This presentation includes
1.Types of castings Furnaces viz.crucible, Open hearth, electric arc, cupola.
2. Inspection methods of castings such as sound test, impact test, pressure test, radiography test, penetrant test, ultrasonic test, magnetic particle test etc.
3. Cleaning of casting: various methods such as removal of cores, gates, risers, unwanted metal projections, fins and nails.Surface cleaning etc.
Cupola furnace is a cylindrical furnace used in foundries for melting iron. It has a refractory lined interior and is charged from the top with coke, scrap iron, and flux materials. Hot gases from the combustion of coke pass up through the charge, preheating and melting it layer by layer from the bottom up. Molten iron drains from the bottom of the furnace through a tap hole, while slag is removed through a separate slag hole. Cupola furnaces can melt up to 100 tons of iron per hour and provide economical, high throughput melting due to the efficient use of coke fuel. However, composition control of the final iron product can be challenging.
The document discusses different types of furnaces used for metal casting, including crucible furnaces, cupola furnaces, induction furnaces, and reverberatory furnaces. It focuses on crucible furnaces and cupola furnaces. Crucible furnaces melt metals indirectly using refractory crucibles and are used for non-ferrous metals. Cupola furnaces are tall cylinders that melt iron and alloys by alternately layering coke, metal scrap, and limestone and blasting air from below to produce combustion and melt the metal, which flows out the bottom.
The document discusses different types and production processes of steel. It begins by introducing different types of steel based on carbon content, such as mild steel and alloy steels. It then describes the basic steelmaking route involving iron making, primary and secondary steelmaking, and continuous casting. The main secondary steelmaking processes discussed are AOD, VOD, CLU, ladle furnace treatment, and RH degassing. Each process's purpose and functioning are explained briefly.
The LD process, also called the basic oxygen process, is a steelmaking method where scrap metal and iron ore are refined in an LD vessel. Key steps include charging materials, blowing oxygen through a lance at high pressure and temperature to burn off impurities, sampling the molten steel, and tapping purified steel into a ladle. The process is much faster than open hearth and produces steel with low sulfur and phosphorus using ordinary raw materials without external heat or fuel. However, it is limited in scrap usage and can result in steel wastage from splashing.
The document summarizes different types of industrial furnaces. It describes fuel-fired furnaces like coal, gas, and oil furnaces. Coal furnaces are classified as subcritical, ultra-supercritical, and supercritical based on their operating temperatures. Cupola furnaces are used for melting cast iron and consist of a vertical steel shell lined with refractory. Rotary furnaces can be used for processes like cement, lime, and aluminum production. Electrical furnaces include electric arc furnaces which can be direct or indirect, and induction furnaces which provide a clean melting process.
A pit furnace is constructed by digging a pit and building a furnace structure within it. The furnace body is made of steel plates lined with ceramic fiber insulation. It has a lid with a central fan for circulating gases. Pit furnaces can be used to melt metals by placing crucibles containing metal inside. Coke fuel is burned to heat the furnace to the desired temperature for processes like carburizing, hardening, annealing, and nitriding steel parts. Pit furnaces provide flexibility, economic operation, and precision for heat treating large loads.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Cupola furnace is a cylindrical furnace used in foundries for melting iron. It has a refractory lined interior and is charged from the top with coke, scrap iron, and flux materials. Hot gases from the combustion of coke pass up through the charge, preheating and melting it layer by layer from the bottom up. Molten iron drains from the bottom of the furnace through a tap hole, while slag is removed through a separate slag hole. Cupola furnaces can melt up to 100 tons of iron per hour and provide economical, high throughput melting due to the efficient use of coke fuel. However, composition control of the final iron product can be challenging.
The document discusses different types of furnaces used for metal casting, including crucible furnaces, cupola furnaces, induction furnaces, and reverberatory furnaces. It focuses on crucible furnaces and cupola furnaces. Crucible furnaces melt metals indirectly using refractory crucibles and are used for non-ferrous metals. Cupola furnaces are tall cylinders that melt iron and alloys by alternately layering coke, metal scrap, and limestone and blasting air from below to produce combustion and melt the metal, which flows out the bottom.
The document discusses different types and production processes of steel. It begins by introducing different types of steel based on carbon content, such as mild steel and alloy steels. It then describes the basic steelmaking route involving iron making, primary and secondary steelmaking, and continuous casting. The main secondary steelmaking processes discussed are AOD, VOD, CLU, ladle furnace treatment, and RH degassing. Each process's purpose and functioning are explained briefly.
The LD process, also called the basic oxygen process, is a steelmaking method where scrap metal and iron ore are refined in an LD vessel. Key steps include charging materials, blowing oxygen through a lance at high pressure and temperature to burn off impurities, sampling the molten steel, and tapping purified steel into a ladle. The process is much faster than open hearth and produces steel with low sulfur and phosphorus using ordinary raw materials without external heat or fuel. However, it is limited in scrap usage and can result in steel wastage from splashing.
The document summarizes different types of industrial furnaces. It describes fuel-fired furnaces like coal, gas, and oil furnaces. Coal furnaces are classified as subcritical, ultra-supercritical, and supercritical based on their operating temperatures. Cupola furnaces are used for melting cast iron and consist of a vertical steel shell lined with refractory. Rotary furnaces can be used for processes like cement, lime, and aluminum production. Electrical furnaces include electric arc furnaces which can be direct or indirect, and induction furnaces which provide a clean melting process.
A pit furnace is constructed by digging a pit and building a furnace structure within it. The furnace body is made of steel plates lined with ceramic fiber insulation. It has a lid with a central fan for circulating gases. Pit furnaces can be used to melt metals by placing crucibles containing metal inside. Coke fuel is burned to heat the furnace to the desired temperature for processes like carburizing, hardening, annealing, and nitriding steel parts. Pit furnaces provide flexibility, economic operation, and precision for heat treating large loads.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Mr. Mubassir I. Ghoniya has satisfactorily completed his term work in mechanical engineering at the university. The document then discusses the definition of weldability as the ease with which two metals can be joined together through welding. It outlines several factors that affect the weldability of metals, such as melting point, thermal conductivity, and surface condition. Metals with better weldability like iron and steel are easier to weld and provide mechanically sound joints.
The document discusses non-ferrous alloys, beginning with an introduction on the limitations of ferrous alloys and advantages of using non-ferrous alloys. It then covers various non-ferrous metals and their alloys including copper and copper alloys like brass and bronze, aluminum and aluminum alloys, magnesium and magnesium alloys, and titanium and its alloys. For each metal/alloy, it describes common compositions, properties, and applications. It also discusses bearing materials and includes detailed information on composition and uses of various copper, aluminum, and magnesium alloys.
