Casting
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Casting is a manufacturing process where a solid material is melted and poured into a mold cavity to form a part. This allows both simple and complex shapes to be produced from any material that can be melted. The terminology used in metal casting includes patterns, molds, cores, and gating systems. The casting process involves obtaining the casting geometry, patternmaking, coremaking and molding, alloy melting and pouring, and cleaning the finished casting. Casting provides advantages for mass production and forming parts from materials that cannot be easily shaped by other processes.
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Casting
Casting involves introducing molten metal into a mold cavity where it takes the shape of the cavity. Important factors include the solidification process and heat transfer during cooling. There are two main casting methods - ingot casting and continuous casting. Ingot casting produces ingots that are further processed, while continuous casting directly produces final products like steel slabs. Permanent molds are reused, while expendable molds like sand are only used once. Considerations in casting design include risers, draft angles, and machining/shrinkage allowances.
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Casting is a process where molten metal is poured into a mold and solidifies. It can create complex geometries and large parts. Molds are made of materials like sand, plaster or metal. Expendable molds are destroyed to remove parts while permanent molds can be reused. Direction solidification, from remote areas to risers, minimizes shrinkage. Riser design uses the minimum metal needed based on solidification calculations.
manufacturing technology -foundary
The document provides information on metal casting processes including definitions of key terms. It discusses the basic steps of metal casting which include making a pattern, preparing molds and cores, melting metal, pouring the molten metal into molds, solidification and cooling, removing and finishing the casting. Key sections include the foundry process, casting terms, pattern making, molding materials, melting and pouring, solidification, inspection and applications of casting.
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Fundamentals of Manufacturing Processes-Casting Technology
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Cold work involves plastic deformation below the recrystallization temperature through processes like rolling and wire/tube drawing. This increases strength but introduces brittleness. Hot work occurs above the recrystallization temperature through processes like forging, hot rolling, and extrusion. This allows grain recrystallization, increasing ductility. Common casting methods include sand casting, lost-wax casting, and pressure die casting, each with their own advantages and disadvantages for part quality and production efficiency.
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Die casting is a metal casting process where molten metal is forced under high pressure into a mold cavity created by hardened steel dies. Most die castings are made from non-ferrous metals like zinc, aluminum, magnesium, and copper. There are two main types of die casting machines: hot-chamber machines that keep molten metal in the machine, and cold-chamber machines that melt metal separately before injection. Common die casting defects include misruns, cold shuts, gas porosity, and shrinkage caused by issues like cold dies, low metal temperature, or lack of venting during solidification.
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Slush Casting is a traditional method of permanent mold casting process, where the molten metal is not allowed to completely solidify in the mold. When the desired thickness in obtained, the remaining molten metal in poured out. Slush casting method is an effective technique to cast hollow items like decorative pieces, components, ornaments, etc.
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Casting
This document provides information on various metal casting processes. It discusses the history of casting and defines the basic casting process as pouring liquid metal into a mold to solidify. It describes the main features of casting like molds, risers, gates, and cores. It categorizes casting processes as open mold or closed mold casting. It further classifies casting into expandable mold casting like sand casting and investment casting, and permanent mold casting like die casting and centrifugal casting. For each process, it provides details on the mold material, advantages, disadvantages and recommended applications. It emphasizes the importance of selecting the right casting process based on alloy, shape, tolerance and cost considerations.
Casting
Solidification processes like casting involve pouring molten material into molds to create parts. Casting is one of the oldest manufacturing processes, dating back 6000 years, where molten metal is poured into a mold and allowed to solidify. There are two main types of casting - expendable molds that are destroyed to remove the casting, like sand casting, and permanent molds that can be reused, like die casting. Casting can produce complex shapes in both ferrous and nonferrous metals.
Manufacturing Process - Casting
B.Sc. (Engineering)
Department of Mechanical Engineering
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Course - Manufacturing Process
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Sand casting is a metal casting process where molten metal is poured into a sand mold cavity and allowed to solidify. There are five basic steps: 1) patternmaking to create a replica of the casting exterior, 2) coremaking to form interior contours using sand cores, 3) molding to pack sand around the pattern and core in a flask mold, 4) melting and pouring the molten metal into the mold, and 5) cleaning to remove sand from the solidified casting.
