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Glossary of Foundry Terms - A

Abrasion

The displacement and/or detachment of metallic particles from a surface as a consequence of being exposed to flowing solids, fluids or gases.

Abrasion Resistance

Degree of resistance of a material to abrasion or wear.

Abrasive

Any substance used for abrading, such as grinding, polishing, blasting etc. Abrasive materials come in all shapes and forms, powders, bonded to wheels, boards, papers; they can be sand, files, emery, and so on.

Abrasive Wear

The displacement and / or detachment of metallic particles from a surface as a consequence of being exposed to flowing fluids or gases. See Abrasion.

Abrasives

Materials for grinding, polishing, blasting, either in loose form or bonded to form wheels, bricks, or files, or applied to paper and cloth by glue or resin. Natural abrasives include emery, corundum, garnet, sand, flint, etc. Metallic shot and grit are also used as abrasives in cleaning castings.

Ac1

The temperature at which austenite begins to form on heating. See Austenite.

Ac3

In hypoeutectoid steel, the temperature at which transformation of ferrite into austenite is completed upon heating. See Hypoeutectoid Steel, Ferrite, Austenite.

Accelerator

A substance that hastens a reaction usually acting as a catalyst; as used in sand additive resins.

Acceptable Quality Level (AQL)

A quality level established on a prearranged system of inspection using samples selected at random.

Accm

In hypereutectoid steel, the temperature at which cementite goes into complete solution with austenite. See Hypoeutectoid Steel.

Acid

A solution or liquid with a pH less than 7. A term applied to slags, refractors, and minerals containing a high percentage of silica. A chemical term to define a material, which gives an acid reaction. See pH, Slag.

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Acid Brittleness (Picking brittleness)

Lack of ductility, induced in steel when it is pickled in dilute acid to remove scale - commonly attributed to the absorption of hydrogen. See Ductility.

Acid Embrittlement

Embrittlement during pickling due to absorption of hydrogen.

Acid Melting

Melting in a furnace with refractory material that has an acid reaction. Material may be silica, sand, siliceous rock, or silica brick.

Acid Process

A steel making method using an acid refractory-lined (usually silica) furnace. Neither sulfur nor phosphorus is removed.

Acid Steel

Steel melted in a furnace which has an acid bottom and lining, under a predominantly siliceous slag.

Adapti Investment Casting Process

A lost wax process employing one of three methods; centrifugal, vacuum or gravity-pouring casting. See Investment Casting.

Addition Agent

Any material added to a charge of molten metal in bath or ladle to bring alloy to specifications. A reagent added to the plating bath. See Alloy, Ladle.

Additives

Any material added to molding sand for reasons other than bonding or improvement of bond is considered an additive. Bonds can be of varying types: carbonaceous (sea coal, pitch, fuel oil, graphite, gilsonite); cellulose (wood flour, cereal hulls); fines (silica flour, iron oxide, fly ash); cereals (corn flour, dextrine, sugar); and chemical (boric acid, sulfur, ammonium compounds, diethylene glycol). See Sea Coal.

Adeline Steelmaking Process

Method of producing a precision casting of steel or steel alloys using aluminolthermic process and lost wax, followed by centrifugal action. See Lost Wax Process.

ADI - Austempered Ductile Iron

A very high strength, high ductility, iron grade created through heat treating. See Ductility.

Aecm, Ae1, and Ae3

Equilibrium transformation temperatures in steel.

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Aeration

Making contact between air and a liquid by spraying liquid into the air or by agitating the liquid to promote absorption of air. Also act of fluffing molding sand.

Aerator

A device for fluffing (or decreasing the density of) and cooling sand by the admixture of air. See Molding Sand.

AFS Fineness Number

Approximately the number of meshes per inch of a sieve that just would pass the sand sample if its grains were uniform in size. In other words, it is the average of the grains in the sand sample. See American Foundrymen's Society.

AFS Tests

A number of standard tests determined by American Foundrymen's Society to evaluate molding and core sands. See Core Sand, Molding Sand.

Age Hardening

Hardening by aging, usually after rapid cooling or cold working. See Precipitation Hardening.

Aging

A change in properties of metals and alloys which occurs slowly at room temperature and will proceed rapidly at higher temperatures. A change in the metal or alloy by which its structure recovers from an unstable condition produced by quenching, quench aging, or by cold working, strain aging. The change in structure consists. The change in properties is often, but not always, due to a phase change, precipitation, but never involves a change in chemical composition of the metal or alloy. See Age Hardening, Precipitation Hardening.

Air Belt

Chamber, surrounding the cupola at the tuyeres, to equalize the volume and pressure of the blast and deliver it to the tuyeres. See Cupola, Tuyere.

Air Channel

A groove or hole which carries the vent from a core to the outside of a mold. See Core, Mold.

Air Control Equipment

Any device used to regulate the volume, pressure, or weight of air.

Air-Dried (Dry)

A core or mold dried in air, without application of heat. See Core, Mold.

Air Furnace

A form of reverberatory furnace for melting ferrous and nonferrous metals and alloys. Flame from fuel burning at one end of the hearth passes over the bath to the stack at the opposite end of the furnace. Heat also is reflected from the roof and side walls.

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Air Hammer

Chipping hammer operated by compressed air.

Air Hardening

Full hardening of a metal or alloy during cooling in air or other gaseous medium from a temperature above its transformation range.

Air Hoist

Lifting device operated by compressed air.

Air Hole

Hole in a casting caused by air or gas trapped in the metal during solidification. See Casting.

Air Injection Machine

An early type of die casting machine in which air pressure acting directly on the surface of molten metal in a closed gooseneck forces the metal into the die.

Air Quenching

Accelerated cooling of alloy in an air stream from temperatures above the Ac3 temperature. See Ac3.

Air Scale

Scale left on ferrous metal in processing, usually from heating in presence of air.

Air Setting

The property of some materials to take a permanent set at normal air temperature. Examples are gypsum slurry, investment molding materials, core and mold washes, etc. See Core, Mold.

Airblasting

A cleaning operation, as cleaning sand from molds.

Air-Hardening Steel

A steel containing sufficient alloy to fully harden during cooling in air. Typically this term is restricted to steels being able to harden in sections of about 2 inches (51 mm) or more.

Airless Blast Cleaning

A process whereby the abrasive material is applied to the object being cleaned by centrifugal force generated by a rotating-vane-type wheel.

Alkaline Derusting

An electrical process for derusting steel, cast iron and other ferrous alloys without using heat.

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Allowance (Tolerance)

In a foundry, the clearance specified; difference in limiting sizes, as minimum clearance or maximum interference between mating parts, as computed arithmetically.

Alloy

A substance having metallic properties and composed of two or more chemical elements of which at least one is metal. A metallic material formed by mixing two or more chemical elements. Usually possess properties different from those of the components. As examples, Brass is an alloy of copper and zinc and Cast Iron contains iron, carbon and silicon. See Cast Iron.

Alloy Steel

Steel containing significant quantities of alloying elements other than carbon and the commonly accepted amounts of manganese, silicon, sulfur, and phosphorus.

Alloying

Procedure of adding elements other than those usually comprising a metal or alloy to change its characteristics and properties.

Alloying Elements

Elements added to nonferrous and ferrous metals and alloys to changer their characteristics and properties.

Alpha-Ferrite

Body-centered cubic type of pure iron stable below 1,670°F (910°C).

Alpha Martensite

A form or stage of martensite of somewhat arbitrary distinction, probably representing the least developed and most distorted stage in the transformation of austenite to martensite at ordinary temperatures. See Martensite.

Alpha Process

A shell molding and core-making method in which a thin resin-bonded shell is baked with a less expensive, highly permeable material. See Shell Molding.

Alternating Stress

Stress produced in a material by forces acting alternating in opposite directions.

Ambient Air

The surrounding air.

Ambient Temperature

Temperature of the surrounding air.

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American Foundry Society

Association that provides and promotes knowledge and services that strengthen the metal casting industry for the ultimate benefit of its customers and society.

Ames Portable Hardness Tester

The Rockwell penetration method of testing hardness of metals can be made with this tester by applying pressure to the penetrator by screw action. See Rockwell Hardness.

Analysis Line

In spectrographic analysis, the particular spectral line used in determining the concentration of an element.

Anchor

Appliance used to hold cores in molds.

Angle Testing

A method of ultrasonic testing using shear waves introduced from the surface of the material at approximately 45°F or °C.

Anisotropy

The characteristic of exhibiting different property values in different directions with respect to a fixed reference system in the material.

Annealing

The process of heating a metal and slowly cooling it, reducing the brittleness and increasing the strength of the metal. See Bright Annealing, Double Annealing.

Anodizing

Forming a conversion coating on a metal surface by electrolytic oxidation with the work forming the anode. This process is most frequently applied to aluminum.

Anticarburizing Compounds

Compounds applied to metallic surfaces to prevent surface carbonization.

Antimony

One of the elements; its chemical symbol is Sb. Its formula weight is 121.76, specific gravity 6.62, and melting point 630.5°C.

Antioch Process

Plaster molding process using a mixture of about 50% sand, 40% gypsum, and 8% fibrous talc mixed with water in the proportion of 100 parts by weight material with 50 parts water.

Antipiping (Material)

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Usually refers to an insulating material placed on top of a sprue or riser that keeps the metal in liquid or semiliquid form for a long period of time and minimizes the formation of the usual conical pipe or shrink in the top of a sprue or riser. See Riser, Sprue.

Apparent Contraction

The net contraction of a casting dimension due to true metal contraction, mold wall movement and restraint during solidification and cooling. See Solidification.

Arbor

A metal barrel, frame, or plate to support or carry part of a mold or core. A device to reinforce or lift a mass of sand. See Core, Mold.

Arc Cutting

Using an electric arc to cut metal.

Arcair Torch

An electric arc torch with air ducts running parallel to the electrode, used to remove metal and surface defects from ferrous castings. See Casting.

ARD Process

A refinement of the precision casting process, using plastic patterns produced in automatic injection machines. See Casting, Pattern.

Argon Oxygen Decarburization (AOD)

A secondary refining process in which argon, oxygen and nitrogen are injected into a molten bath of steel. The AOD process improves metal cleanliness and thus gives superior mechanical properties.

Arnold's Fatigue Test

(Named after John Arnold), a test for fractures using 850 cyclic stress reverses per minute, recording the number of cycles required to produce fracture.

Arrestor, Dust

Equipment for removing dust from air.

Artificial Aging

An aging treatment above room temperature. See Aging, Age Hardening.

As Cast (As-Cast, u.m.)

Referring to metal which has not received finishing (beyond gate removal or sandblasting) or treatment of any kind including heat treatment after casting. Similarly as drawn as forged and as rolled. See Heat Treatment.

As-Cast Condition

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Casting without subsequent heat treatment. See Casting, Heat Treatment.

Assembling (Assembly) Line

Conveyor system where molds or cores are assembled. See Core, Mold.

Atomic Probe Field Ion Microscopy (APFIM )

An analytical technique in which atoms are ionized by an electric field near a sharp specimen tip. The field then forces the ions to a fluorescent screen which shows an enlarged image of the tip and individual atoms are made visible.

