The document discusses recommendations for reducing defects in the foundry process. It suggests that defects from a rough mold surface can be reduced by smoothing the polystyrene mold with sandpaper. It also recommends pouring molten metal slowly into the mold to avoid bubbles and porosity defects. Properly ramming and packing the mold layers can further improve the quality of the casted metal parts. The preparation of molding sand, including moisture content, is also important to reduce fragility and ensure even packing.
The document discusses recommendations for reducing defects in the foundry process. It suggests that defects from a rough mold surface can be reduced by smoothing the polystyrene mold with sandpaper. It also recommends pouring molten metal slowly into the mold to avoid bubbles and porosity defects. Properly ramming and packing the mold layers can further improve the quality of the casted metal parts. The preparation of molding sand, including moisture content, is also important to reduce fragility and ensure even packing.
The document discusses recommendations for reducing defects in the foundry process. It suggests that defects from a rough mold surface can be reduced by smoothing the polystyrene mold with sandpaper. It also recommends pouring molten metal slowly into the mold to avoid bubbles and porosity defects. Properly ramming and packing the mold layers can further improve the quality of the casted metal parts. The preparation of molding sand, including moisture content, is also important to reduce fragility and ensure even packing.
The document discusses recommendations for reducing defects in the foundry process. It suggests that defects from a rough mold surface can be reduced by smoothing the polystyrene mold with sandpaper. It also recommends pouring molten metal slowly into the mold to avoid bubbles and porosity defects. Properly ramming and packing the mold layers can further improve the quality of the casted metal parts. The preparation of molding sand, including moisture content, is also important to reduce fragility and ensure even packing.
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CONCLUSION AND RECOMMENDATION
Foundry process is one of the sand casting process. We can use various metals such as Aluminium and cast iron in this process. Our group choose to use Aluminium as our metal to be melted and shaped in foundry process. We can shape metal by melting them into a liquid, pouring the molten metal into a mold that we had provided. As it cools, we removed the mold material after the metal has solidified. Our group used polystyrene to create the mold. So, our shaped metal has some defects such as the surface of the metal is rough and not smooth.
There are some ways and recommendations to reduce the defects in foundry process.
1. Smoothen the surface of the mold.
By using sand paper, smooth the surface of the polystyrene used as mold. By this, we will able to obtain a smooth surface of our product.
2. Avoid bubble in the molten metal.
We should pour the molten metal into the mold slowly and carefully to avoid bubbles or air trapped in the molten. If there are bubbles in the molten metal, our final product will have holes and it is considered as defects due to porosity.
3. Ramming a mold. Few inches of sand over the pattern should be carefully rammed and tightly packed. Soft spots, packets should be rammed properly. The mold should be rammed layer by layer. Besides, ramming should be done as close to vertical surfaces of pattern.
4. Moulding sand preparation and moisture content determination.
Water should be added sufficiently into the sand to bring the moisture content to within desired limits and uniform distribution of water all over the sand so that all the part of the sand received the same moisture properly. Do not let the sand dry out or else the sand will be fragile. Use sand riddle to cover the first layer just the pattern only and ensure there is no lumps. If the sand is too wet, it will become squishy and cannot be packed properly.