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Casting is a process where molten metal is poured into a mold and solidifies, taking the shape of the mold cavity. It involves melting metal, pouring it into a mold, and allowing it to solidify. Sand casting uses molds made of sand that must be destroyed to remove the casting. The mold contains the cavity shape and may include cores and a gating system to guide the molten metal flow before solidifying.
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sand casting and other expendable casting
Sand casting involves pouring molten metal into a sand mold. Patterns are used to define the shape and are made of materials like wood, metal, or plastic. There are different types of patterns including solid, split, match-plate, and cope-and-drag patterns. Shell molding uses a thermosetting resin to bind sand into a thin shell mold with better dimensional accuracy than sand casting. Lost-wax casting involves making a wax pattern, coating it with refractory material to form a mold, then heating to melt out the wax leaving a cavity to pour molten metal into. Continuous casting is used for steel and involves pouring molten metal directly into a water cooled mold to slowly solidify into sheets or plates
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1. The document discusses various metal casting processes, focusing on sand casting and die casting.
2. Sand casting involves pouring molten metal into a mold made of sand. Die casting uses molds made from two hardened steel dies and forces molten metal in under high pressure.
3. Both processes involve pouring molten metal into a mold and allowing it to solidify, then breaking the mold away to retrieve the casting. Sand casting is best for medium and large parts while die casting produces large quantities of small to medium parts.
Casting technique
Casting is one of the oldest manufacturing process in which a liquid metal is poured into a cavity(mould) of desired shape. It is then allowed to solidify. The solidified part is also known as a casting, which is taken out of the mould to complete the process.
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1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
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Its a class lecture about Centrifugal Casting in Production Process subject. This class held at Khulna University of Engineering & Technology. Class conducted by Md. Abdullah Al Bari.
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Shell mold casting is a metal casting process that uses a resin-coated sand mixture to form a thin-walled mold shell around a metal pattern. The pattern is heated and pressed into the sand-resin mixture to form the shell, which is then cured in an oven. Two shell halves are joined to form the complete shell mold, into which molten metal is poured to create the casting. This allows for high-precision casting of small to medium parts like gear housings, cylinder heads, and connecting rods. The shell mold casting process provides advantages over sand casting like better surface finish and dimensional accuracy for the final casting.
Metallurgy Casting
Casting involves pouring molten metal into a mold to create shapes. It is an economical process for producing complex shapes in a single piece, especially for low production runs or large products. Key factors that influence the casting process include solidification rate, flow of molten metal, heat transfer during cooling, and properties of the mold material. Proper gating system design is important to avoid defects from shrinkage and porosity during solidification as the metal cools and contracts.
Sand casting explained
In sand casting, sand is used to define the cavity inside a mold. In addition, sand is used to make any cores that are contained in the mold. The molten metal solidifies in the cavity between the interior of the mold and the exterior of the core.
Gravity die casting
The document discusses gravity die casting or permanent mold casting, which uses permanent molds made of materials like cast iron or steel to pour molten metal into without external pressure. It describes the design of permanent molds including parting lines, risers, and cores. The summary also lists some applications of permanent mold casting such as carburetor bodies, brake cylinders, and aircraft/missile castings.
Die casting
Die casting is a metal casting process where molten metal is forced under high pressure into a mold cavity created by hardened steel dies. Most die castings are made from non-ferrous metals like zinc, aluminum, magnesium, and copper. There are two main types of die casting machines: hot-chamber machines that keep molten metal in the machine, and cold-chamber machines that melt metal separately before injection. Common die casting defects include misruns, cold shuts, gas porosity, and shrinkage caused by issues like cold dies, low metal temperature, or lack of venting during solidification.
PPT on fully study about DIE CASTING by M.M.RAFIK.
In this presentation following parameters like Introduction,
History of casting,
Types of Die casting,
Types of Dies are used in Die casting.