Heat treatment defects &and its remediesNIAJ AHMED
Heat Treatment involves various heating and cooling procedures performed to effect structural changes in a material, which turn affect its mechanical properties
The Bessemer process has limitations that make it outdated for steel production. It requires specific pig iron composition, can only remove some impurities, and produces steel with high nitrogen levels. The open hearth process overcomes many of these issues. It can use scrap iron alone, takes longer but allows for more control and uniform product quality. The open hearth process involves charging raw materials into a Siemens furnace, melting them, refining to the desired analysis, and then tapping the molten steel. Fettling repairs the furnace lining between heats to improve furnace life.
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
The document discusses different types of carbon and alloy steels. It begins with an introduction to carbon steels, outlining their classification and composition limits. It then discusses alloy steels, explaining that alloying elements are added to improve properties over plain carbon steel. Alloy steels are classified as low, medium, and high alloy steels. High alloy steels include stainless steels. The document explores various stainless steel types and how alloying elements affect their microstructure. In particular, it examines how elements can expand or contract the gamma phase field. Finally, it briefly discusses tool steels and their classification system.
Various types of melting furnaces are used in foundries depending on the metal and quantity. The main furnaces described are the cupola furnace and blast furnace. The cupola furnace is used to melt scrap metal and pig iron to produce cast iron. It consists of a refractory lined steel shell and uses coke as fuel with forced air. Charges of iron, coke, flux and alloys are loaded through the top and molten metal is tapped from the bottom.
Production of Direct Reduced Iron in Rotary Hearth FurnaceSateesh Kumar
The document discusses the production of direct reduced iron (DRI) using a rotary hearth furnace (RHF). DRI is produced by reducing iron ore to a purity of 90-97% iron through a process using reducing gases like hydrogen and carbon monoxide at high temperatures below iron's melting point. In an RHF, iron ore and carbon pellets are heated on a rotating hearth through burners as the iron oxides are reduced over 6-12 minutes to produce DRI pellets. The furnace uses heat transfer primarily through radiation to facilitate the exothermic reduction reactions between iron oxides and reducing gases like carbon monoxide to produce solid sponge iron. RHF allows for efficient and lower cost
The document provides information about electric arc furnaces (EAF) used for steelmaking. It discusses that EAFs use electric arcs between graphite electrodes and metallic charges to melt scrap steel at temperatures over 4000°C. EAFs allow oxidizing or reducing conditions and can use different slags. While costly due to electrical energy needs, EAFs offer flexibility in steel grades produced and can use scrap steel or hot metal from blast furnaces. Modern developments aim to reduce energy use and emissions in EAF steelmaking.
The document discusses various aspects of solidification processes for pure metals and alloys. It covers topics such as solidification curves, grain structure formation, mushy zone formation in alloys, segregation of elements, shrinkage during solidification, and directional solidification techniques. It also discusses the functions and design of gating systems, including elements like pouring basins, sprues, runners, gates, and risers.
The document discusses the cupola furnace, which is a cylindrical furnace used in foundries for melting scrap iron to produce molten cast iron. It operates by layering coke, flux materials, and scrap iron, then blasting heated air up through the bottom to melt the charge. The furnace interior is divided into distinct zones - combustion, melting, and preheating - where different chemical reactions occur. Molten iron is tapped from the bottom after the charge is fully melted. Cupola furnaces can melt up to 100 tons of iron per hour but lack precise temperature control.
This document provides information on the carbonitriding process. Carbonitriding involves diffusing both carbon and nitrogen into base metals between 700-900°C, producing a case that is shallower than carburizing but with better hardness. The process uses ammonia to provide nitrogen while methane provides the carbon. The treated parts experience increased surface hardness, wear and fatigue resistance. Typical applications include gears, pistons, rollers and tools.
Heat treatment involves heating and cooling metals to alter their internal structure and properties. There are several heat treatment methods for carbon steels including annealing, normalizing, hardening, and tempering. Annealing involves heating steel to high temperatures and slowly cooling to relieve stresses and improve ductility. Normalizing also starts with heating above the critical point but involves air cooling to refine grain size. Hardening greatly increases hardness but causes brittleness, so tempering is used to relieve stresses and improve toughness through controlled reheating.
This document summarizes steel melt processing and refinement techniques. It discusses primary steelmaking processes like electric arc furnaces and basic oxygen furnaces. It also covers secondary refining using various furnaces and vessels. Some key secondary processes mentioned are argon oxygen decarburization (AOD), vacuum induction melting, and ladle metallurgy techniques. The document provides detailed information on the equipment, processes, reactions, and purposes involved in steel melt processing and refinement.
This document discusses alternative iron making processes that are more relevant for India given concerns over resource depletion, rising energy demands, and environmental regulations. It describes several emerging smelting reduction technologies including COREX, FINEX, and Hismelt that allow for more flexible use of raw materials like iron ore fines and non-coking coal. These processes aim to eliminate sintering and coke-making while producing high quality iron. COREX and FINEX have been implemented commercially while Hismelt offers potential cost savings over blast furnaces and lower environmental impact. Overall, alternative technologies are needed to sustainably meet India's growing steel demand given restrictions on raw material quality and availability.
The document discusses various aspects of hardening hypoeutectoid and hypereutectoid steels. It explains that hardening involves heating steel to the appropriate temperature, holding, and then rapidly quenching to form martensite. Factors like chemical composition, part size/shape, heating/cooling rates, and quenchant properties influence the hardening process and final properties. Different hardening methods like direct, stage, and self-tempering quenching are also summarized.
Corex Process - iron Manufacturing TechnologyAsad Jamil
The Corex process is an alternative ironmaking technology to the blast furnace that uses non-coking coal, iron ore, and oxygen instead of coke and hot blast. It consists of a reduction shaft and a melter-gasifier that work in countercurrent to reduce iron ore to hot metal. The Corex process offers advantages over traditional blast furnaces such as using coal and lump ore without sintering, producing hot metal with suitable quality for all steel applications, and having outstanding environmental compatibility through reduced CO2 emissions per ton of iron produced. Some commercial Corex units are operated by companies such as POSCO, JSW Steel, and ArcelorMittal.
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.
