17 Filtration and the running and gating of iron castings
21、245 Introduction245 Conventional running systems without filters245 Filtration of iron castings250 SEDEX ceramic foam filters256 Cellular ceramic filters259 Combined filter, feeder and pouring cup, the KALPUR direct pouring system266 Chapter 18 Filtration and the running and gating of steel castings
22、272 Introduction272 Controlling the flow of metal272 Conventional running systems without filters274 The use of ceramic foam filters277 Inclusions in steel castings277 STELEX ZR ceramic foam filters279 KALPUR ST direct pour unit286 Cost savings through the use of STELEX and KALPUR294 Chapter 19 Feed
23、ing of castings296 Introduction296 Natural feeders296 Aided feeders feeding systems297 The calculation of feeder dimensions301 Determination of feeding requirements305 Steel, malleable iron, white irons, light alloys and copper based alloy castings305 Grey and ductile irons307 Foseco feeding systems
24、310 KALPUR filter feeder units322 Breaker cores323 Application of feeder sleeves325 FERRUX anti-piping compounds for iron and steel castings331 Aids to the calculation of feeder requirements334 FEEDERCALC335 Chapter 20 Computer simulation of casting processes344 Introduction344 Solidification modell
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