Possible Defects in Die casting.
Minimum recommended wall thickness.
Design Rules in Die casting.
Advantages & Disadvantages of die casting.
covered by M.M.RAFIK.
Chapter 1 introduction to casting process
The document discusses manufacturing processes and sand casting. It begins by defining manufacturing as processes that convert raw materials into products through value addition. It then discusses the classification of manufacturing processes into shaping/forming, joining, removal, and regenerative categories. The majority of the document focuses on describing the fundamentals and steps of sand casting, which involves pouring molten metal into a mold cavity to produce castings. Key aspects covered include mold materials, solidification, defects, and post-casting processing steps.
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Slush Casting is a traditional method of permanent mold casting process, where the molten metal is not allowed to completely solidify in the mold. When the desired thickness in obtained, the remaining molten metal in poured out. Slush casting method is an effective technique to cast hollow items like decorative pieces, components, ornaments, etc.
APPLICATIONS
Some casting of pewter is cast using slush casting method. Using pewter and other metals mainly hollow products are casted. Decorative and ornamental objects that are casted are as vase, bowls, candlesticks, lamps, statues, jewelery, animal miniatures, various collectibles etc. Small objects and components for industry like tankard handle, handles for hollow wares, etc.
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Slush casting is used to produce hollow parts without the use of cores
The desired thickness can be achieved by pouring our the left over molten metal
A variety of exquisitely designed casting can be casted for decorative and ornamental purpose.
Casting
This document provides information on various metal casting processes. It discusses the history of casting and defines the basic casting process as pouring liquid metal into a mold to solidify. It describes the main features of casting like molds, risers, gates, and cores. It categorizes casting processes as open mold or closed mold casting. It further classifies casting into expandable mold casting like sand casting and investment casting, and permanent mold casting like die casting and centrifugal casting. For each process, it provides details on the mold material, advantages, disadvantages and recommended applications. It emphasizes the importance of selecting the right casting process based on alloy, shape, tolerance and cost considerations.
Casting
Solidification processes like casting involve pouring molten material into molds to create parts. Casting is one of the oldest manufacturing processes, dating back 6000 years, where molten metal is poured into a mold and allowed to solidify. There are two main types of casting - expendable molds that are destroyed to remove the casting, like sand casting, and permanent molds that can be reused, like die casting. Casting can produce complex shapes in both ferrous and nonferrous metals.
Manufacturing Process - Casting
B.Sc. (Engineering)
Department of Mechanical Engineering
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Topic - Casting
Sandcasting
Sand casting is a metal casting process where molten metal is poured into a sand mold cavity and allowed to solidify. There are five basic steps: 1) patternmaking to create a replica of the casting exterior, 2) coremaking to form interior contours using sand cores, 3) molding to pack sand around the pattern and core in a flask mold, 4) melting and pouring the molten metal into the mold, and 5) cleaning to remove sand from the solidified casting.
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The document discusses key terms and steps related to mould section and casting nomenclature. It defines important parts of the moulding process including the flask, pattern, parting line, and cores. It also outlines the basic six steps to making sand castings: (1) pattern making, (2) core making, (3) moulding, (4) melting and pouring, (5) cleaning. The pattern is a physical replica of the final object and is used to form the mould cavity. Cores are additional patterns used to form hollow sections. Moulding involves packing sand around the pattern to form the mould, then removing the pattern to leave the mould cavity.
Basic Mp.docx
Metal casting is one of the oldest manufacturing processes where molten material is poured into a prepared mold cavity and allowed to solidify. Some key advantages of casting include its ability to create intricate shapes with small sections, cast a wide variety of materials, and require simple and inexpensive molding tools. Important terms in casting include the flask that holds the mold, patterns that replicate the final object, parting lines that divide molds, and risers that feed castings as they shrink.
