Complete Casting Handbook: Metal Casting Processes, by John Campbell

By John Campbell

Complete Casting guide is the results of a long-awaited replace, consolidation and enlargement of professional John Campbell's market-leading casting books into one crucial source for metallurgists and foundry pros who layout, specify or manufacture steel castings.

The first single-volume advisor to hide sleek rules and methods in such breadth and intensity while preserving a transparent, sensible concentration, it includes:

  • A logical, two-part constitution, breaking the contents down into casting metallurgy and casting manufacture
  • Established, must-have info, reminiscent of Campbell's '10 principles' for profitable casting manufacture
  • New chapters on filling approach layout, melting, molding, and regulated solidification thoughts, plus prolonged insurance of a brand new method of casting metallurgy

Providing in-depth casting wisdom and technique knowledge, from the noteworthy occupation of an industry-leading authority, whole Casting guide supplies the specialist recommendation had to assist you make profitable and ecocnomic castings.

  • Long-awaited replace, consolidation and enlargement of specialist John Campbell's market-leading casting books into one crucial handbook.
  • Separated into components, casting metallurgy and casting manufacture, with prolonged assurance of casting alloys and new chapters on filling procedure layout, melting, moulding and regulated solidification suggestions to go with the well known Campbell '10 Rules'.
  • Delivers the specialist suggestion that engineers want to make profitable and ecocnomic casting decisions.

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Extra info for Complete Casting Handbook: Metal Casting Processes, Techniques and Design

Sample text

Consider, for instance, the powerful reaction between the oxygen in dry air and liquid aluminum: no disastrous burning takes place; the reaction is held in check by the surface oxide film which forms, slowing the rate at which further oxidation can occur. This is a beneficial interaction with the environment. e. inhibiting) reactions are seen in the melting of magnesium under a dilute SF6 (sulfur hexafluoride) gas, as described, for instance, by Fruehling and Hanawalt (1969). A further example is the beneficial effect of water vapor in strengthening the oxide skin on the zinc alloy during hot-dip galvanizing so as to produce a smooth layer of solidified alloy free from ‘spangle’.

Ductile irons (otherwise known as spheroidal graphite or nodular irons) are markedly more difficult to cast free from oxides and other defects when compared to gray (otherwise known as flake graphite) cast iron. This is the result of the minute concentration of magnesium that is added to spherodize the graphite, resulting in a solid magnesium silicate surface film that is easily entrained during pouring to create bifilms and dross. In the course of this work we shall see how in a few cases the chemistry of the surface film can be altered to convert the film from a solid to a liquid, thus reducing the dangers that follow from an entrainment event.

A wide range of other important alloys exist whose main constituents would not cause any problem in themselves, but which form troublesome films in practice because their composition includes just enough of the above highly reactive metals. These are discussed later in the metallurgical section, Chapter 6. Al–Mg alloy family, where the magnesium level can be up to 10 weight per cent, are widely known as being especially difficult to cast. Along with aluminum bronze, those aluminum alloys containing 5–10% Mg share the dubious reputation of being the world’s most uncastable casting alloys!

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