Atmosphere, Furnace

Gases with which metal is in contact during melting or heat treating. See Heat Treating.

Atmosphere, Neutral

Furnace atmosphere which is neither oxidizing nor reducing can be made up of an inert gas e.g. argon, or the products of combustion.

Atmosphere, Oxidizing

Furnace atmosphere which gives off oxygen under certain conditions or where there is an excess of oxygen in the product of combustion, or the products of combustion are oxidizing to the metal being heated.

Atmosphere, Reducing

Furnace atmosphere which absorbs oxygen under suitable conditions or in which there is insufficient air to completely burn the fuel, or the product of combustion is reducing to the metal being heated.

Atmospheric Riser (Williams)

Blind riser that employs atmospheric pressure to aid feeding. Insertion of a small sand core into the riser provides a means for ingress of air into the interior of the riser, and forces the metal into the casting cavity. See Riser, Cavity, Mold or Die.

Atom

The smallest particle of an element.

Austenite

The face-centered-cubic phase of iron and steel, also referred to as gamma iron. In steel, a solid solution in which gamma iron is the solvent. See Gamma Iron.

Austenite Steel

Any steel containing sufficient alloy to produce a stable austenitic (gamma iron) crystalline structure at ambient temperatures. See Gamma Iron.

Austenitic

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Usual reference is to an alloy steel or iron with structure at room temperature that is normally composed essentially of austenite.

Glossary of Foundry Terms - B

Back (Backing) Sand

Sand between the facing sand and the flask. See Facing Sand, Flask.

Backdraft

A reverse taper from the designed direction of draw from a pattern or corebox; prevents removal of a pattern from a mold without damage to the mold-tear ups. See Molds, Pattern.

Backing Board (Backing Plate)

A second bottom board where molds are opened.

Backing Sand

The bonding agent used as an additive to mold or core sand to impart strength or plasticity in a "green" or dry state. See Green Sand.

Baffle Plate

Plate or wall in a firebox or furnace to change direction of the flame.

Bail

Connection between crane and hook and ladle. See Ladle.

Bainite

In steel, an acicular aggregate of ferrite and carbide, resulting from an isothermal transformation of austenite at a temperature below the pearlitic range and above Ms. See Austenite.

Bake

Heat in an oven to a low controlled temperature to remove gases or to harden a binder.

Baked Core

A core which has been heated through sufficient time and temperature to produce the desired physical properties attainable from its oxidizing or thermal-setting bindersas opposed to a green-sand core, which is used in the moist state. See Binder, Core, Green Sand.

Baked Permeability

Property of a molded mass of sand heated at a temperature above 230ƒ F until dry and cooled to room temperature, to permit passage of gases through it; particularly those generated during pouring of molten metal into a mold. See Mold.

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Baked Strength

Compressive, shear, tensile or transverse strength of a mold sand mixture when baked at a temperature above 231ƒF (111ƒC) and then cooled to room temperature. See Molding Sand.

Ball Burnishing

A method of obtaining a high luster on small parts by rotating them in a wooden-lined barrel with water, burnishing soap, and stainless steel shot.

Band, Inside

A loose steel frame placed inside a removable flask to reinforce the sand at the parting line. See Flask, Parting Line.

Banking the Cupola

Method of keeping cupola hot and ready for immediate production of hot iron after an unexpected shutdown of several hours. Procedure is to drain all molten iron and slag from the cupola, place extra coke on the top charge, and open one or two tuyeres to supply a small natural draft to keep coke combustion going. See Coke, Cupola, Tuyeres.

Bark

The decarburized layer just beneath the scale resulting from heating steel in an oxidizing atmosphere.

Bar / Bars

Metal supports placed in a flask, usually the cope to reinforce sand. See Cope, Flask.

Bars (Cleats)

Ribs of metal or wood placed across the flask to help support the sand in the cope. See Cope.

Base Plate

A plate to which the pattern assemblies are attached and to which a flask is subsequently attached to form the mold container.

Basic

A chemical term for a material which gives an alkaline reaction.

Basic Bottom or Lining (Furnace)

Inner lining and bottom of a melting furnace composed of materials having a basic reaction. Materials may be crushed burnt dolomite, magnesite, magnesite brick, or basic slag. See Manganese Briquets.

Basic Steel

Steel melted in a furnace with a basic bottom and lining under a predominantly basic slag.

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Basin

A cavity on top of the cope into which metal is poured before it enters the sprue. See Cope, Sprue.

Batch

Amount or quantity of core or mold sand or other material prepared at one time.

Batch Oven

Oven use to bake a number of cores at one time.

Bath

Molten metal pool on the hearth of a furnace in a ladle or furnace. See Ladle.

Batten

A wooden bar or strip fastened to bottom or follow board for rigidity or to prevent distortion during ramming of the mold. See Ramming.

Baume

Designating or conforming to either of the scales used by the French chemist Antoine Baume in the gradation of his hydrometers for determining the specific gravity of liquids.

Bauxite

An ore of aluminum consisting of moderately pure hydrated alumna, Al2O3× 2H2O.

Bead

Half-round cavity in a mold, or half-round projection or molding on a casting.A single deposit of weld metal produced by fusion.

Beam and Sling

Tackle used in conjunction with a crane for turning over the cope or drag of a mold prior to assembly. See Cope, Drag.

Bed Charge

The charge of iron placed on the coke bed in a cupola. See Coke Bed, Cupola.

Bed Coke

Coke placed in the cupola well to support the following iron and coke charges.

Bedding

Sinking a pattern down into the sand to the desired position and ramming the sand around it. See Ramming.

Bedding A Core

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Resting an irregularly shaped core on a bed of sand for drying.

Bedding In

Sinking a pattern in to the sand by excavating a "bed" in which the pattern is placed for ramming up.

Bed-In

Method whereby drag may be rammed in the pit or flask without necessity of rolling over. Process used in production of heavy castings. See Drag, Ramming, Pit, Flask.

Beehive Coke

Coke which is produced in hemispherical ovens about 12 feet in diameter and charged through the top to form a layer of coal 18 to 24 inches deep. Coke is ignited and air for partial combustion is supplied over the top by doors around the bottom of the ovens. Air burns volatile matter released by coke and during the later stages of carbonization burns some 5% to 8% of the coke. See Coke.

Bellows

A device operated with both hands, to produce a current of air. Some bellows are mechanically operated.

Bench

Frame support on which small molds are made.

Bench Molder

Man who makes small molds on a molder's bench. See Molding Bench.

Bench Rammer

A short rammer used by a bench molder. See Bench Molder.

Bench-Blower

A small core-blowing machine, utilizing a removable sand magazine and blow heat.

Bending Strength

Upper limit of normal stress of a beam at which fracture or excessive plastic deformation occurs.

Bentonite

A widely distributed, peculiar type of clay which is considered to be the result of devitrification and chemical alteration of the glassy particles of volcanic ash or tuff. Used in a foundry to bond sand.

Bernoulli's Theorem

A theorem which states that in a stream flowing without friction, the total energy in a given amount of the fluid is the same at any point in its path of flow.

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Bessemer Process

Method of making steel by blowing air through molten pig or carbon-bearing iron contained in a suitable vessel which causes rapid oxidation of silicon, carbon, etc.

Bimetal

Casting, usually centrifugal, made of two different metals, fused together.

Binary Alloy

An alloy of two metals.

Binder

The bonding agent is a material used as an additive to mold or core sand to impart strength or plasticity in a "green" or dry state. May be cereal, oil, clay, resin, pitch, etc. See Green Sand.

Binder, Plastic (Resin)

Synthetic resin material used to hold grains of sand together in molds or cores; may be phenol formaldehyde or urea formaldehyde thermosetting types. See Cores, Molds.

Black Heart

American type of malleable iron. The normal fracture shows a velvety black appearance having a mouse-gray rim. See Malleable Iron.

Black Lead

A natural form of graphite used for sleeking green sand molds, or applied in a water suspension to skin dried molds. Graphite for facing molds and cores. See Cores, Green Sand.

Blackening Scab

A form of casting defect related to an improper coating rather than to the sand.

Blackheart

American type of malleable iron. The normal fracture has a medium gray outer rim and a very black interior. See Malleable Iron.

Blacking

Carbonaceous material for coating mold or core surfaces.

Blacking Carbon

Carbonaceous materials such as plumbago, graphite or powdered coke usually mixed with a binder and frequently carried in suspension in water or other liquid; used as thin facing applied to surfaces of molds or cores to improved casting finish. See Plumbago.

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Blacking Hole

Irregular-shaped surface cavities in a casting containing carbonaceous matter. Caused by spilling off of the blacking from the mold surface.

Blacking Scab

A casting defect formed by blacking flaking off due to sand expansion and being retained in or on the surface of the metal.

Blast

Air driven into the cupola or furnace for combustion of fuel.

Blast Cleaning

Removal of sand or oxide scale from castings by the impinging action of sand, metal shot, or grit projected under air, water, or centrifugal pressure.

Blast Furnace

Closed-top-shaft furnace for producing pig iron from iron ore.

Blast Gate

Sliding plate in the cupola blast pipe to regulate the flow of air. See Cupola.

Blast Meter

Instrument indicates the volume or pressure, or both, of air passing through the blast pipe.

Blast Pressure

Pressure of air in blast pipe or wind belt of the cupola, depending on the location of indicating instrument. Usually given in ounces of water pressure.

Blasting (Blast Cleaning)

A process for cleaning or finishing metal objects by use of an air blast or centrifugal wheel that throws abrasive particles against the surface of the work pieces. Small, irregular particles of steel or iron are used as the abrasive in grit blasting, and steel or iron balls in shot blasting. See Blast Cleaning.

Bleed (Bleeder, Bleeding)

Molten metal oozing out of casting stripped or removed from the mold before solidification. See Solidification.

Bleeder

A defect wherein a casting lacks completeness due to molten metal draining or leaking out of some part of the mold cavity after pouring has stopped.

Blended Molding Sands

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Naturally bonded molding sands which have been mixed or modified by the supplier to produce desirable properties. See Molding Sands.

Blended Sand

Mixture of sands of different grain sizes, clay content, etc., to produce one possessing characteristics more suitable for foundry use.

Blind Riser

A riser not opened to the atmosphere or does not reach to the exterior of the mold. See Riser.

Blister

A defect on the surface of a casting appearing as a shallow blow with a thin film of metal over it. In die-casting, it is a surface bubble or eruption caused by expansion of gas (usually as a result of heating) trapped within the die-casting or beneath the plating on the die-casting. See Blow, Die-Casting (noun).

Blocking

Adding ferrosilicon or other deoxidizing agent to a refined heat to stop all oxidizing reactions.

Blocking the Heat

Stopping the carbon drop in production of steel by addition of deoxidizers such as silicomanganese, spiegel, or ferrosilicon and ferromanganese. See Spiegeleisen.

Blow

A casting defect due to trapping of gas in molten or partially molten metal. See Blister.

Blow Gun

A valve and nozzle attached to a compressed air line to blow loose sand or dirt from a mold or pattern. Also to apply wet blacking.

Blow Hole

A hole, or void, left in the casting caused by trapped air or gases. See Blow.