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12.casting of metals
Metal casting is a manufacturing process where liquid metal is poured into a mold and solidifies. Sand casting is a common type of metal casting that uses sand as the mold material. Key steps in sand casting include pattern making, molding, melting and pouring the metal, solidification, and cleaning. Sand provides advantages as a mold material such as low cost, high temperature stability, and permeability. Shell molding is an alternative casting method that uses a resin-bonded sand mixture to form the mold around a pattern.
CASTING PPT
The document discusses the casting process. It begins by describing how a liquid material is poured into a mold cavity to take its shape, then solidifies. This allows for complex geometries and net-shape production. Casting can be done with any material that melts and is suited for mass production. Common casting defects and their causes are also outlined.
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Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. The solidified part is known as a casting. Investment casting, also known as lost-wax casting, involves creating a wax pattern, coating it with refractory material to create a ceramic mold, melting away the wax to leave a cavity, and pouring molten metal into the mold cavity. This allows for very intricate parts to be cast with close tolerances and smooth finishes. Investment casting is commonly used for parts that are difficult to machine from difficult to machine alloys like aluminum, copper, and steels.
advanced casting.pdf
Investment casting, also known as lost-wax casting, involves making a wax pattern of the desired part, coating it with refractory material to create a ceramic mold, melting away the wax, and pouring molten metal into the mold cavity. This allows for the production of parts with complex geometries and close tolerances with minimal finishing required. Suitable for casting metals that are difficult to machine like aluminum, copper, and alloys. While allowing for intricate designs, investment casting has limitations on part size, thickness, and material selection due to the high costs involved.
12chapter_2_a_fundamental_of_metal_CASTING_FULL_final_material.ppt
This document provides an overview of metal casting fundamentals and processes. It defines metal casting as a process where molten metal is poured into a mold and solidifies. The main types of casting processes discussed are sand casting, permanent mold casting, and die casting. Sand casting uses expendable molds made of sand while permanent mold and die casting use reusable metal molds. The document explains the key steps in casting like heating, pouring, solidification and explains concepts like gating, risers and shrinkage. It also discusses advantages and limitations of different casting processes.
Metal casting process
Metal casting involves pouring liquid metal into a mold to produce parts of a desired shape. The key steps are melting metal to create a liquid, pouring it into a mold to achieve a solid shape as it cools and extracts heat, and then removing the solidified part from the mold. The quality of castings depends on factors like the flow of molten metal into the mold, the solidification and cooling process, and the type of mold material used. Common casting methods include sand casting, die casting, and investment casting.
Metal casting process
Metal casting involves pouring liquid metal into a mold to produce parts of a desired shape. The key steps are melting metal to create a liquid, pouring it into a mold to achieve a solid shape as it cools and extracts heat, and then removing the solidified part from the mold. The quality of castings depends on factors like the flow of molten metal into the mold, the solidification and cooling process, and the type of mold material used. Common casting methods include sand casting, die casting, and investment casting.
casting ppt
This document provides information on various metal casting processes. It discusses the history of casting and defines the basic casting process as pouring liquid metal into a mold to solidify. It describes the main features of casting like molds, risers, gates, and cores. It categorizes casting processes as open mold or closed mold casting. It further classifies casting into expandable mold casting like sand casting and investment casting, and permanent mold casting like die casting and centrifugal casting. For each process, it provides details on the mold material, advantages, disadvantages and recommended applications. It emphasizes the importance of selecting the right casting process based on the alloy, shape, tolerance and cost requirements of the final part.
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The document describes the casting process and its key terms. It discusses the main steps: pattern making, mould preparation including gating and risering, core making, melting and pouring, and cleaning and inspection. It provides details on each step and describes how a mould is made by packing sand around a pattern. Common components produced by casting are also listed, such as automobile and aircraft parts. Advantages include the ability to make complex shapes easily and economically, while limitations include potential defects and inferior properties compared to other processes.
Casting Process.ppt
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The document outlines two of the 17 sustainability goals adopted by the international community in 2015 to be achieved by 2030 - Goal 1 of no poverty and Goal 6 of clean water and sanitation. It states that a sustainably managed environment is necessary for socio-economic development and poverty reduction by supplying ecosystem services. It also notes that sustainable water management and access to safe water/sanitation unlock economic growth and productivity while improving resilience to water shortages.