This presentation provides an overview of the blast furnace iron making process. It describes the construction of the blast furnace, including its four main zones: stack, bosh, tuyere, and hearth. The presentation outlines the chemical reactions that take place in each zone, including the reduction of iron oxides and combustion of coke. Molten iron, slag, and gas are produced as outputs. Energy consumption is evaluated, and applications of blast furnaces in various industries are reviewed before concluding with the importance of iron and steel as engineering materials.
Blast Furnace Iron Making Process with Construction and Chemical Reactions in...029DevendraKumarSing
This document provides an overview of the blast furnace iron making process. It describes the key components of a blast furnace, including the stack, bosh, tuyere zone, and hearth. It explains the chemical reactions that take place in each zone, such as the reduction of iron oxides by carbon monoxide. Molten iron, slag, and gas are produced as outputs. The document also evaluates energy consumption in the blast furnace process and discusses applications of blast furnace technology.
Mr. Mubassir I. Ghoniya has satisfactorily completed his term work in mechanical engineering at the university. The document then discusses the definition of weldability as the ease with which two metals can be joined together through welding. It outlines several factors that affect the weldability of metals, such as melting point, thermal conductivity, and surface condition. Metals with better weldability like iron and steel are easier to weld and provide mechanically sound joints.
The document discusses non-ferrous alloys, beginning with an introduction on the limitations of ferrous alloys and advantages of using non-ferrous alloys. It then covers various non-ferrous metals and their alloys including copper and copper alloys like brass and bronze, aluminum and aluminum alloys, magnesium and magnesium alloys, and titanium and its alloys. For each metal/alloy, it describes common compositions, properties, and applications. It also discusses bearing materials and includes detailed information on composition and uses of various copper, aluminum, and magnesium alloys.
Heat treatment defects &and its remediesNIAJ AHMED
Heat Treatment involves various heating and cooling procedures performed to effect structural changes in a material, which turn affect its mechanical properties
The Bessemer process has limitations that make it outdated for steel production. It requires specific pig iron composition, can only remove some impurities, and produces steel with high nitrogen levels. The open hearth process overcomes many of these issues. It can use scrap iron alone, takes longer but allows for more control and uniform product quality. The open hearth process involves charging raw materials into a Siemens furnace, melting them, refining to the desired analysis, and then tapping the molten steel. Fettling repairs the furnace lining between heats to improve furnace life.
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
The document discusses different types of carbon and alloy steels. It begins with an introduction to carbon steels, outlining their classification and composition limits. It then discusses alloy steels, explaining that alloying elements are added to improve properties over plain carbon steel. Alloy steels are classified as low, medium, and high alloy steels. High alloy steels include stainless steels. The document explores various stainless steel types and how alloying elements affect their microstructure. In particular, it examines how elements can expand or contract the gamma phase field. Finally, it briefly discusses tool steels and their classification system.
Various types of melting furnaces are used in foundries depending on the metal and quantity. The main furnaces described are the cupola furnace and blast furnace. The cupola furnace is used to melt scrap metal and pig iron to produce cast iron. It consists of a refractory lined steel shell and uses coke as fuel with forced air. Charges of iron, coke, flux and alloys are loaded through the top and molten metal is tapped from the bottom.
Production of Direct Reduced Iron in Rotary Hearth FurnaceSateesh Kumar
The document discusses the production of direct reduced iron (DRI) using a rotary hearth furnace (RHF). DRI is produced by reducing iron ore to a purity of 90-97% iron through a process using reducing gases like hydrogen and carbon monoxide at high temperatures below iron's melting point. In an RHF, iron ore and carbon pellets are heated on a rotating hearth through burners as the iron oxides are reduced over 6-12 minutes to produce DRI pellets. The furnace uses heat transfer primarily through radiation to facilitate the exothermic reduction reactions between iron oxides and reducing gases like carbon monoxide to produce solid sponge iron. RHF allows for efficient and lower cost
The document provides information about electric arc furnaces (EAF) used for steelmaking. It discusses that EAFs use electric arcs between graphite electrodes and metallic charges to melt scrap steel at temperatures over 4000°C. EAFs allow oxidizing or reducing conditions and can use different slags. While costly due to electrical energy needs, EAFs offer flexibility in steel grades produced and can use scrap steel or hot metal from blast furnaces. Modern developments aim to reduce energy use and emissions in EAF steelmaking.
The document discusses various aspects of solidification processes for pure metals and alloys. It covers topics such as solidification curves, grain structure formation, mushy zone formation in alloys, segregation of elements, shrinkage during solidification, and directional solidification techniques. It also discusses the functions and design of gating systems, including elements like pouring basins, sprues, runners, gates, and risers.
The document discusses the cupola furnace, which is a cylindrical furnace used in foundries for melting scrap iron to produce molten cast iron. It operates by layering coke, flux materials, and scrap iron, then blasting heated air up through the bottom to melt the charge. The furnace interior is divided into distinct zones - combustion, melting, and preheating - where different chemical reactions occur. Molten iron is tapped from the bottom after the charge is fully melted. Cupola furnaces can melt up to 100 tons of iron per hour but lack precise temperature control.
This document provides information on the carbonitriding process. Carbonitriding involves diffusing both carbon and nitrogen into base metals between 700-900°C, producing a case that is shallower than carburizing but with better hardness. The process uses ammonia to provide nitrogen while methane provides the carbon. The treated parts experience increased surface hardness, wear and fatigue resistance. Typical applications include gears, pistons, rollers and tools.
Heat treatment involves heating and cooling metals to alter their internal structure and properties. There are several heat treatment methods for carbon steels including annealing, normalizing, hardening, and tempering. Annealing involves heating steel to high temperatures and slowly cooling to relieve stresses and improve ductility. Normalizing also starts with heating above the critical point but involves air cooling to refine grain size. Hardening greatly increases hardness but causes brittleness, so tempering is used to relieve stresses and improve toughness through controlled reheating.
This document summarizes steel melt processing and refinement techniques. It discusses primary steelmaking processes like electric arc furnaces and basic oxygen furnaces. It also covers secondary refining using various furnaces and vessels. Some key secondary processes mentioned are argon oxygen decarburization (AOD), vacuum induction melting, and ladle metallurgy techniques. The document provides detailed information on the equipment, processes, reactions, and purposes involved in steel melt processing and refinement.