Blow Holes

The holes in the head plate or blow plate of a core-blowing machine through which sand is blown from the reservoir into the core box. The irregular shaped cavities with smooth walls produced in a casting when gas is entrapped during mold filling. The gas sources may be air, binder decomposition products or gases dissolved in the molten steel. See Blow.

Blow Pipe

A small pipe or tube through which the breath is blown to remove loose sand from small molds.

Blow Plate

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Plate on the bottom of the sand hopper on core or mold blower machines which contains holes through which the sand is blown into the core box or flask. The plate containing the core sand entrance holes or blow holes used in open-face core boxes. See Core Box, Flask.

Blower

Machine or device for supplying air under pressure to the melting unit.

Blower, Core Or Mold

A machine or device using compressed air to inject sand into a core box or a flask. See Core Box, Flask.

Blowing Off A Mold

Cleaning a mold cavity with a stream of compressed air. See Cavity, Mold Cavity.

Blowpipe

A small pipe or tube through which the breath is blown in removing loose sand from small mold cavities.

Blows

See Blow Holes.

Bluing

The formation of a thin film of oxide on polished steel to improve its appearance and protect its surface.

Bob

A riser or feeder, usually blind, to provide molten metal to the casting during solidification, thereby preventing shrinkage cavities. See Riser.

Bod (Bott) Stick

A stick or rod on which the bod is mounted to that it may be forced into the tap hole. See Tap Hole.

Bod, Bott

A piece of clay or other material to stop the flow of metal from the tap hole. See Tap Hole.

Body Core

The main core.

Boil

Agitation of a bath of metal by using steam or gas beneath its surface. May be deliberately induced by the addition of oxidizing material to a bath containing excess carbon. In the later case it is called a carbon boil and CO or CO2 are liberated.

Bond

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(a) A bonding substance or bonding agents - any material other than water, which, when added to foundry sands, imparts bond strength. The overlapping of brick so as to give both longitudinal and transverse strength. (b) Cohesive material in sand. See Foundry Sand.

Bond Clay

Any clay suitable for use as a bonding material in molding sand. See Molding Sands.

Bond Strength

a property of foundry sand that offers resistance of foundry sand to deformation. See Foundry Sand.

Bonding Clay (Bonderise)

Any clay suitable for use as a bonding material.

Booking

Method of assembling or bringing together two halves of a core in a manner similar to closing a book. See Core.

Boric Acid

An inhibitor used in facing sand for magnesium-base and aluminum-base alloys high in magnesium to prevent reaction with moisture in the sand. See Facing Sand.

Boring

A machining method using single point tools on internal surfaces of revolution.

Borings

Metal in chip form resulting from machining operations.

Boron

One of the periodic chart elements. Its chemical symbol is B and its atomic weight is 10.82. In the form of borax and boric oxide, it is used as a flux in nonferrous metallurgy, and in the form of an alloy with other elements, as an addition to ferrous alloys. See Alloy, Flux.

Boron Trichloride

A product used for degasification of aluminum alloys.

Bosh

Sloping of the cupola lining to form a smaller diameter just above the tuyeres. See Cupola, Tuyeres.

Boss

A projection of circular cross-section on a casting, usually intended for drilling and tapping for attaching parts. See Casting.

Boss (Pad)

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A projection of circular cross-section on a casting. Usually intended for drilling and tapping for attaching parts. See Casting.

Bottom Board

The board that the mold rests on that supports the mold.

Bottom Doors

The doors that are underneath the cupola. See Cupola.

Bottom Pour Ladle

Ladle in which metal, usually steel, flows through a nozzle in the bottom. See Ladle, Bottom Pouring.

Bottom Pour Mold

A mold that is gated at the bottom.

Bottom Running Or Pouring

Filling of the mold cavity from the bottom by means of gates from the runner. See Gate, Runner, Mold Cavity.

Bottom Sand

Layer of molding sand rammed into place on the doors at the bottom of a cupola.

Bracket

Strengthening strip, rib, or projection on a casting; usually used to prevent hot tearing. See Cracking Strip.

Branch Core

Part of a core assembly.

Branch Gate

Two or more gates leading into the casting cavity. See Cavity.

Brass

Copper-base alloy with zinc as the major alloying element. See Alloy.

Brazing

Joining metals and alloys by fusion of nonferrous alloys with melting points above 800ƒ F, but lower than those of the materials being joined.

Breaker Ring

An intentionally weak ring within mass of a ring shell mold to be broken by force of casting shrinkage. Prevents hot tear stress. See Hot Tear.

Breakoff Notch

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A thinner section of a gate or riser to facilitate and ensure clean breaking-off during the cleaning process of casting.

Breast

Area surrounding the tap hole of a melting furnace. See Tap Hole.

Breeze

Coke or coal screenings.

Brettleness

A tendency to fracture without appreciable deformation.

Bridge

Material adhering to the cupola wall which slows or prevents descent of the stock charges. See Cupola.

Bright Annealing

A process carried out usually in a controlled furnace atmosphere, so surface does not oxidize, remaining bright. See Annealing.

Brinell Hardness

The value of hardness of a metal on an arbitrary scale representing kg/mm2 determined by measuring the diameter of the impression made by a ball of given diameter applied under a known load. Values are expressed in Brinell Hardness Numbers, BHN. See BHN.

Brinell Hardness Number (BHN)

A measure of how hard a material is. The higher the hardness number, the harder the material. It is the most appropriate measurement scale for measuring hardness in iron castings.

Briquets

Compact cylindrical or other shaped blocks formed of finely divided materials by incorporation of a binder, by pressure, or both. Materials may be ferroalloys, metal borings or chips, silicon carbide, etc.

Brittle Fracture

Fracture with little or no plastic deformation.

Broaching

Smoothing machined holes or outside surfaces of castings by drawing pushing on or more broaches (special cutting tools) through the roughed out hole.

Bronze

A copper-base alloy, using tin as the major alloying element. See Alloy.

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Buckle

Bulging of a large flat face of a casting; in investment casting, caused by dip coat peeling from the pattern. Defect on a casting surface, appearing as an indention resulting from an expansion scab. An indentation in a casting, resulting from expansion of the sand, may be termed the start of an expansion defect.

Built-Up Plate

A pattern plate of suitable material with the cope pattern mounted on or attached to one side with the drag on the other. See Matchplate.

Bulb Sponge

Rubber ball with a small piece of sponge inserted in the hole.

Bulk Density

The ratio of the weight of a material to its over-all volume (including any inherent porosity).

Bull Ladle

See Ladle.

Bumper

Machine for ramming sand in a flask by repeated jarring or jolting action.

Burden

Term used to designate the metal charge for a melting furnace. It is also used in cost accounting to indicate certain additional charges to be included in assessing costs in the different areas.

Buring In

See Penetration, Metal.

Burn

The process of cutting metal by a stream of fuel and oxygen. To permanently damage a metal or alloy by heating to cause either incipient melting or intergranular oxidation.

Burned Sand

Sand in which the binder or bond has been removed or impaired by contact with molten metal.

Burned-On-Sand

A misnomer usually indicating metal penetration into sand resulting in a mixture of sand and metal adhering to the surface of a casting. Sand adhering to the surface of the casting which is extremely difficult to remove. This condition may be due to soft molds, poor sand compaction, insufficient mould coating (graphite) paint, or high pouring temperature.

Burner

21

A device which mixes fuel and air intimately to provide perfect combustion when the mixture is burned. Types include acetylene, oil, gas, powdered coal, stoker, etc.

Burn-In/Burn-On

A misnomer usually indicating metal penetration into molding and core sand resulting in a mixture of metal and sand on a casting usually due to the metal penetrating into the sand. See Core Sand, Molding Sands.

Burnishing

Developing a smooth finish on a metal by tumbling or rubbing with a polished hand tool.

Burn-Out

Usually refers to removal of the disposable wax or plastic pattern in the investment-molding process by heating the mold gradually to a sufficiently high temperature to consume any carbonaceous residues.

Burnthrough

In shell molding, resin burned out too soon. See Shell Molding.

Bushing

A sleeve, metallic or nonmetallic, usually removable or replaceable, which is placed in a body to resist wear, erosion, etc.

Butt Off

Operation performed at times to supplement ramming by jolting, either hand or air rammer. See Ramming.

Butt Rammer

The flat end of the molder's rammer. See Ramming.

Glossary of Foundry Terms - C

C

Degrees Centigrade or Celsius.

C or Croning Process

See Shell Molding.

Computer Aided Design (CAD)

The computer software/hardware used to produce part drawings electronically.

CAE

Abbreviation for Computer Aided Engineering.

22

Calcium Boride

An alloy of calcium and boron corresponding (when pure) to the formula CaB6, containing about 61% boron and 39% calcium, and used in deoxidation and degasification of nonferrous metals and alloys.

Calcium Carbide

A grayish-black, hard crystalline substance made in the electric furnace by fusing lime and coke. Addition of water to calcium carbide forms acetylene and a residue of slaked lime. See Electric Furnace.

Calcium Molybdate

A crushed product containing 40-50% molybdenum, 23-25% lime, 3% iron maximum and 5-10% silica, used to add molybdenum to iron and steel produced in the open hearth, air furnace, or electric furnace. See Open Hearth, Air Furnace, Electric Furnace.

Calcium Silicon

An alloy of calcium, silicon, and iron containing 28-35% Ca, 60-65% Si, and 6% Fe, maximum used as a deoxidizer and degasser for steel and cast-iron; sometimes called calcium silicide.

Calcium Wired Injection

Wire feeding of steel clad calcium wire into molten bath to provide favorable kinetics for inclusion modification.

Calcium-Aluminum-Silicon

An alloy composed of 10-14% calcium, 8-12% aluminum, and 50-53% silicon, sued for degasifying and deoxidizng steel. See Alloy.

Calcium-Manganese-Silicon

An alloy containing 17-19% calcium, 8-10% manganese, 55-60% silicon, and x0 to 14% iron, used as a cavenger for oxides, gases, and nonmetallic impurities in steel. See Alloy.

CAM

Acronym for Computer-Aided Manufacturing.

Camber

Deviation from edge straightness usually referring to the greatest deviation of side edge from a straight line.

Captive Foundry

A foundry that is an operating part of a manufacturing plant, and whose production products, castings, are used within the plant as parts of finished objects.

Carbide

A compound of carbon with a more positive element, such as iron. Carbon unites with iron to form iron carbide or cementite, Fe3C. See Cementite.

Carbon

23

Element occurring as diamond and as graphite. Carbon reduces many metals from their oxides when heated with the latter, and small amounts of it greatly affect the properties of iron. Though classed as a nonmetallic, metallurgically, like boron, it is treated as a metal.

Carbon Boil

Refers to the practice of adding oxidizing agents such as iron ore or oxygen to molten steel in the furnace to react with carbon and create a boiling action. In addition to reducing the carbon content, it removes occluded gasses such as hydrogen, oxygen, and nitrogen. See Boil.

Carbon Dioxide Process (Silicate process, Schmidt Philip process)

A process for hardening molds or cores in which carbon dioxide gas is blown through dry clay-free silica sand to precipitate silica in the form of a gel from the sodium silicate binder. See Silica Sand.

Carbon Equivalent

Relationship of total carbon, silicon, and phosphorus in gray iron, expressed by the formula CE=TC%+Si%/3+P%/3.