Sulphuric acid..
The document discusses sulfuric acid, including its chemical formula, properties, and manufacturing processes. It provides details on the contact process, which involves burning sulfur to produce SO2, purifying the SO2, oxidizing it to SO3, absorbing the SO3 in sulfuric acid to form oleum, and diluting the oleum. Sulfuric acid is a strong acid that is corrosive and widely used to make fertilizers and other chemicals. The largest global producers are China, the US, India, and Russia.
Sulphuric acid
Sulfuric acid is a colorless, oily and corrosive liquid produced through a reaction between sulfur trioxide and water. It is used to manufacture fertilizers and other chemicals. There are three main processes to produce sulfuric acid - the contact process, lead chamber process and wet sulfuric acid process. The contact process is the most widely used as it produces higher concentrations of sulfuric acid. Strict safety precautions must be followed when handling sulfuric acid due to its highly corrosive nature.
Sodium hydroxide
Sodium hydroxide was discovered in 1807 by Humphrey Day in England. It is a white solid compound consisting of sodium and hydroxide ions. It is produced industrially through electrolysis of brine using the Castner-Kellner or Nelson cell processes. Sodium hydroxide is very basic and has many industrial uses such as in soap production, rayon manufacturing, and petroleum products. It has important chemical properties like reacting with acids to form salts and water. Major sodium hydroxide producers in Pakistan include Sitara Chemicals, Tufail Chemicals, and ICI Pakistan.
Sodium carbonate
This document summarizes information about sodium carbonate (Na2CO3), including its chemical formula, properties, common names, production methods, and uses. It occurs naturally as a crystalline dehydrate and is highly soluble in water. The most common production methods are the Leblanc process and Solvay process. Sodium carbonate has many industrial and household uses, such as in glassmaking, soap production, water softening, and cleaning products. China is currently the world's largest producer of sodium carbonate.
Sodium carbonate.
Sodium carbonate, also known as washing soda, has the chemical formula Na2CO3. It occurs naturally as the minerals trona and nahcolite and is mainly produced commercially via the Solvay process. It has important industrial uses in glass, chemicals, detergents, and other products. The Solvay process involves purifying sodium chloride brine, precipitating sodium bicarbonate by reaction of the brine with carbon dioxide and ammonia, and thermally decomposing the bicarbonate to produce sodium carbonate. Trona deposits are also mined and processed to produce sodium carbonate.
Silicates and allied products
Silicates are minerals consisting of silica combined with metal oxides, forming a major component of the earth's crust. They have a basic tetrahedral structure and comprise 40% of common minerals. The main types are ortho, pyro, sheet, ring, and chain silicates. Silicates have many important uses including in microchips, quartz crystals, glass, ceramics, and as allied products such as sodium silicate, aluminum silicate, and potassium silicate. China is the world's largest producer and consumer of silicates.
Nitric acid
Nitric acid is produced through a two-step Ostwald process involving the oxidation of ammonia to nitric oxide followed by the absorption of nitrogen dioxide in water to form nitric acid. It is a colorless, corrosive, and toxic mineral acid that is commonly used in fertilizers and explosives due to its oxidizing properties. Some of the major producers of nitric acid in Pakistan include Ahmad Chemicals, Karakuram Scientific Company, and several fertilizer companies.
Nitric acid
The document provides information about nitric acid, including its physical and chemical properties, manufacturing processes, uses, and production in Pakistan compared to worldwide. It describes nitric acid as a colorless liquid used to make fertilizers, dyes, and explosives. Three common industrial methods are discussed for manufacturing nitric acid: the Chile saltpeter method using sodium nitrate, Birkland-Eyde's method using air, and Ostwald's ammonia oxidation process. Nitric acid production in Pakistan is compared to global production levels, and major Pakistani nitric acid producers are listed.