This document discusses alternative iron making processes that are more relevant for India given concerns over resource depletion, rising energy demands, and environmental regulations. It describes several emerging smelting reduction technologies including COREX, FINEX, and Hismelt that allow for more flexible use of raw materials like iron ore fines and non-coking coal. These processes aim to eliminate sintering and coke-making while producing high quality iron. COREX and FINEX have been implemented commercially while Hismelt offers potential cost savings over blast furnaces and lower environmental impact. Overall, alternative technologies are needed to sustainably meet India's growing steel demand given restrictions on raw material quality and availability.
The document discusses various aspects of hardening hypoeutectoid and hypereutectoid steels. It explains that hardening involves heating steel to the appropriate temperature, holding, and then rapidly quenching to form martensite. Factors like chemical composition, part size/shape, heating/cooling rates, and quenchant properties influence the hardening process and final properties. Different hardening methods like direct, stage, and self-tempering quenching are also summarized.
Corex Process - iron Manufacturing TechnologyAsad Jamil
The Corex process is an alternative ironmaking technology to the blast furnace that uses non-coking coal, iron ore, and oxygen instead of coke and hot blast. It consists of a reduction shaft and a melter-gasifier that work in countercurrent to reduce iron ore to hot metal. The Corex process offers advantages over traditional blast furnaces such as using coal and lump ore without sintering, producing hot metal with suitable quality for all steel applications, and having outstanding environmental compatibility through reduced CO2 emissions per ton of iron produced. Some commercial Corex units are operated by companies such as POSCO, JSW Steel, and ArcelorMittal.
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.
This presentation provides an overview of the blast furnace iron making process. It describes the construction of the blast furnace, including its four main zones: stack, bosh, tuyere, and hearth. The presentation outlines the chemical reactions that take place in each zone, including the reduction of iron oxides and combustion of coke. Molten iron, slag, and gas are produced as outputs. Energy consumption is evaluated, and applications of blast furnaces in various industries are reviewed before concluding with the importance of iron and steel as engineering materials.
Blast Furnace Iron Making Process with Construction and Chemical Reactions in...029DevendraKumarSing
This document provides an overview of the blast furnace iron making process. It describes the key components of a blast furnace, including the stack, bosh, tuyere zone, and hearth. It explains the chemical reactions that take place in each zone, such as the reduction of iron oxides by carbon monoxide. Molten iron, slag, and gas are produced as outputs. The document also evaluates energy consumption in the blast furnace process and discusses applications of blast furnace technology.
THIS IS TWIN HEARTH FURNACE IS A RUSSIAN TECHNOLOGY FURNACE IN BHILAI STEEL PLANT.THIS PROCESS IS A CULTURAL PROCESS OF STEEL MAKING IN INDIA. BHILAI STEEL PLANT HAVE 4 TWIN HEARTH FURNACES.FIRST TWIN HEARTH FURNACE ESTABLISH IN BHILAI STEEL PLANT(BSP) IN 1986.
THE BSP, INDIA'S FIRST AND MAIN PRODUCER OF STEEL RAILS,AND OTHER STEEL PRODUCTS.
The document discusses six main steel manufacturing processes: Bessemer, open hearth, Linz-Donawitz (LD), basic oxygen furnace (BOF), electric arc furnace, and induction furnace. It provides details on the equipment, materials, and basic steps used in each process. The Bessemer process was an early technique using air to oxidize impurities, while open hearth involves preheating gases in regenerators. Modern processes like BOF and electric arc furnace use oxygen jets and electric arcs to melt scrap and refine alloys. The document also classifies iron and carbon alloys into irons, steels, and cast iron based on carbon content and applications.
A cupola furnace is a melting device used in foundries that can be used to melt cast iron, Ni resist iron and some bronzes
Cupola furnace is employed for melting scrap metal or pig iron for production of various cast irons.
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The document discusses different types of furnaces used in foundries for melting metals. It describes cupola furnaces, which are vertical cylindrical furnaces used to melt iron. Cupola furnaces have a charge of coke, metal, and flux layers that are heated by hot exhaust gases rising through the furnace. As the materials are consumed, additional charges can be added. Molten metal emerges from the bottom tap hole while slag is removed from the slag hole. Other furnace types discussed include direct fuel-fired furnaces, crucible furnaces, electric-arc furnaces, and induction furnaces.
There are several types of melting furnaces used for different materials and processes. The electric arc furnace uses electric arcs to melt scrap metal and can reach temperatures over 3000°C. The basic oxygen furnace converts molten pig iron to steel by blowing oxygen through it to reduce the carbon content. The blast furnace is a large chimney that produces molten iron from iron ore, coke and limestone using hot air blown in from the bottom. The induction furnace melts metals using powerful alternating currents that induce eddy currents within the metal to heat and stir it without contact.
There are several types of furnaces used for melting metals in metal casting, with the choice depending on the type of metal and production needs. Crucible furnaces are small and suitable for batch processes, melting metal in crucibles heated indirectly. Cupola furnaces are tall cylinders that melt iron and alloys by layering them with coke and limestone and heating from the bottom. Reverberatory furnaces heat metal to melting through indirect radiation from burners on refractory walls. Induction furnaces use an induction coil powered by alternating current to generate a magnetic field and directly heat electrically conductive materials without contact.
The document provides information about Bhilai Steel Plant located in Bhilai, India. It is India's first and main producer of steel rails. The plant produces steel rails up to 260 meters long, as well as wide steel plates and other steel products. It also produces and sells chemical by-products from its coke ovens and coal chemical plant. The plant was established in 1955 with assistance from the Soviet Union. It is the largest and most profitable facility of Steel Authority of India Limited.
Metal furnaces are selected based on criteria like the metal's melting point, required quantity and purity, pouring type, maximum temperature, and cost factors. Common furnace types include crucible, pot, rotary, and electric furnaces.
The crucible furnace uses a crucible container and can be coke, gas, or oil fired. The pot furnace contains molten metal in a pot to avoid smoke impurities. The rotary furnace rotates horizontally for homogeneous melting. Electric furnaces like direct arc, indirect arc, and induction furnaces provide high purity but at a higher cost.
The cupola furnace is a cylindrical furnace that produces molten cast iron. It operates
Iron is produced through the blast furnace process and steel is produced through basic oxygen furnace or electric arc furnace processes. There are three main types of plain carbon steel based on carbon content: low carbon steel contains 0.05-0.3% carbon, medium carbon steel contains 0.3-0.6% carbon used for bolts and shafts, and high carbon steel known as tool steel contains 0.6-1.5% carbon used for tools. Alloy steels contain additional elements like chromium, manganese, silicon or sulfur to improve properties such as strength, toughness, wear and corrosion resistance.