Carbon Sand

A molding aggregate consisting principally of carbon (graphite) granules.

Carbon Steel

Steel which owes its properties chiefly to various percentages of carbon without substantial amounts of other alloying elements; also known as ordinary steel or straight carbon or plain carbon steel.

Carbon, Combined

The carbon in iron or steel which is combined with other elements and therefore is not in the free state as graphite or as temper carbon. See Temper Carbon.

Carbonitriding (Nicarbing)

A process in which a ferrous alloy is case hardened by first being heated in a gaseous atmosphere of such composition that the alloy absorbs carbon and nitrogen simultaneously, and then being cooled at a rate that will produce desired properties.

Carburizing

A form of case hardening that produces a carbon gradient inward from the surface, enabling the surface layer to be hardened by either quenching directly from the carbonizing temperature or by cooling to room temperature, then reaustenitizing and quenching.

Case

The surface layer of an iron-base alloy which has been suitably altered in composition and can be made substantially harder than the interior or core by heat treatment.

Case Hardening

24

A process of hardening a ferrous alloy so that the surface layer or case is made substantially harder than the interior or core. Typically case hardening process are carburizing, carbonitriding, and nitriding. See Carburizing, Carbonitriding, and Nitriding.

Cast Iron

Iron shaped using any number of casting processes. Gray Iron is by far the oldest and most common form of cast iron. As a result, it is assumed by many to be the only form of cast iron and the terms "cast iron" and "gray iron" are used interchangeably. Generic term for a series of alloys of iron, carbon, and silicon, in which the carbon is in excess of the amount which can be retained in solid solution in austenite at the eutectic. When cast iron contains a specially added element or elements in amounts sufficient to produce a measurable modification of the physical properties under consideration, it is called alloy cast iron. Silicon, manganese, sulfur, and phosphorus, as normally obtained from raw materials, are not considered as alloy additions. Term used to describe a series of ferrous alloys containing over 1.74% of carbon. See Alloy, Gray Iron, Iron.

Cast Plate

Metal plate, usually aluminum, cast with the cope pattern on one side and the drag pattern on the other. See Matchplate.

Casting (verb)

A process where molten metal is poured into a mold and solidification is allowed to take place. The act of pouring metal.

Casting (noun)

A metal object obtained by pouring molten metal into a mold. The metal shape, exclusive of gates and risers, that is obtained as a result of pouring metal into a mold. See Gate, Riser.

Casting Defect

A defect in a casted object or casting.

Casting Drawing

An engineering drawing which depicts the shape and size of a part to be cast.

Casting Industry

Is the sixth largest Industry in North America, behind Petroleum, Agriculture, Lumber, Mining, Textile, Transportation according to data supplied by the AFS. The Casting Industry is the making of products from metals, earth, glass, etc. See AFS.

Casting Layout

A check of dimensions against applicable drawings and specifications.

Casting Porosity

The porosity of a casting artifact.

Casting Process

25

A forming process in which a molten metal, polymer, or other heated liquid or plastic material is poured into a mold or onto a substrate with little or no pressure applied; the substance cools, solidifies, and the formed object is removed.

Casting Strains

Strains resulting from internal stresses created during cooling of a casting.

Casting, Machine (verb)

Process of casting by machine.

Casting, Open Sand (noun)

Casting poured into an uncovered mold.

Cast-Weld

Welding one casting to another to form a complete unit. See Fabrication.

Cast-Weld Assembly

Welding one casting to another to form a complete assembly.

Cavitation

The formation and collapse of cavities or bubbles within a liquid.

Cavity, Mold Or Die

Impression or impressions in a mold or die that give the casting its shape. See Casting (noun).

Cement

Mineral substances in finely divided form, which are hardened through chemical reaction or crystallization. A common one is Portland cement.

Cement Molding

Process in which the sand bonding agent is a type of portland cement that develops high strength early in the hardening stage. Approximately 13 pounds of cement, 6 pounds of water, and 100 pounds of clayfree sand are mixed together. This mixture must be used within 3 to 4 hours. Molds are air dried for 72 hours before use.

Cement, Refractory

Highly refractory material in paste or dry form, ready to be mixed with water which may be used as a mortar, a patching material, or to form a complete lining in a furnace or other unit where high temperatures are encountered.

Cementation

Process of introducing elements into the outer layer of metal objects by means of high-temperature diffusion.

26

Cementite

A hard brittle, crystalline compound of iron and carbon commonly known as iron carbide and having the approximate chemical structure, Fe3C. Cementite is characterized by an orthorhombic crystal structure.

Centrifugal Casting (verb)

Process of filling molds by pouring the metal into a sand or metal mold revolving about either its horizontal or vertical axis, or pouring the metal into a mold that subsequently is revolved before solidification of the metal is complete. Molten metal is moved from the center of the mold to the periphery by centrifugal action.

Centrifugal Casting (noun)

Casting made in molds which are rotating so as to produce a centrifugal force in the molten metal. See Casting.

Ceramic Mold

Mold in which the refractory and binder are such that when fired at high temperature, a rigid structure is formed. Mold can be made in a flask or in the form of a shell. See Binder, Flask, Mold.

CERCLA

Abbreviation for Comprehensive Environmental Response, Compensation and Liability Act. 1980.

Cereal

Substance derived principally from corn flour, which is added to the core and molding sands to improve their properties for casting production. See Core, Molding Sands.

Cerium

Metallic element, malleable and ductile, most abundant of rare-earth group. Atomic weigh 140.13, sp. Gr. 7.04, hardness (Mohs) about 2, melting point 640°C. Has exceptionally strong affinity for oxygen, sulfur, hydrogen, nitrogen, etc.

Ceroxide

See Inclusions.

Chalk Test

Method of crack detection which consists of applying a penetrating liquid to the part, removing the excess from the surface which is then coated with whiting or chalk. After a short time the penetrant seeps out of the cracks into the whiting, causing an appreciable difference in whiteness.

Chamfer

Breaking or beveling the sharp edge or angle formed by two faces of a piece of wood or other material.

Chamotte

Coarsely graded refractory material prepared from calcined clay and ground firebrick mulled with raw clay, used in steel foundries.

27

Chaplet

Metal supports or spacers used in molds to maintain the cores, or parts of a mold, which are not self-supporting. Chaplets maintain these dimensions during the casting process, they then become part of the casting itself as the molten metal solidifies around the chaplet and fuses it into the finished casting.

Charcoal (Pig) Iron

Pig iron reduced in a blast furnace, using charcoal as the fuel. See Blast Furnace.

Charge

A given weight of metal introduced into the furnace. See Blast Furnace.

Charging Crane

System for charging the melting furnace with a crane.

Charging Door

Opening through which the furnace is charged.

Charging Floor

Floor from which the furnace is charged.

Charging Machine

Machine for charging the furnace, particularly the open hearth.

Charpy Impact Test

A pendulum type of impact test which a specimen, supported at both ends as a simple beam, is broken by the impact of the falling pendulum. Energy absorbed in breaking the specimen, as determined by the decreased rise of the pendulum, is a measure of the impact strength of the metal. See Brinell Hardness Test.

Cheek

Intermediate sections of a flask inserted between cope and drag. Necessitated by difficulty in molding unusual shapes, or in cases where more than one parting line is required.

Chicken Wire Cracks

See Craze Crack.

Chill (External)

Metal, graphite or carbon blocks that are incorporated into the mold or core to locally increase the rate of heat removal during solidification and reduce shrinkage defects. See Directional Solidification, Solidification.

Chill (Internal)

28

A metallic device / insert in molds or cores at the surface of a casting or within the mold to increase the rate of heat removal, include directional solidification and reduce shrinkage defects. The internal chill may then become a part of the casting. See Casting, Core, Mold.

Chill (noun)

A device used to cool an isolated area of a mold.

Chill (verb)

To cool rapidly.

Chill Coating

A material applied to metal chills to prevent oxidation or other deterioration of the surface which might result in blows when molten metal comes in contact with the chills.

Chill Coils

Chills made of steel wire formed into helical coils or spirals.

Chill Nails

Chills in the form of nails.

Chill Test

Method of determining the suitability of a gray iron for specific castings through its chilling tendency, as measured from the tip of a wedge-shaped test bar.

Chill Zone

Area of a casting in which chilling occurs, as long sharp edges or exterior corners.

Chilled Iron

Cast iron poured against a chill to produce a hard, un-machinable surface.

Chip (verb)

To remove extraneous metal from a casting with hand or pneumatically operated chisels.

Chlorination

A refining or degasification process, wherein dry chlorine gas is passed through molten aluminum-base and magnesium-base alloys to remove entrapped oxides and dissolved gases.

Choke

Restriction in the gating system that controls the flow rate of metal into the mold cavity.  See Cavity, Mold Cavity.

Choke or Primary Choke

29

The part of the gating system that most restricts or regulates the flow of metal into the mold cavity. See Cavity, Mold Cavity.

Chromel

A 90Ni - 10Cr alloy used in thermocouples.

Chromite

FeCr2O4. Specialty sand used in molding, has a similar effect to chills.

Chromium

Alloying element used as a carbide stabilizer. See Ferrochromium.

Chvorinov's Rule

A rule which states that solidification time is proportional to the square of the volume of the metal and inversely proportional to the square of the surface area, or t (solidification time)=KV2/SA2.

Clamp

A device for holding parts of a mold, flask, corebox, etc., together.

Clamp-Off

Indentation on a casting surface due to displacement of sand in the mold.

CLAS

A casting process in which metal fills the mold through the drag by application of a vacuum. See Drag.

Clay Wash

Clay and water mixed to a creamy consistency.

Clay, Refractory

A clay which, in addition to its capability of resisting high temperatures, also possesses strong bonding power.

Cleaning

Process of removing sand, surface blemishes, runners, risers, flash, surplus metal, and sand etc., from the exterior and interior surfaces of castings. Includes degating, tumbling or abrasive blasting, grinding off gate stubs, etc. See Runners, Risers, Flash, Surplus Metal, and Sand.

Close Over

The operation of lowering a part of the mold over some projecting portion such as a core.

CMM

Abbreviation for Coordinate Measuring Machine.

30

Computerized Numerical Control (CNC)

The use of computers and software to control metal cutting machines. Cutting tool paths can be generated directly from CAD produced part drawings.  See Computer Aided Design (CAD).

Coalescence

Agglomeration of fine particles into a mass. Also growth of particles of a dispersed phase by solution and reprecipitation. Also grain growth by absorption of adjacent undistorted grains.

Cobalt

Blue-white metal, melting at 2,715°F (1,492°C), used in very hard alloy such as stellite, and a binder in carbide cutting tools. See Alloy, Stellite.

Cobalt 60

A radioactive isotope of the element cobalt used in radiographic examinations of castings, and for determining height of molten metal in cupola well.  It is aslo used in used in medical and industrial radiography. See Cupola.

Cocoon Process

A method of protecting metal parts by spraying on a cover of plastic filaments.

Code Holes

The information holes in perforated tape, as opposed to feed or sprocket holes.

Coefficient of Expansion

Unit increase in size resulting from a unit increase in temperature; measured in inches per inch per degree Fahrenheit (in/in/1/2°F) or in millimeter per millimeter per degree Celsius (mm/mm/1/2°C).