Co2
This document provides an overview of carbon dioxide, including its physical and chemical properties, common uses, and sources. It discusses that CO2 is a naturally occurring gas that is colorless and odorless. It is non-flammable and plays a role in photosynthesis and the greenhouse effect. The document also outlines industrial production of CO2 as a byproduct in industries like ammonia production and describes some of the major CO2 producing industries in Pakistan, which ranks 138th globally in CO2 production.
Carbon dioxide
Carbon dioxide is a colorless, odorless gas composed of carbon and oxygen that constitutes about 0.041% of the atmosphere. It was first observed in the 17th century by Jan Baptist Van Helmont during a charcoal burning experiment. Carbon dioxide has a linear molecular shape with a bond angle of 180 degrees. It is diamagnetic with no dipole moment due to its molecular structure. Carbon dioxide is used in many applications including fire extinguishers, refrigeration, winemaking, and enhancing the hardness of metal castings. It can be prepared in the laboratory by reacting calcium carbonate with hydrochloric acid.
Steel manufacturing
The document outlines the process of manufacturing steel. Raw materials like iron ore, limestone, and coke are fed into a blast furnace along with preheated air. Inside the blast furnace, coke burns and acts as a reducing agent to remove oxygen from iron oxide. The chemical reactions produce pig iron and slag as products. Pig iron contains around 4% carbon and needs further processing to become steel using methods like the Bessemer process or electric arc furnace.
Safety
This document provides an overview of industrial chemical engineering training on basic safety procedures and emergency plans. It covers topics like personal protective equipment, types of fires and fire extinguishers, emergency response plans, confined space entry procedures, and permit to work procedures. Personal protective equipment like eye, face, head, foot and hand protection are described. Different classes of fires and corresponding fire extinguisher types are defined. Emergency response plans, evacuation procedures, and criteria for fighting small fires are outlined. Requirements for confined space entry and various work permit types are also summarized.
Plastics
Plastic is a synthetic or semi-synthetic material made from polymers that can be molded. The first man-made plastic was Parkesine created in 1862, while celluloid was invented in 1868. Common plastics include polyethylene, polyvinyl chloride, and polyurethane. Plastics are made through polymerization of monomers and may contain additives. They are manufactured through processes like injection molding, blow molding, and extrusion. Major plastic products include packaging, bottles, fibers, sheets, and pipes.
Paint
Paint is composed of pigments, binders, solvents, and additives. The pigments impart color while the binder forms a solid film and binds the pigments when dry. Common binders include resins, while solvents like water are used to adjust viscosity. Additives modify properties. Paint is manufactured through mixing, grinding, thinning, filtering, filling, and packaging steps to produce the final product. The ideal paint forms a protective film that is opaque, dries quickly, and resists corrosion, water, heat, fading, abrasion, and flexes without cracking.
Flow meter
This document compares different types of flow measuring devices. It discusses differential pressure flow meters like orifice plates, venturi meters, and rotameters that measure flow based on pressure differences. Positive displacement flow meters like gear meters and turbine meters directly measure flow volume. Electromagnetic flow meters measure flow velocity electromagnetically in conductive liquids. Ultrasonic and vortex flow meters use ultrasonic signals or vortex shedding to determine flow velocity. The document provides details on the working principles and applications of these common flow meter technologies.
Valves
This document discusses different types of valves used in industrial processes. It defines what a valve is and its main functions, which include starting and stopping flow, regulating flow, preventing backflow, and controlling pressure. The document then covers various classifications of valves based on their mechanical motion and usage. It provides details on common valve types like globe valves, gate valves, ball valves, butterfly valves, and check valves; describing their design, applications, and advantages/disadvantages. Relief valves, flap valves, foot valves are also briefly explained.
Hydrogen gas
The document discusses the introduction, preparation, and properties of hydrogen gas. It begins by introducing hydrogen and how it was first artificially produced. It then discusses various methods of preparing hydrogen gas, including the reaction of metals with acids or water, electrolysis of water, and from hydrocarbons like methane. The document outlines the process for producing hydrogen from methane, including desulfurization, reforming, shift reactions, and methanation. It concludes by discussing the physical and chemical properties of hydrogen gas and its various industrial uses such as in rockets, fuel cells, and ammonia production.