This topic introduces the methods of irons, steels and cast irons production. It also describes the structure, properties and the usage of irons, steels and cast irons in the engineering field.
The document discusses two options to improve super heaters in AFBC boilers. The first option is designing radiant super heaters that avoid problems with bed super heaters like clinker formation and space constraints. Radiant super heaters have a longer replacement period of 25 years. The second option is coating existing bed super heater tubes with infiltration brazed tungsten carbide cladding, which reduces corrosion and erosion while increasing tube life four times. Both options greatly increase super heater availability.
The document summarizes the process of manufacturing cast iron using a cupola furnace. It begins with a brief history of cupola furnaces, noting they were first developed in the 3rd century BC in China. It then describes the key stages of operation, including starting the furnace with wood and coke, continuously charging layers of coke, flux, and iron, and how the countercurrent design allows heat exchange and melting. Molten metal and slag are then tapped from separate openings. The document also outlines the different temperature zones within the furnace where combustion, reduction, melting, and preheating occur. It concludes by noting advantages like simplicity and ability to process dirty scrap, as well as drawbacks like pollution compared to
The document discusses different types of metal melting furnaces used in metal casting. It describes Cupola Furnaces, Electric Arc Furnaces, Induction Furnaces, and Metal Pot Furnaces. Cupola Furnaces use layers of metal, coke and limestone fed into the top to melt iron and ferrous alloys through combustion. Electric Arc Furnaces use carbon electrodes to generate arcs and melt metal through heat. Induction Furnaces use electromagnetic induction to rapidly heat and melt metals. Metal Pot Furnaces are used for low melting point alloys like aluminum and are heated by gas or oil without direct contact between flames and metal.
The document describes an automatic ingot feeder for furnaces. It uses two pneumatic cylinders to pick up aluminum ingots and move them slowly into the furnace tank using compressed air. A DC motor and microcontroller circuit are used to control the movement of the ingot material. The feeder aims to reduce difficult manual methods and labor previously used to load ingots.
The document discusses the open hearth furnace process used in foundries. The open hearth furnace uses direct contact between fuel and metals to melt iron, aluminum, and other materials. It consists of a shallow bath capable of holding 60-300 tons of metal, with heating chambers on the sides and openings at each end to allow heated gases to burn and escape. The furnace lining depends on the impurities in the metal. Once charged and heated to 1500C, the scrap and pig iron melt over 3 hours as impurities are removed. The molten steel is then tapped and deslagged before being poured into ingots or castings.
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Metal joining Processes( Riveting, Soldering, Welding)Prashant Borakhede
Metal joining processes includes Riveting, Soldering, Brazing, Welding etc. In this presentation, types of welding like gas welding metal arc welding are also included. advantages and disadvantages of the processes are also included.
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2. CONTENTS
Melting Furnaces
1. Crucible Furnaces
2. Cupola Furnace
3. Open Hearth Furnace
4. Electric Arc Furnace
Inspection of Casting
Cleaning of Casting
3. INTRODUCTION
An effective melting of various metals in suitable
furnaces is always carried out in a foundry shop.
The various melting operations carried out in foundries
are actually remelting processes in that the ores found
in mines are not directly used.
Remelting is done in different types of furnaces and
poured at suitable temperature into mould to give the
casting.
The large number of furnaces are have been
developed.
The furnaces are based on following factors:
a) Rate of melting desired, depending upon quantity of
metal required to be melted per hour.
Prof. P.B. Borakhede, MGI-COET, Shegaon
4. b) Type of metal to be melted.
c) Temperature required.
d) Capability of melting medium for absorbing impurities.
e) Method of pouring the molten metal
f) Economical considerations; ie initial investment to be
made as cost of equipment and its installation,
maintenance cost and cost of fuel to be consumed.
Prof. P.B. Borakhede, MGI-COET, Shegaon
5. TYPES OF FURNACES
1. Crucible Furnaces
o These are simplest of all the furnaces used in
foundries.
o They are used in most of the small foundries where
melting is not continuous and a large variety of metals
is to be melted in small quantities.
o In these furnaces the entire melting of metal takes
place inside a melting pot, called crucible which is
made of clay and graphite.
These furnaces can be classified in two groups
a) Coke-fired furnace b) Oil and gas fired Furnace.
Prof. P.B. Borakhede, MGI-COET, Shegaon
6. a) Coke Fired Furnace
These furnaces are generally
installed in a formed Pit and are
used in a small quantities of ferrous
Metals( pig iron) for producing iron
Castings and also for non ferrous
metals and alloys.
They are provided with Refractory Linings inside a
Chimney at the top.
Coke is used as a fuel. Both natural as well as artificial
droughts can be used.
The air flow is provided to coke for burning.
Broken pieces of metal are placed in the crucible.
Prof. P.B. Borakhede, MGI-COET, Shegaon
7. Bed coke is fired in the furnace and crucible placed into
it.
When coke is burnt the crucible in pit gets heated and
metal inside the crucible is melted.
This melted metal is used for casting purpose.
Advantages:
Faster Heating
Saves Floor Space
Easy to Load
Lower installation and startup cost.
Prof. P.B. Borakhede, MGI-COET, Shegaon
8. b) Oil and Gas Fired Furnaces
These furnaces utilize oil or gas as a
Fuel.
A mixture of gas and air or oil and air
is fed into the furnace which burns inside
to produce the desired temperature.
The mixture usually enters tangentially and encircles
the crucible while burning.
The furnaces essentially consists of a cylindrical steel
shell, provided with refractory lining inside and proper
passage for entry of the fuel mixture.
The crucible is seated on pad formed at the bottom.
A cover is produced at the top to prevent heat losses.
Prof. P.B. Borakhede, MGI-COET, Shegaon
9. These furnaces may be of stationary type or tilting type.
Advantages:
Low investment costs
easy operation and maintenance ability
capable of melting small batches of various alloys
the melt can be treated directly in the crucible and the
alloy can be quickly and easily replaced as necessary.
Prof. P.B. Borakhede, MGI-COET, Shegaon
11. For melting of cast iron in foundry the Cupola Furnace
is used.
Figure shows cross sectional view of cupola.
It has a construction in the form of hollow vertical
cylinder made of strong mild steel plates and riveted or
welded at the seams.
In cupola the stress in the whole structure is distributed
uniformly.
The bottom door of shell can be in one piece or two
piece hinged to supporting leg.
The bottom door is supported by a prop so that it may
not be collapsed.
When prop is removed door drops down providing a
clear space for the coke fire, residue of the molten
metal with slag and sand bed.