Coercive Force

The magnetizing force that must be applied in the direction opposite to that of the previous magnetizing force in order to remove residual magnetism; thus, an indicator of the strength of magnetically hard materials.

Cohesion

The force by which like particles are held together. It varies with different metals and depends upon molecular arrangement due to heat treatment.

Coining

A process of straightening and sizing castings by die pressing. See Castings.

Coke

Coal derivative resulting from the distillation of bituminous coal in the absence of air. The distillation process removes all of the volatile material from the coal so it can be used as a very intense source of fuel in cupola melting. Source of some carbon found in iron. 

31

Coke Bed

First layer of coke placed in the cupola. Also the coke used as the foundation in constructing a large mold in a flask or pit.

Coke Breeze

Fines from coke screening, used in blacking mixes after grinding; also briquetted for cupola use.

Coke Furnace

Type of pot or crucible furnace using coke as the fuel. See Coke, Crucible Furnace.

Coke Porosity

The percentage volume of cell space in coke.

Coke, Beehive

Coke produced from a bituminous coal by the beehive process where heat for the coking process comes from a partial combustion of the coke. Generally characterized by an elongate stringy structure.

Coke, By-Product

Coke produced from bituminous coal in airtight code ovens where heat for coking process is externally applied. Generally more uniform in size than beehive coke, and usually ball or cube shape.

Coke, Petroleum

Residue left from the distillation of petroleum crude, used as a carbon raiser.

Cold Blast Pig Iron

Pig iron produced in a blast furnace without the used of the heated air blast. See Pig Iron.

Cold Box Process

A rapid coremaking process which does not require application of heat to cure the cores. Hardening of the cores is accomplished by chemical reaction rather than by conventional baking. A phenolic resin is added to the sand used to make the core. This resin reacts chemically when exposed to an accelerator, typically an active organic gas, and hardens very quickly, forming an organic bond in the core sand. This reaction occurs at room temperature and does not require special coreboxes or equipment. Additionally, since the bond is organic, the sand collapses readily during shakeout and can be recovered easily from the casting.

Cold Chamber Machine

A diecasting machine where the metal chamber and plunger are not immersed in hot metal.

Cold Chamber, Club Sandwich, Two-Faced, Three-Piece Die

A diecasting die in which two different pieces are cast in two widely separated cavities.

32

Cold Cracking

Cracks in cold or nearly cold metal due to excessive internal stress caused by contraction. Often brought about when the mold is to hard or casting is of unsuitable design.

Cold Lap

Wrinkled markings on the surface of an ingot or casting from incipient freezing of the surface. See Ingot, Casting.

Cold Setting Binders

Term used to describe any binder that will harden the core sufficiently at room temperature so core can be removed from its box without distortion; commonly used in reference to oil-oxygen type binders. See Binder.

Cold Setting Process

An of several systems for bonding mold or core aggregates by means of organic binders, relying upon the use of catalysts rather than heat for polymerization (setting).

Cold Short

A characteristic of metals that are brittle at ordinary or low temperatures.

Cold Shortness

Brittleness when metal is at a low temperature.

Cold Shot

Small globule of metal embedded in but not entirely fused with the casting.

Cold Shut

A surface imperfection due to unsatisfactory fusion of metal. It is caused by insufficient fluidity, low pouring temperature, improper choice of alloy, or inadequate runner systems. The location where two streams of metal do not unite thoroughly in a casting. It may have the appearance of a crack or seam with smooth, rounded edges. Also see Cold Lap.

Cold Work

Plastic deformation of a metal at room temperature. Substantial increases in strength and hardness may occur.

Cold-Box Process

Any core binder process that uses a gas or vaporized catalyst to cure a coated sand while it is in contact with the core box at room temperature.

Collapsibility

Tendency of a sand mixture to break down under conditions of casting.

Collapsible Sprue

33

A sprue pattern of flexible material, or of spring-tube design, used in squeeze-molding of plated patterns, and incorporating a pouring cup. See Pattern, Sprue, Pouring.

Collimator

A device for confining the elements of a beam of radiation within an assigned solid angle.

Colloidal Clay

Finely divided clay of montmorillonite, kaolinite, or illite class; prepared for foundry purposes as in sand bonding.

Colloids

Finely divided material, less than 0.5 micron, 0.00002 in., in size, gelatinous, highly absorbent, and sticky when moistened.

Colloids, Colloidal Material

Finely divided material less than 0.5 micron, 0.00002 in., in size, such as albumin, glue, starch, gelatin, and bentonite.

Coloimetric Analysis

Determining the amount of an element in a solution by measuring the intrinsic color.

Color Etching

A micro-etch resulting from the formation of a thin film of a definite compound of the metal.

Columnar Structure

Coarse structure of parallel columns of grains caused by highly directional solidification resulting from sharp thermal gradients.

Combination Die

A die-casting die having two or more cavities of dissimilar parts. See Multiple-Cavity Die.

Combined Carbon

The carbon in iron or steel combined with other elements and therefore not in the free state as graphite or temper carbon.

Combined Water

That water in mineral matter which is chemically combined and driven off only at temperatures above 231°F (111°C).

Combustibles

Materials capable of combustion; inflammable.

34

Combustion

Chemical change as a result of the combination of the combustible constituents of the fuel with oxygen, producing heat.

Combustion Chamber

Space in furnace where combustion of gaseous products from fuel takes place.

Combustion Efficiency

The amount of heat usefully available divided by the maximum amount which can be liberated by combustion; usually expressed in percentage.

Comfort Zone (Average)

The range of effective temperature over which the majority (50% or more) of adults feel comfortable.

Comodizing

A rust-proofing process for steel.

Compacted Graphite Iron

An iron with with elongated graphite particles with rounded edges and roughened surfaces. It possesses characteristics of both gray and ductile iron. See Gray Iron, Ductile Iron.

Composite Construction

Welding a steel casting to a rolled or forged steel object or to another casting. See Cast-Weld.

Compression Test

Imposing a dead load on a small cylindrical test piece to determine compressive strength, expressed in pounds per square inch.

Compressive Strength

The maximum compressive strength which a material is capable of developing.

Compressor

Device for providing gas under pressure. Usually connotes high pressures and not so high volume.

Compressive Strength (Yield)

The maximum stress in compression that can be withstood without plastic deformation or failure.

Contact Cement

Patternmaking bonding technique, in which liquid bonding agent is painted on both surfaces to be joined and allowed to dry. These dry surfaces placed in contact adhere firmly.

Condensing Rings

35

A special form of chill used for cast iron to produce a dense but graphite structure. See Cast Iron.

Conduction

The transmission of heat, sound, etc. by the transferring of energy from one particle to another.

Conductivity

The quality or power of conducting or transmitting heat, electricity, etc.

Conductivity (Thermal)

The quantity of heat that flows through a material measured in heat units per unit time per unit of cross-sectioned area per unit of length, (electrical) the quantity of electricity that is transferred through a material of know cross-section and length.

Connor Gate (Runner) (Lip feeder)

A runner in which the feed block overlaps the casting by 1/16 in. (1.6 mm). See Runner.

Constant Intensity Pyrometer

Use of a comparison lamp filament's glow to estimate metal temperature.

Constantan

An alloy of nickel and copper use in thermocouples.

Constituent

A micrographically distinguishable part of an alloy or mixture.

Consumer's Risk

The risk the consumer runs of accepting lots of quality p2. See P2.

Contact Printing (Ink Print)

A method of recording details of a macroetched structure. See Sulfur Prints.

Contamination

The presence of small percentages of deleterious elements in an alloy adversely affecting the alloy's mechanical properties and/or casting soundness.

Continous Tapping

A furnace or holding ladle that is made of discharge molten metal continuously during normal operation.

Continuous Annealing Furnace

36

Furnace in which castings are annealed or heat treated by being passed through different zones kept at constant temperatures. See Annealing.

Continuous Desulfurization

A process of removing sulfur from molten ferrous alloys on a continuous basis.

Continuous Mixer

Used to continuously mix chemically bonded sand.

Continuous Phase

The phase that forms the matrix or background in which the other phases are present as isolated units.

Controlled Area

A defined area in which the occupational exposure of personnel to radiation or to radioactive material is under the supervision of an individual in charge of radiation protection.

Contraction

Decrease in size or volume due to cooling of the metal after it is poured. Shrinkage is the term applied to the decrease in volume of a metal from liquid to solid stage. Contraction immediately follows shrinkage.

Contraction Cracks

Cracks formed by restriction of the metal while contracting in the mold; may occur just after solidification, called a hot tear, or a short time after the casting has been removed from the mold. See Hot Tea.

Contraction Rule

See Shrinkage, Patternmaker's.

Controlled Atmosphere

Any gas or mixture of gases that prevents or retards oxidation and decarburization.

Controlled Cooling

Process by which a metal object is cooled from an elevated temperature in a predetermined manner of cooling to avoid hardening, cracking, or internal damage.

Convection

The motion resulting in a fluid from the differences in density. In heat transmission, this meaning has been extended to include both forced and natural motion or circulation.

Converter

Vessel for refining molten metal by blowing a gas, usually air, through it. Used in making steel from molten cast iron and in refining copper. See Cast Iron.

Conver, Vibratory

37

A materials-handling device used usually with shakeout operations, to help clean sand from the castings as they are moved from one place to another in the foundry and as a feeding device to regulate materials flow. Operations with vibrational energy.

Conveyor

A mechanical apparatus for carrying or transporting materials from place to place. Types include apron, belt, chain, gravity, roller, monorail, overhead, pneumatic, vibrating, etc.

Conveyor Belt

A continuously moving belt used in an automated or semiautomatic foundry to move materials from one station to another. See Conveyor.

Conveyor Screw

Rotary worm-type blade used to move materials in automated core and mold making and other continuous sand-mixing operations.

Conveyor, Pallet

A materials-handling device that holds one or more molds and transports them from the molding station through pouring to shakeout. See Conveyor.

Conveyor, Pneumatic Tube

An air-tube means of moving materials from on place to another, primarily orders, light metal samples, and sand and other finely divided materials, as bentonite.

Conveyor, Roller

A line of conveyance in an automated or semiautomated foundry which employs a series of steel roller for moving objects.

Conveyor, Slat

A materials-handling device built on a continuous belt of metal slats that moves granular materials and castings throughout a foundry. See Conveyor.

Cooler

The largest of three water coolers surrounding the cinder notch of a blast furnace.

Cooling Curve

A curve delineating the relationship between temperature and time during the cooling of a metal or alloy test specimen. Since most phase changes involve evolution or absorption of heat, there may be abrupt changes in the slope of the curve. See Cracking Strip.

Cooling Stress

Stresses developed by uneven contraction or external constraint of metal during cooling.

38

Cooling, Controlled

A process of cooling from an elevated temperature in a predetermined manner used to produce a desired microstructure to avoid hardening, cracking or internal damage.

Cope

The top half of a horizontally parted mold. The upper or topmost section of a flask, mold, or pattern. See Flask, Mold, Pattern.

Cope, False

Temporary cope used only in forming the parting and therefore not a part of the finished mold. See Cope.