Nitrogen gas.
This document discusses nitrogen gas, including its discovery, properties, production via cryogenic distillation, and uses. Nitrogen makes up 78% of the atmosphere and is essential for life. It is produced commercially through cryogenic distillation of air, which involves compressing, cooling, and distilling air into its primary components in distillation columns. Nitrogen gas is nonflammable, odorless and colorless. It has various industrial and medical applications such as food preservation, welding, fertilizers, and medical anesthesia.
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Casting
- 2. CASTING Casting is a manufacturing process where a solid is melted, heated to proper temperature (sometimes treated to modify its chemical composition), and is then poured into a cavity or mold, which contains it in the proper shape during solidification. Thus, in a single step, simple or complex shapes can be made from any metal that can be melted. The resulting product can have virtually any configuration the designer desires The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.
- 4. TERMINOLOGY Metal casting processes uses the following terminology: Pattern: An approximate duplicate of the final casting used to form the mold cavity. Molding material: The material that is packed around the pattern and then the pattern is removed to leave the cavity where the casting material will be poured. Flask: The rigid wood or metal frame that holds the molding material. Cope: The top half of the pattern, flask, mold, or core. Drag: The bottom half of the pattern, flask, mold, or core.
- 6. Core: An insert in the mold that produces internal features in the casting, such as holes. Core print: The region added to the pattern, core, or mold used to locate and support the core. Mold cavity: The combined open area of the molding material and core, where the metal is poured to produce the casting. Gating system: The network of connected channels that deliver the molten material to the mold cavities. Pouring cup or pouring basin: The part of the gating system that receives the molten material from the pouring vessel. Sprue: The pouring cup attaches to the sprue, which is the vertical part of the gating system. The other end of the sprue attaches to the runners. Runners: The horizontal portion of the gating system that connects the sprues to the gates. Gates: The controlled entrances from the runners into the mold cavities. Riser: An extra void in the mold that fills with molten material to compensate for shrinkage during solidification.
- 7. Vents: Additional channels that provide an escape for gases generated during the pour. Parting line or Parting surface: The interface between the cope and drag halves of the mold, flask, or pattern. Draft: The taper on the casting or pattern that allow it to be withdrawn from the mold Core box: The mold or die used to produce the cores.
- 8. CASTING PROCESS The metal casting process has been divided into the following five major operations: Obtaining the Casting Geometry : The process is referred as the study of the geometry of parts and plans, so as to improve the life and quality of casting.
- 9. Casting Patternmaking : In pattern making, a physical model of casting, i.e. a pattern is used to make the mold. The mold is made by packing some readily formed aggregated materials, like molding sand, around the pattern. After the pattern is withdrawn, its imprint leaves the mold cavity that is ultimately filled with metal to become the casting.
- 10. Coremaking & Molding : In core making, cores are formed, (usually of sand) that are placed into a mold cavity to form the interior surface of the casting. Thus the annul space between the mold-cavity surface and the core is what finally becomes the casting. Molding is a process that consists of different operations essential to develop a mold for receiving molten metal.
- 12. Alloy Melting and Pouring : Melting is a process of preparing the molten material for casting. It is generally done in a specifically designated part of foundry, and the molten metal is transported to the pouring area wherein the molds are filled.
- 13. Casting Cleaning: Cleaning is a process that refers to the different activities performed for the removal of sand, scale, and excess metal from the casting. However, all the operations may not apply to each casting method but such processes play an important role to comply with environmental guidelines.
- 14. ADVANTAGES OF CASTING Casting process enjoys certain advantages : Owing to physical properties, some metals can only be cast since they cannot be re-modelled into bars, rods, plates or other shapes. It's a process highly adaptable to the requirements of mass production. Large numbers of a given casting can be produced quickly. For example; in the automotive industry there is massive production of cast engine blocks and transmission cases. Certain light metal alloys because of their respective strength and weakness, can be produced only as castings. Shows excellent bearing qualities.