Prof. P.B. Borakhede, MGI-COET, Shegaon
12. A wind chamber is connected to furnace blower by
means of blast pipe.
The amount of air required is forced into the chamber by
blower, which enters in the furnace through openings
called tuyeres.
The charging door is located at a suitable height above
the charging platform.
This platform is of robust mild steel supported by four
legs.
Weighted quantities of metal, coke, scrap and flux are
collected on this platform which are charged into cupola
when required.
The top of cupola is provided with a mesh screen and
spark arrester. It is a cone shaped construction.
Prof. P.B. Borakhede, MGI-COET, Shegaon
13. This attachment facilitates a free escape of waste gases
at the same time deflects spark and dust back to
furnace.
Working:
Soft and dry pieces of wood is first placed over the sand
bed followed by a small amount of coke charge known
as coke bed.
Coke is put gradually in furnace through charging door.
Cover plates are opened to allow free entry of air for
combustion and they are open till entire bed is fully
ignited.
A weighed proportionate amount of metal (pig iron,
scrap), flux and coke is then fixed over the bed charge.
Prof. P.B. Borakhede, MGI-COET, Shegaon
14. They are repeated in alternate layers of each until the
cupola is full to the charging door.
The furnace is preheated before charge in the furnace.
As the charge enters in furnace blower starts, tuyers
directs the air flow.
The amount of flux to be added in metal charge
depends upon quality of the charged metal and scrap
and composition of coke.
Usually limestone is used as flux.
When the coke burns, the metal melts.
Molten metal is drained out through well and slag is
removed through slag hole.
This molten metal is used for casting purpose.
Prof. P.B. Borakhede, MGI-COET, Shegaon
15. Zones in Cupola
Various zones of cupola are shown in figure.
Number of chemical reactions are takes place in these
zones which are explained below.
1. Well
• It is space between bottom of tuyers and sand bed.
The metal after melting, trickles down and collects in
the space before it is tapped out.
2. Combustion Zone
• It is also known as oxidising zone. It is located above
the top of the tuyeres.
• Total height of this zone is 15 cm to 30 cm.
• The actual combustion is takes place in this zone,
consuming all free oxygen from air blast and
Prof. P.B. Borakhede, MGI-COET, Shegaon
16. producing a lot of heat, which is sufficient enough to meet
the requirements of other zones of cupola.
• A temperature of about 1540˚C to 1870˚C is produced in
this zone.
• Reactions takes place in this zone can be represented
C + O2 CO2 + Heat
Si + O2 SiO2 + Heat
2Mn + O2 2MnO+ Heat
3. Reducing Zone
• It is also known as the protective zone. It is located
between the top of the combustion zone and the top
level of coke bed.
• CO2 is reduced to CO in this zone through an
endothermic zone temperature to about 1200 ˚C.
Prof. P.B. Borakhede, MGI-COET, Shegaon
17. • The reaction is as follows
CO2 + C ( of Coke) 2CO – Heat
• Nitrogen and other main constituents of the upward
moving hot gases does not participate in reaction.
4. Melting Zone
• The first layer of metal charge over the coke bed
constitutes this zone.
• The solid metal changes to molten state in metal picks
up sufficient carbon content in this zone as represented
by following reaction:
3Fe + 2CO Fe3C + CO
5. Preheating Zone
• It extends from above the melting zone to the bottom
level of charging door and contains a number alternate
layers of coke and metal charge.
Prof. P.B. Borakhede, MGI-COET, Shegaon
18. • The function of this zone is to preheat the charges from
atmospheric temperature to about 1093 ˚C before they
settle downwards to enter the melting zone.
• This preheating takes place due to upward advancing
hot gases.
6. Stack
The empty portion of cupola above the preheating zone,
which provides the passage to hot gases to go to
atmosphere, is known as stack.
Prof. P.B. Borakhede, MGI-COET, Shegaon
19. Advantages of Cupola Furnace
• Initial cost is comparatively lower than other furnaces.
• Operation and maintenance of this furnace does not
involve too many complications.
• Cost of operation and maintenance is lower.
• Floor area required is very small.
• It can be operated for a number of hours continuously.
• It does not involve very complicated problems in its
design which is comparatively simpler.
Prof. P.B. Borakhede, MGI-COET, Shegaon
20. 3. OPEN HEARTH FURNACE
Open hearth process is also known as Siemens
process, who was the first to introduce the idea of using
a regenerator for preheating the air for combustion
before entering the open hearth furnace.
Prof. P.B. Borakhede, MGI-COET, Shegaon
21. These furnaces are used to melt pig iron which is used
in steel making.
The furnace is heated by burning of gas.
It operates on preheat fuel and air.
There is a combustion chamber in which iron ore is
melted.
The charging doors are attached to combustion
chambers through which charge inserts into chamber.
Refractory chambers are connected combustion
chamber .
On the other side there are regenerative chambers
which are preheated by flue gases.
The gas and air pipelines are connected to these
chambers.
Prof. P.B. Borakhede, MGI-COET, Shegaon
22. At first the gas and air flows through pipelines and
refractory chambers to combustion chamber.
When they enters in combustion chamber they mixed
together and burning takes place.
They creates a flame which increase the temperature of
combustion chamber and the metal charge with flux
melts.
There is generation of flue gases because of melting of
flux and metal.
These flue gases flows through pipelines to
regenerative chambers, which preheats the chambers
and exits through chimneys.
Next time the gases and air flows through regenerative
chambers which are already preheated.
Prof. P.B. Borakhede, MGI-COET, Shegaon
23. When burning gases and air passes through regenerative
chamber they gets heated, when they enters in
combustion chamber the efficiency of burning increases.
Advantages
Scrap Iron, low grade pig and cast iron and the iron ore
(haematite) can he directly converted to steel.
The temperature can be controlled more effectively since
external source of heat Is used.
The composition of steel is uniform and accurate and can
be controlled easily as the product is analysed from time
to time.
Iron is not lost as slag since blast of hot air is not passed
through the molten mass.
Steel obtained is of high grade and good quality.
Prof. P.B. Borakhede, MGI-COET, Shegaon
24. Electric furnaces are widely used in steel-making.
Two types of electric furnaces are commonly used in steel
making. They are:
a) The direct Arc Furnace
b) High frequency induction furnace
a) Direct Arc Furnace
It consist of a steel shell having spherical bottom.
The complete furnace is mounted on rollers, so that it
can be tilted for pouring the melt into the laddle.