Coping Out

The extension of sand of the cope downward into the drag, where it takes an impression of a pattern. See Drag.

Copper

For foundry applications, copper is meant to include all alloys containing 98% or more copper. Used for conductivity castings. Melting point 1,083°C (1,981.4°F).

Copper, Electrolytic

Copper produced by the electrolysis method.

Corbel

One or more projecting courses of brick each projecting beyond the course below.

Core

A bonded sand insert placed in the mold to form an undercut or hollow section in the casting which cannot be shaped by the pattern.  A core is frequently used to create openings and various shaped cavities in the casting. The shaped body of sand which forms interior of casting and also selected external features.

Core Arbor

An iron framework embedded in a large core to stiffen it and for convenience in handling.

Core Assembly

A complex core made from a number of cores or sections.

Core Barrel

Pipe-shaped device upon which a cylindrical core is formed.

Core Binder

Any material used to hold the grains of core sand together.

Core Blow

39

A gas pocket in a casting adjacent to a core cavity caused by entrapping gases from the core.

Core Blowing Machine

Machine which reams the core by blowing sand into the core box. See Core, Core Box.

Core Box

A mold in which a core is formed. A wood, metal or plastic box, whose cavity has the shape of the desired core which is to be made therein. See Core, Mold.

Core Box, Combination

Core box and core dryers from the same pattern. One half is used as a half core box and a core drier. See Core Box, Pattern.

Core Branch

Part of a core assembly. See Core Assembly.

Core Breaker

A machine for crushing cores or for removing cores from castings.

Core Cavity

The interior form of a core box that gives shape to the core. Also, the cavity produced in a casting by use of a core. See Core Box.

Core Collapsibility

The rate of disintegration of the core at elevated temperature.

Core Compound

A commercial mixture used as a binder in core sand. See Binder, Core Sand.

Core Crab

An iron framework embedded in a large core to stiffen it and for convenience in handling.

Core Crack

Appears in a casting after solidification and cooling due to excessive strain generally resulting from nonuniform cooling.

Core Density

Either the permeability of core or the weight per unit volume.

Core Driers or Dryers

40

Supports used to hold cares in shape while being baked; constructed from metals or sand for conventional baking, or from plastic material for use with dielectric core-baking equipment. See Dielectric Baking.

Core Extruder

A special shell-core-making machine that produces a continuous length of cores, usually of cylindrical cross-section.

Core Filler

Material used in place of sand in the interiors of large cores -coke, cinder, sawdust, etc., usually added to aid collapsibility.

Core Fin

A casting defect, a depression in the casting caused by a fin on the core that was not removed before the core was set, or by paste that has oozed out from between the joints.

Core Float

A casting defect caused by core movement towards the cope surface of the mold, as a result of core buoyancy in liquid steel, resulting in a deviation from the intended wall thickness.

Core Frame

Frame of skeleton construction used instead of a complete core box in forming intermediate and large cores. See Core Box.

Core Grinder

Machine for grinding a taper on the end of a cylindrical core or to grind a core to a specified dimension, usually flat face.

Core Gum

A pitch material used as a core binder. See Core Binder.

Core Hardness

The ability of a core to resist scratching or abrasion.

Core Jig (Fixture)

Device in which a number of cores are assembled outside the mold, then used to locate the assembly in the proper position in the mold.

Core Knockout Machine

A mechanical device for removing cores from castings. See Core, Casting.

Core Lightener

A core material of any size and shape used to lighten pattern castings and match plates.

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Core Machine

Machine for making cores. See Core.

Core Maker

A core seat shaped or arranged that the core will register correctly in the mold; also termed locator, indicator, register, telltale. A core maker is also a person who makes cores.

Core Mud

A daubing mixture used to correct defect in cores. See Core.

Core Oil

Linseed-base or other oil used as a core binder. See Core Binder.

Core Oven

An oven for baking cores.

Core Paste

Material in paste form used as an adhesive to join sectional cores.

Core Plate

A plate or board made of metal or heat-resisting material on which certain types of cores are baked.

Core Print

Projections on a pattern that form and locate cores in a mold. A core print is also a projection on the core or an area in the mold for same purpose.

Core Refractiveness

The ability of a core to resist breakdown when exposed to heat.

Core Rod

Steel rods imbedded in a core used to reinforce the core and strengthen it. See Core.

Core Sand

Sand for making cores to which a binding material has been added to obtain good cohesion and permeability after drying. Core sand is usually low in clays.

Core Sand Mixer

Equipment in which cores are made. See Core.

Core Setter

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An operator or machine for placing cores in molds.

Core Setting Jig

A device used to help set and position a core into the mold.

Core Shift

A dfect resulting from the movement of the core from its proper position in the mold cavity. A variation from specified dimensions of a cored section due to a change in position of the core or misalignment of cores in assembling.

Core Shooter

A device using low air pressure to fluidize the sand mix which is released quickly in such a way as to force it into a core box. See Core Box.

Core Spindle

A shaft on which a core barrel is rotated in making cylindrical cores.

Core Sprayer

A device for spraying a coating on cores. See Core.

Core Stickle Template (Sweep)

Device of wood or metal to give shape to certain types of cores or molds.

Core Strainer (Strainer Tub)

Baked sand or refractory disc with uniform size holes through its thickness used to control the discharge of metal from pouring basins into sprues or to regulate the flow of metal in gates systems of molds; also to prevent entrance of dross or slag into the mold cavity.

Core Truck

Truck or carriage used for transporting cores.

Core Vents

A wax product, round or oval in form, used to form the vent passage in a core. Also refers to a metal screen or slotted piece used to form the vent passage in the corebox employed in a core blowing machine.

Core Wash

A suspension of a refractory material applied to cores and dried. Intended to improve the surface finish of the casting. A refractory coating for a core.

Core Wires Or Rolls

See Core Rod.

Core, Ram-Up

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Core attached to the pattern and rammed up in the mold, where it remains when the pattern is withdrawn.

Core-Baking Dielectric

Heating cores to baking temperatures by means of high-frequency dielectric equipment; particularly adapted to thermo-setting resin core binders. See Core, Dielectric Baking.

Corebox

See Core Box.

Coreless Induction Furnace

See Induction Furnace.

Core-Making Machine

A device to make cores. See Core.

Coremaker

A craftsman skilled in the production of cores for foundry use.

Coreprint

A projection on a pattern which leaves an impression in the mold for supporting the core. See Core, Pattern.

Corer, Sag

A decrease in the height of a core, usually accompanied by an increase in width, as a result of insufficient green strength of the sand to support its own weight.

Coreroom

Department of the foundry in which cores are made.

Coring (Metallurgical)

Variable composition due to the solidification characteristics of an alloy. Typically these compositional differences occur on a micro scale, the distances between compositional extremes being controlled by the solidification structure of the alloy.

Coring Up

Placement of cores chills, and chaplets in mold halves before closing the mold. See Chaplets.

Cornerslick (inside and outside corners)

A molder's tool used for repairing and slicking the sand in molds. Used primarily on dry sand and loam.

Corrective Effective Temperature Chart

44

A chart on which information can be plotted resulting in an adjustment temperature reading more indicative of human comfort.

Corrosion

Gradual chemical or electrochemical attack on a metal by atmosphere, moisture or other agents. A chemical attack of furnace linings by gases, slags, ashes or other fluxes occurring in various melting practices.

Corrosion Index

A number expressing the maximum depth in mils to which corrosion would penetrate in one year on the basis of a linear extrapolation of the penetration occurring during the lifetime of a given test or service.

Corrosion Wear

Wear in which chemical or electrochemical reaction with the environment is significant.

Corundum

Native alumna, or aluminum oxide, Al2O3, occurring as rhombohedral crystals and also in masses and variously colored grains. Applied specifically to nontransparent kinds used as abrasives. It is hardest mineral except the diamond. Corundum and its artificial counterparts are abrasives especially suited to the grinding of metals.

Coslettizing

Producing a black, rust-resisting surface on iron and steel by boiling for some hours in water containing phosphoric acid and iron filings.

Cottrell Process

An electrostatic method of removing solid particles from gases.

Count rate meter

A device which gives a continuous indication of the average rate of ionizing events.

Couple

Two dissimilar conductors in electrical contact. An electromotive force in created under proper electrolytic influences or during heating.

Courses

Alternate layers of material in a pattern, or brickwork.

Cover

A protective blanket laid on a melt to exclude oxidizing atmosphere and in the case of magnesium to prevent its igniting. Neutral covers simply protect metal from atmosphere; reacting covers contain an agent such as a deoxidizer.

Cover Core

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A core set in place during the ramming of a mold to cover and complete a cavity partly formed by the withdrawal of a loose part of the pattern. Also used to form part or all of the cope surface of the mold cavity. A core placed over another core to create a flat parting line. See Core, Mold Cavity, Pattern.

Cover Half

In Die casting, the stationary half of the die.

Crab

See Core Crab.

Crack, Hot

Developed in a casting before it has cooled completely, and usually due to some part of the mold restraining solid contraction of the metal. See Tear, Hot Tear.

Crack, Hot Tear

A rupture occurring in a casting at or just below the solidifying temperature by a pulling apart of the soft metal, caused by thermal contraction stresses. See Quench Crack.

Cracking Strip

A fin of metal molded on the surface of a casting to prevent cracking. See Fin, Cooling Curve.

Crane

A machine for lifting heavy weights; may be hand or power operated. Type include electric, gantry, jib, monorail, etc.

Crane, Gantry

A bridge carrying a traveling crane and supported by a pair of trestles running on parallel tracks.

Crane, Jib

A crane suspended from a jib.

Crane, Mobile

A crane supported on structure that rolls on wheels; may be moved manually or by its own power.

Crane, Wall Jib

A jib crane mounted on a wall rather than on an overhead beam.

Craze Crack (Crazing)

Minute crack on ceramic or refractory surface caused by thermal or mechanical shock.

Crazing (Worming)

46

A defect found in pack-hardened tools, manifested in surface markings.

Creep

Time rate of deformation continuing under stress intensities well within the yield point, proportional limit, or the apparent elastic limit for the temperature.

Creep Limit

The maximum stress that will result in creep at a rate lower than an assigned rate. See Creep.

Crib

Network of cast iron used to support the cope when no cope flask is used.

Cristobalite

Simplest crystallographic form of SiO2.

Critical Cooling Rate

The minimum rate of continuous cooling just enough to prevent undesired transformations.

Critical Points (Temperatures)

Temperatures at which changes in the phase of a metal talk place, and are determined by the liberation of heat when the metal is cooled and by the absorption of heat when the metal is heated, resulting in halts or arrests on cooling and heating curves.

Critical Shear Stress

The shear stress required to cause slip in a single crystal, in a designated slip direction on a given slip plane. Referred to as the critical resolved shear stress if the shear stress reaches a threshold level.

Critical Strain

A term used in stress corrosion cracking tests to indicate the maximum strain rate necessary to promote stress corrosion cracks.

Croning Process (C Process, Cronizing)

A casting process name after its German developer Johannes Croning. It is a precision production process using a phenol formaldehyde resin binder. See Shell Molding.

Cross Gate

See Runner.

Cross Section

A view of the interior of an object that is represented as being cut in two, the cut surface presenting the cross section of the object.

Crossbar

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Wood or metal bar placed in a flask to give greater anchorage to the sand than is afforded by its four walls.

Crown

Furnace roof, especially when dome-shaped; highest point of an arch.

Crucible

A ceramic pot or receptacle made of materials such as graphite or silicon carbide, with relatively high thermal conductivity, bonded with clay or carbon, and used in melting metals; sometimes applied to pots made of cast iron, steel, or wrought steel. The name derives from the cross, the Crux, with which ancient alchemists adorned it. See Cast Iron.

Crucible Furnace

A furnace fired with coke, oil, gas, or electricity in which metals are melted in a refractory crucible. See Coke, Crucible.

Crucible Zone

The zone in the cupola between the bottom and the tuyere. See Cupola, Tuyere.

Crush

A casting defect, such as buckling or breaking, of a section of mold due to incorrect register when closing. Also, an indentation in the casting surface due to displacement of sand in the mold when the mold is closed.

Crush Strip Or Bead

An indentation in the parting line of a pattern plate which ensures that cope and drag have good contact by producing a ridge of sand which crushes against the other surface of the mold or core.

Crushing

The pushing out of shape of core or mold when two parts of the mold do not fit properly.

Crystal

A physically homogeneous solid in which the atoms, ions, or molecules are arranged in a three-dimensional repetitive pattern.

Crystal Analysis

Determination of crystal structure.

Crystal Lattice

The way atoms are arranged in a crystal. Spacewise, there are only 14 different lattices.

Crystalline Fracture

Fracture of a brittle metal, showing definite crystal faces in the fractured surface.

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Crystallization

Act or process of forming crystals or bodies formed by element or compounds solidifying so they are bounded by plane surfaces, symmetrically arranged, and are the external expressions of definite internal structure.

Cumulative Trauma Disorder (CTD)

Illnesses that develop gradually over time and involve disorders of the soft tissues of the body. Caused or aggravated by repeatedly or constantly applied excessive forces, awkward postures, or highly repetitive movements of the body.

Cupola

A cylindrical straight shaft furnace usually lined with refractories, for melting metal in direct contact with coke by forcing air under pressure through openings near its base. Vertical shaft furnace lined with refractories used to produce cast iron by high temperature melting of metallic and mineral charge materials. See Tuyere.

Cupola Blower

A machine which compresses a large volume of air at low pressure for operation of the cupola.

Cupola Dust Arrester

A device attached to the stack of a cupola which removes dust and sparks for the outgoing gases. See Cupola.

Cupola, Basic

Cupola with refractory lining which has a basic reaction, usually magnesite, and is operated with slags high in lime. Lining may be neutral material like carbon, used with high lime slags. See Cupola, Slag.

Cupola, Hot Blast

Cupola in which the air blast is heated to temperatures from 400° to 1,000°F.

Cupola, Water-Cooled

Cupola in which the melting zone and tuyeres are cooled with water. Cooling of melting zone may be internal through jackets or steel tubing under the refractory lining. Cooling is also accomplished externally by water flowing down the outer shell. See Cupola.

Cure

To harden.

Curing Time (No Bake)

That period of time needed before a sand mass reaches maximum hardness.

Cut

Defect in a casting resulting from erosion of the sand by metal flowing over the mold or cored surface. See Casting.

Cutoff Machines, Abrasive

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A machine using a thin abrasive wheel and employed in cutting off gates and risers from casting or in similar operations. See Abrasive.

Cuts

Defects in castings resulting from erosion of the sand by the molten metal pouring over the mold or core surface. See Casting.

Cutter, Gate

A piece of sheet metal or other tool for removing a portion of the sand in a mold to form the gate or metal entrance into the casting cavity. A scoop or other form of cutting gates in the mold. See Gate.

Cutter, Sprue

A piece of metal tubing or other tool used to remove a portion of the sand from a mold to form the sprue or passage from the exterior of the mold to the gate. Also a machine used for shearing sprues and gates from castings. See Gate, Sprue.

Cutting Wheel

The plastic discs impregnated with an abrasive for cutting ceramics and metals. Used on abrasive cutoff machines.

Cyclone (Centrifugal Collector)

In air pollution control, a controlled descending vortex created to spiral objectionable gases and dust to the bottom of a collector core.

Cyclonic Scrubber

In air pollution control, radial liquid (usually water) sprays introduced into cyclones to facilitate collection of particles.

Cyclotron

A device for accelerating charged particles to high energies by means of an alternating electric field between electrodes placed in a constant magnetic field.

Glossary of Foundry Terms - D

D (Fordath) Process

Shell molding in which the shell is made by blowing sand into a box like heated structure so that a shell of controlled thickness is created. See Shell Molding.

Damping Capacity

The ability to absorb vibration. More accurately defined as the amount of work dissipated into heat by a unit volume of material during a completely reverse cycle of unit stress.

Datum Plane

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In layout and machining operations the reference plane from which dimensions are measured in the perpendicular direction.

Datum Points

In layout and machining operations the reference points on a datum plane from which dimensions are measured.

Daub

To coat or plaster the inside of a cupola at the melting zone or the inside of a ladle with a refractory mixture.

Daubing

Filling of cracks in molds or cores by specially prepared pastes or coatings to prevent a mechanical penetration of metal into these cracks during pouring. Also, the final plastering or coating of the cupola or ladle after shrinkage has taken place during the drying period. Clay slurry or clay wash with various coating compounds are applied. See Clay Wash.

DC (Direct Chill) Casting

A continuous method of making ingots or billets or extrusion by pouring the metal into a short mold. Some times called semi-continuous casting.

Dead Annealing

See Annealing.

Dead Steel

Fully killed steel, also applied to steel which fails to respond to heat treatment. See Heat Treatment, Killed Steel.

Deadburned

Term applied to refractory materials obtained by calcimining at a temperature high enough to form a product inert to atmospheric moisture and carbon dioxide, and less apt to contract. See Refractory.

Deadburned Dolonite

Dolonite burned at high temperature with additions of an agent, such as oxide of iron.

Deadhead

The useless metal projecting on a casting which corresponds to the position of a riser in the mold. See Casting, Riser.

Decant

Pour from one vessel to another. Pour off molten metal without disturbing the sludge.

Decarburiztion

Loss of carbon from the surface of a ferrous alloy as a result of heating in a medium, usually oxygen, that react with carbon.

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Decibel (dB)

Unit for measuring the ration amounts of acoustical power; one-tenth of a bel.

Deep Etching

Macroetching; etching for examination at a low (less that 10X) magnification, in a reagent that attacks the metal to a much greater extent than normal for microscopic examination. Gross features may be developed; i.e., abnormal grain size, segregation, cracks, or grain flow.

Deep Red Filter

A gas filter in air pollution control, consisting of a loosely packed mat of fibrous materials; not practical where high grain loading are encountered.

Defect

A discontinuity in the product whose severity is judged unacceptable in accordance with the applicable product specification.

Deformation test

An AGS test using an instrument such as the Dietert Universal Sand-Strength Testing machine (with deformation accessory) to determine the amount in inches that the sand specimen is compressed before it ruptures.

Degasifier

A material employed for removing gases from molten metals and alloys.

Degassing

Usually a chemical reaction resulting from a compound added to molten metal to remove gases from the metal. Often inert gases are used in this operation.

Degassing Flux

A flux for removing gas from the melt.

Degree of Ramming

The extent of hardness to which a sand mold is rammed. See Ramming, Sand Molding.

Delay Screen (Skim gate (Erroneously), Skim Strainer)

A small piece of perforated light gage tinned sheet steel, or of copper, aluminum, and/or magnesium alloys, frequently placed in the pouring basin at the top of the downsprue. It delays the flow of metal long enough to allow the basin to fill before it melts to permit only clean metal from the bottom of the basin to enter the downsprue. Delay screens are also use elsewhere in the gating system.

Delta Iron

An allotropic (polymorphic) form of iron, stable above 2550°F, crystallizing in the body-centered-cubic lattice.

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Dendrite

A crystal of branched appearance, formed during solidification of alloys, the branching habit being controlled by specific crystallographic directions with the branching structure resembling a a fir tree.

Densitometer

Instrument utilizing the photoelectric principle to determine the degree of darkening of developed photographic film.

Density

The mass per unit volume of a substance, usually expressed in grams per cubic centimeter or in pounds per cubic foot.

Density (Photographic)

Density is used to denote the degree of darkening of photographic film. Logarithm of opacity of exposed and processed film. Opacity is the reciprocal of transmission; transmission is the ratio of transmitted to incident intensity.

Dephosphorization

Elimination of phosphorus from molten steel.

Dermatis

An inflammation of the skin, which may be caused by allergy to certain casting adjuncts, as resins; particularly in the shell process.

Descale

Remove the fire scale from the surface of casting. See Casting.

Design Base Line

The noise spectrum which is the goal of any particular noise reduction program.

Designations

Type of metal named, as steel, malleable, nonferrous, etc.

Despersion Hardening

Hardening by the formation of hard microconstituents dispersed in a softer matrix. See Precipitation Hardening.

Desulfurization

Removal of sulfur from the molten metal by addition of suitable compounds.

Desulfurizer

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A material used to remove sulfur from molten metals and alloys. Also, a form of holding ladle or basin in which the molten metal and desulfurizing material are brought into contact. See Ladle.

Detroit Cup Test

A cupping test for sand, using a steel ball as plunger, the depth of cup being shown on a dial.

DeVries Test

A test to give the relative hardness of deep hardening steels. See BHN, Brinell Hardness.

Dew Point

The temperature at which moist air will become saturated and condensation of water vapor will take place.

Dewaxing

The process of melting out the expendable was pattern from an investment mold by the application of heat, usually at temperatures less than 250°F (121°C).

Dexidation

Removal of excess oxygen from molten metal, usually accomplished by adding materials with a high affinity for oxygen, the oxides of which are either gaseous or readily form slags.

Dextrin

Soluble gummy carbohydrate formed by the decomposition of starch by heat, acids, or enzymes; it is use din core compounds, mold compounds, mold washes, core pastes, and other compounds requiring high dry compressive strengths.

Dezincification

Corrosion of some copper-zinc alloys, involving loss of zinc and the formation of a spongy porous copper. See Alloy.

Diameters

In microscopy, an indication of the amount of magnification. 1000 diameters = 1000 times original size.

Diammonium Phosphate

Used to fireproof clothing of foundry workers.

Diaphragm Shell Molding Machine

An arrangement for applying a squeeze pressure with a high-temperature silicone rubber diaphragm.

Diaspore Clay

A rocklike mineral consisting chiefly of diaspore (HAlO2) bonded by fire clay substance with an alumina content higher than 63%.

Dia-Tester (Wolpert Hardness Tester)

54

A hardness testing machine using the Vickers or Brinell ball indenter. See BHN, Brinell Hardness, Vickers Diamond.

Diathermometer

An instrument for examining the thermal resistance or the heat conducting power of objects.

Diatomaceous Earth (Infusorial Earth)

A hydrous of silica which is soft, light in weight and consists mainly of microscopic shells of diatoms or other marine organisms.

Die

A metal block used in forming materials by casting, molding, stamping, threading, or extruding. A metal form used as a permanent mold for die casting or lost wax process. See Lost Wax Process.