The hearth has a bowl shape and it provided with
basic lining with magnesite or dolomite.
Prof. P.B. Borakhede, MGI-COET, Shegaon
4. ELECTRIC ARC FURNACE
25. Two spouts are provided on opposite side one for slag
and one for molten metal.
The roof is detachable type and charge id feed through
it.
Three vertical electrodes are suspended through the
top, through which a 3- phase current is led into the
furnace.
Prof. P.B. Borakhede, MGI-COET, Shegaon
26. These electrodes can be raised up or lowered as
desired.
After charging, the furnace top is closed and the
electrodes lowered.
The current is switched on to generate the arc, thereby
producing a high temperature of about 2000˚C or above.
This intense heat melts the charge. As the level of
molten metal rises, the electrodes are also raised
automatically.
The charge usually consist of light and heavy steel scrap
together with suitable amount of flux.
Prof. P.B. Borakhede, MGI-COET, Shegaon
27. This furnace consist of a crucible surrounded by water
cooled coil copper tubing.
This coil also conducts the high frequency current and
acts as primary winding.
Prof. P.B. Borakhede, MGI-COET, Shegaon
b) High Frequency Electric Furnace
( Indirect Electric Arc Furnace, Induction Furnace)
28. The metal charge in the crucible serves as secondary
winding.
Thus furnace works on the principle of a transformer.
As high frequency current is passed into primary winding,
Eddy currents are produced in metal charge (secondary
winding) through induction.
Thus charge is rapidly melted and agitated.
The furnace is of tilting type.
Prof. P.B. Borakhede, MGI-COET, Shegaon
29. 3. Indirect Arc Furnace
It is used for making carbon steel or ferrous steel from
scrap iron, iron ore.
Pig iron, iron carbide is melted and converted it into high
quality steel.
Lime stone is used as a flux.
High power electric arc is used between electrodes.
In this furnace the charge is heated indirectly by radiant
heat from electric arc.
Prof. P.B. Borakhede, MGI-COET, Shegaon
30. It consist of a horizontal barrel shape steel shell lined with
refractories.
First metal charge and flux are inserted into the
combustion chamber.
Then two graphite electrodes are inserted in combustion
chamber and placed in front of each other horizontally
near the charge.
When electric supply is passed through both electrodes,
the arc is produced, which will give a heating effect.
This heat melts the metal and flux, the slag will be at
upper side of the molten metal which removes impurities
in metal.
The barrel shaped shell is designed to rotate and reverse
through approximately 180°C in order to avoid excessive
heating of the refractories above the melt level and to
increase the melting efficiency of the unit.
Prof. P.B. Borakhede, MGI-COET, Shegaon
31. Advantages of Electric arc furnace
It allow steel to be made from 100% scrap metal
feedstock.
These furnaces are used when closed control of
temperature and exact amount of alloying elements are
important.
These are good for making high carbon steel, steel
alloyed with metals, stainless steel.
Higher temperature can be reached other steel making
furnaces.
Prof. P.B. Borakhede, MGI-COET, Shegaon
32. INSPECTION OF CASTING
Inspection is done to detect the internal and external
defects in them.
Since a large number of defects are not visible from
outside, it is likely that casting may be defective inside
inspite though there perfectly clean and defect free
surface outside.
This may ultimately result in the failure of casting to
provide the desired service.
The inspection of casting is necessary to avoid failure.
There two types of inspection
a) Destructive Testing
b) Non destructive Testing.
Prof. P.B. Borakhede, MGI-COET, Shegaon
33. a) Destructive Methods
This method includes picking few sample castings,
cutting them into pieces at the points where defects are
suspected and them examining their section surface to
find out internal defects.
Few methods are described as follows:
1. Visual Inspection
• It comprises of inspecting the surface of the casting
either with naked eye or sometimes with the help of a
magnifying glass or a suitable microscope.
• Almost all the castings are subjected to this inspection.
• This method only detect defects which are on the
surface.
Prof. P.B. Borakhede, MGI-COET, Shegaon
34. 2. Inspection for Dimensional Accuracy
Dimensional accuracy is important in those castings
which are to be machined.
Their dimensions are checked after cleaning in the
foundry.
Various precision measuring instruments are used to
check the dimensions.
A proper checking of dimension also reveals as to
whether the pattern and core boxes used are correct.
All undersized castings are rejected as any further
machining on them will effect more reduction in their
size.
Prof. P.B. Borakhede, MGI-COET, Shegaon
35. 3. Sound Test
It consist of suitably suspending the casting, free of
floor and all other obstructions, and then gently striking
it with a hammer.
The sound is carefully noted.
Tapping by the hammer is done at different points and a
change in the pitch and quality of sound indicates a
discontinuity within the mass of casting.
It is difficult to locate discontinuity and the extent to
which it is present.
4. Impact Test
In this test a hammer of a suitable sixe is either struck
against or allowed to fall on those portions of castings
which are suspected to carry defects.
Prof. P.B. Borakhede, MGI-COET, Shegaon
36. A defective portion will break under this impact and a
sound portion is expected to be capable of withstanding
this blow.
However, it cannot be said to be a reliable and sure test
always.
5. Pressure Test
Pressure tests are always applied to those castings
which are to be used for containing or carrying gases or
liquids.
Such castings are tested for leaks through their wall.
The fluids used for applying pressure are water, steam
or air.
Before applying the pressure, all openings of the
casting are closed.
Prof. P.B. Borakhede, MGI-COET, Shegaon
37. Water pressure may be given with the help of small
pump and the surface inspected to locate the leaks.
When steam is used to provide pressure the leaks are
enlarged due to its heat and become more evident.
When air pressure applied the casting is immensed in
water. If there are leaks, the air bubbles start coming up.
6. Radiography or X-Ray Tests
Radiographic tests involve the use of light rays of
relatively shorter wave lengths.
The rays used for this purpose are X rays and Gamma
rays.
X rays are produced in a high vacuum glass tube
carrying a positive anode and a negative cathode.
Prof. P.B. Borakhede, MGI-COET, Shegaon
38. Electric current is used to heat the cathode, followed by
application of high voltage between anode and
cathode.
As a result of this electrons starts flowing from cathode
to anode, which are obstructed by a tungsten disc to
convert them into a Beam of Rays.
This beam is passed out of tube and is allowed to
penetrate through casting to fall on a photographic film
placed suitably behind the casting.
This film is later developed in the usual way to reveal
internal defects.
Cracks, Blow holes, cavities etc will show by light
portion.
A better penetration through metal is obtained by using
Gamma rays instead of X rays on account of their
shorter wave lengths.
Prof. P.B. Borakhede, MGI-COET, Shegaon
39. This enables application of these rays even at those
places where X rays cannot be used.
Gamma rays are emitted by both Radium and Cobalt 60
and both are commonly used for the purpose.
7. Magnetic Particle Testing
This method can be used only for those metals and
alloys which can develop magnetic properties eg iron
and steel.
The principle involved in this test is that in a magnetized
metal if its magnetic field is interrupted by a crack its
continuity is broken.
Due to low magnetic permeability of air some magnetic
flux lines leak out of the metal.
Prof. P.B. Borakhede, MGI-COET, Shegaon
40. If a magnetic material is spreads over that portion some of
it is held there by the flux lines to show the presence of a
crack or void there.
So for this test, casting is first magnetized and then fine
particles of iron or steel are spread over its surface.
The presence of cracks is revealed by the held up
particles on the surface.
8. Ultrasonic Testing
The technique is using of sound as a basis of judging the
soundness of an article.
Ultrasonic inspection is used to detect very small internal
defects.
Ultrasonic means a sound wave of a small wavelength
which can not be hear by human being.
Prof. P.B. Borakhede, MGI-COET, Shegaon
41. This technique involves sending of very high frequency
vibrations into the material being tested, which is
reflected partially or fully after striking the flaw or the
surface of component.
The noted signal is noted and interpreted to get the
result.
A pulse oscillator is used with transducer to convert
electrical energy into mechanical vibrations.
Transducer carries piezoelectric crystal which changes
electric oscillations to mechanical vibrations.
The transducer is placed at the top surface of component
and Ultrasonic beam of vibrations sent into material.
Another transducer called as reciever transducer is used
to receive reflected signals which are then amplified,
filtered, processed.
Prof. P.B. Borakhede, MGI-COET, Shegaon
42. These signals are displayed on oscilloscope which are
finally interpreted to get the result.
This is highly sensitive technique through which internal
defects, cracks, voids can be detected.
The test is performed speedily and it needs access to
only one side of the component.
It can also be used for measuring thickness and
detecting flaws in joints or between adjoining surface
between materials.
9. Liquid Penetrant Test
It is a simple test for detecting such flaws or defects
which extend up to surface of the material.
At first component is cleaned and dried.
Prof. P.B. Borakhede, MGI-COET, Shegaon
43. Then liquid material called penetrant is applied to
surface.
The penetrant used is such that is can be drawn into the
surface discontinuity by capillary action.
It can be applied to surface by spraying, brushing or
dipping.
A fluorescent material is added into it. This material will
radiate in ultra violate light to make penetrant traces
more evident.
The penetrant is saturates in flaws, cracks voids etc.
Excess penetrant is then wiped out from surface.
Then absorbant material called as developer is added on
the surface which absorbs penetrant.
The cracks, defects etc shines due to flouroscent
material. The cracks are repaired then.
Prof. P.B. Borakhede, MGI-COET, Shegaon
44. CLEANING OF CASTINGS
When casting is manufactured it goes through many
processes.
When casting is removed from mold it is not completely
finished as it carries risers, runners, gates, chills etc
attached to it. Also a lot of sand remains on its surface in
form of core.
The cleaning and finishing is necessary before it can be
brought to usable form.
The various operation are as follows
a) Removal of dry sand cores
b) Removal of gates and risers
c) Removal of unwanted metal projections fins, nails.
d) Surface Cleaning
Prof. P.B. Borakhede, MGI-COET, Shegaon
45. 1. Removal of Cores
For removal of dry sand core from the casting the latter
is first suitably rapped to loosen and break the core
sand.
The core sand is then removed through a poking
action by means of a metallic bar.
2. Removal of Gates and risers
Gates and risers attached to castings can be removed
through various means.
a) They may be broken away by hammering.
b) They may be sawn by means of metal cutting saw.
c) May be sheared off by means of suitable punches or
sprue cutters.
d) May be chipped off by chipping hammers.
Prof. P.B. Borakhede, MGI-COET, Shegaon
46. e) May be cut off by oxy acetylene flame.
f) May be removed by means of Abrasive cut off wheels.
3. Removal of unwanted Metal projections, Fins & Nails
1The operation of removal of these unwanted metal parts
attached to casting called snagging.
1. Chipping with hand or pneumatic chisels.
2. Cutting with oxy-acetylene flame.
3. Grinding by means of grinders.
4. Machining
5. Filing
Prof. P.B. Borakhede, MGI-COET, Shegaon
47. 4. Surface Cleaning
Surface of most of castings are required to be cleaned to
remove adhering sand and oxide scale.
a) Use of wire brush to clean surface.
b) Tumbling :
In this process casting is placed inside large barrel
with number of cast iron pieces.
Both ends of barrel are closed and the same rotated
for some time. The casting is cleaned.
c) Sand blasting:
In this method a stream of high velocity air, carrying
large grain size sand particles is thrown on to surface
of casting.
Abrasive sand particles are introduced into air blast by
means of suction, gravity feed or direct pressure.
Prof. P.B. Borakhede, MGI-COET, Shegaon
48. The abrasive action of sand particles, striking against
casting surface at very high velocity provides cleaning
action.
d) Shot Blasting:
This method is similar to sand blasting, but in this
metallic abrasive are fed into air blast instead of sand
grains.
They may be in form of shots or cut wires.
It provides a very fast rate of cleaning.
Prof. P.B. Borakhede, MGI-COET, Shegaon
49. IMPORTANT QUESTIONS
Discuss direct arc and indirect arc electric furnaces with
neat sketch.
Describe 'Pit Furnace' with figure.
What is 'CUPOLA'? Explain preparation or operations of
Cupola for melting.
Explain 'lnduction furnace' with its importance.
What do you mean cleaning of casting? Explain any one
method.
Explain chemical reactions in different zones of cupola
furnace.
Draw a sectional view of cupola furnace showing details.
Also, explain various cupola operations.
Prof. P.B. Borakhede, MGI-COET, Shegaon
50. Explain the following inspection methods.
Magnetic particle testing.
Radiography
What are the advantages of Electric Furnace? Explain
direct arc furnace with neat sketch.
What do you understand by Non destructive testing of
castings ? Explain any one method of NDT in detail.
What factors governs the selection of type of furnace in
foundry ?
Prof. P.B. Borakhede, MGI-COET, Shegaon