Die Assembly

The parts of a die stamp or press that hold the die and locate it for the punches.

Die Casting

(a) Forcing molten metal into permanent molds, dies. Die Casting is also called Pressure Casting. See Pressure Die Casting. (b) noun Casting resulting from die-casting process. (c) verb Pouring molten metal under pressure into metal molds.

Die Casting, Cold Chamber

Type of casting made in a die-casting machine in which the metal injection mechanism is not submerged in the molten metal.

Die Casting, Hot Chamber

Type of casting made in a die-casting machine in which the metal injection mechanism is submerged in the molten metal.

Die Coating

See Release Agent.

Die Insert

A removable liner or part of a die body or punch.

Die Set

In stamping, the parts of the press that hold the die and locate it in proper relation to the punches.

Die Sinking

Forming or machining a depressed pattern in a die.

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Dielectric Baking

Baking of cores and molds in a field of high-frequency electric current generated by dielectric equipment; employed with resin-bonded cores. See Bake, Baked Core.

Dielectric Oven (Dryer)

A rapid-drying high frequency electric oven used to bake cores. See Bake, Baked Core.

Dietert Process

A patented process for the production of precision molds involving blowing a contoured core around a pattern to form half a mold. See Core, Mold, Pattern.

Dietert Tester

A patented apparatus for the direct reading of a Brinell hardness after impression without using magnification or conversion tables. See BHN, Brinell Hardness.

Differential Heat Treatment

A heating process by which the temperature is varied within the object so that, after cooling, various parts may have different properties as desired. See Heat Treatment.

Diffuser

X-ray equipment, a portion of the condensing and focusing system that permits even distribution of energy. See X-Ray.

Diffusion

Movements of atoms within a solution. Net movement is usually from regions of high concentration to regions of low concentration to achieve homogeneity of the solution which may be a solid, gas, or liquid.

Dike

A patented flexible seal to prevent blow-by in core boxes. See Core Box.

Dilatometer

Instrument for measuring expansion or contraction, the length of a metal sample, caused by changes in temperature or structure.

Dimensional Stability

Ability of a casting to remain unchanged in size and shape under ordinary atmospheric conditions.

Dimensional Tolerance Grades

A system of classifying the tightness of tolerances for the purpose of defining accurately the tolerances involved, and for simplifying the communication process between customer and producer regarding what is wanted, and what is possible, respectively.

Dip Coat

56

In solid and shell mold investment casting, a fine ceramic coating applied as a slurry to the pattern to produce maximum surface smoothness, followed by a cheaper conventional investment. See Investment Precoat.

Dip Tank

A tank, preferably lined with rubber, epoxy, or other nonmetallic, into which die castings are dipped for cooling after leaving the machine.

Dipped Joint

A thin joint made by dipping of the brick in a thin mortar.

Direct Casting

Teeming from the ladle into the casting mold without the use of a tundish.

Direct-Arc Furnace

Electric furnace in which the material is heated directly by an arc established between the electrodes and the work. See Dielectric Furnace.

Directional Solidification

Refers to the arrangement of a solidification pattern in a casting by establishment of high temperature gradients, whereby solidification of the metal begins at the point farthest from the metal entrance or sprue and the metal progressively freezes or solidifies to and including the sprue. See Solidification.

Dirt

Indefinite term referring to any extraneous material entering a mold cavity and usually forming a blemish on the casting surface. See Mold Cavity.

Dirt Trap

A well employed in a gating system to entrap the first metal poured, which may contain dirt or unwanted particles (ineffective). See Slag Trap.

Dirty Casting

A casting containing an excessive amount of nonmetallic inclusions in the body of the metal. See Inclusion.

Disamatic Molding

Disamatic molding is a type of sand molding process in which molten metal is poured into a mold made of sand to make Gray Iron Castings. Disamatic machines are designed to provide molds built for vertical casting and the molds are created in a vertical orientation. Disamatic machines create flaskless molds. Disamatic molding gets its name from the company that manufactures the molding machine, DISA. A Disamatic molding machine is a vertically parted sand molding machine. The vertical molding machine is often the choice for production of very close tolerance Gray Iron Castings. See Gray Iron, Hunter Molding.

Disappearing Filament Pyrometer (Optical Pyrometer)

57

A telescope in which a hot body is viewed through an eyepiece and temperature is measured by the matching color of a calibrated lamp filament with color of hot metal.

Dispersed Shrinkage

Small shrinkage cavities dispersed through the casting, which are not necessarily cause for rejection. See Casting, Cavity, Shrinkage.

Dissolved Carbon

Carbon in solution in steel in either the liquid or solid state.

Distorted Pattern

A pattern untrue to the specified dimensions. See Pattern.

Distortion

See Warpage.

Distribond

A siliceous clay containing Bentonite used as bond in molding sands. See Molding Sands.

Distribution, Sand Grain

Variation or uniformity in particle size of a sand aggregate when properly screened by U.S. Standards screens.

Distruptive Strength

Maximum strength of a metal when subjected to three principal tensile stresses at right angles to one another and of equal magnitude.

Disturbed Metal

The cold worked metal formed on a polished surface during the processes of grinding and polishing.

Divorced Pearlite (Granular perlite, Spheroidite, Spheroidized cementite)

Pearlite in which the cementite has been spheroidized by prolonged annealing just below the Ac1 point, or by annealing at the same temperature after cold working. See Ac1, Pearlite.

Dolomite

A mineral calcium-magnesium carbonate (Ca, MG (CO3)2) used as a flux in iron melting and smelting; also as a base in refractors.

Dosimeter

Instrument used to detect and measure an accumulated dosage of radiation; in common usage it is a pencil-size ionization chamber with a built-in self-reading electrometer; used for personal monitoring. See Dosimeter, Pocket.

Dosimeter, Pocket

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A pocket ionization chamber containing it own electrometer. An auxiliary charging device is usually necessary. See Dosimeter.

Double Annealing

As applied to hypoeutectoid steel, a process of heating to above the upper critical point, Ac3, and holding at that temperature until complete solution of the carbide has been achieved then cooling rapidly and reheating immediately to above A3 and slowly cooling. See Ac3, Annealing.

Double Impression Method

A way of determining approximate Brinell hardness by placing a hardened steel ball between a specimen of known hardness and the metal to be tested and pressurizing in an arbor press. See BHN, Brinell Hardness.

Double Skin (Bottom Splash, Ingot Shell, Plaster)

A defect consisting of a secondary layer of metal sometimes found on top-poured ingots. See Ingot.

Double Tempering

A retempering operation sometimes necessary for steel containing retained austenite which breaks down during cooling from the first tempering to form a new and hence untempered martensite.

Doublebruned

Deadburn; not be mistaken for two firing.

Dowel

A pin used between the sections of parted patterns or core boxes to locate and hold them in position, registering them correctly. See Core Box.

Downcomer

In air pollution control, a pipe for conducting bases down into a conditioner and subsequent cleaning.

Downgate

See Downsprue.

Downsprue (Sprue, Downgate)

The first channel, usually vertical, which the molten metal enters; so called because it conducts metal down into the mold.

Downtime

Time lost from normal casting activity, due to unscheduled interruptions.

Draft

59

The taper on vertical surfaces of a pattern which allows easy withdrawal of the pattern from a compacted sand mixture without distorting or tearing of the sand and without excessive rapping and tearing of the mold walls.

Draft, Pattern

See Pattern Draft.

Drag

Lower or bottom section of a mold, pattern or flask. See Mold, Pattern, Flask.

Draw

A term used to temper, to remove pattern from mold, as an external contraction defect on surface of mold.

Draw (verb)

To remove a pattern from a mold.

Draw Bar (noun)

A bar used for lifting the pattern from the mold. See Mold, Pattern.

Draw Peg

A wooden peg used for drawing patterns.

Draw Plate

A plate attached to a pattern to facilitate drawing of a pattern from the mold.

Draw Screw

A threaded rod with an eye screwed into a pattern to enable it to be drawn from the mold. See Mold, Pattern.

Draw Spike

A steel spike used to rap and draw a pattern from the sand; it is driven into the wood of the pattern, as opposed to a Draw Screw, which threaded.

Draw, Surface

Appearance of shrink on the upper surface of a casting. See Casting, Shrink.

Drawback

A part of the mold, made of green sand, which may be drawn back to clear overhanging portions of the pattern. It is rammed up on a plate or arbor so that it can be lifted away. See Arbor, Mold, Pattern, Ramming.

Drawing

Removing pattern from the mold or mold from pattern in production work. See Temper.

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Dried Sand

Sand which bas been dried by mechanical dryer prior to use in core making.

Drier (Dryer)

A material, as alcohol ammonium nitrate, sodium perborate and manganese oleate, added to a core or mold mixture to remove or reduce the water content.

Drier-Core

Plates for supporting odd shaped cores during baking.

Drillings, Test

Chips, or small particles of metal removed from a test specimen for chemical analysis.

Drop (Dropout)

A casting defect caused by sand dropping from the cope or other overhanging section.

Drop Ball

A heavy weight, usually ball or pear shaped, dropped from a height to break large pieces of metal scrap. Also used to strengthen warp castings.

Drop Gate

A term for a pouring gate or runner leading directly into the top of the mold.

Drop Off or Drop Out

Sand falling from the Cope of a mold. See Drop.

Drop or Drop Out

The falling away of a body of sand when the mold is jarred or lifted.

Dropping the Bottom

Removal of the supporting props under the cupola bottom doors to permit emptying of the remaining contents. See Cupola.

Dross

Metal oxides and other scum on the surface of molten metal or in a metal or alloy (mostly a non-ferrous term).

Drum Ladle

A cylindrical refractory-lined ladle that is completely enclosed. A removable cover at the pouring spout permits addition of molten metal.

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Drum, Magnetic

An electrically energized pulley or drum used for removing magnetic materials from sand, nonferrous borings and turnings, etc.

Dry Analysis

A term applied to spectrographic analysis.

Dry And Baked Compression Test

An AFS test to determine the maximum compressive stress that a baked sand mixture is capable of developing.

Dry Pan

A grinding machine of heavy rollers or millers testing on a bed. Screens or slits allow fine material to pass through.

Dry Permeability

Property of a molded mass of sand dried at 221°F to 230°F and cooled to room temperature, to permit passage of gases through it.

Dry Sand

Sand mixture that is baked to produce strong molds that are moisture free.

Dry Sand Casting

The process in which the sand molds are dried at above 212°F (100°C) before using.

Dry Sand Core

See Core.

Dry Sand Mold

A mold from which the moisture has been removed by heating.

Dry Strength, or Dry Bond Strength

The maximum compressive, shear, tensile, or transverse strength of a sand mixture which has been dried at 220°F to 230°F (105°C to 110°C) and cooled to room temperature.

Dryer, Core

See Core Driers.

Dryer, Dielectric

See Dielectric Oven.

Dry-Sand Mold

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A mold made of prepared molding sand dried thoroughly before being filled with metal. See Mold, Molding Sand.

Dual Metal Centrifugal Casting

Centrifugal castings produced by pouring a different metal into the rotating mold after the first metal poured.

Ductile Iron

A type of iron in which the graphite content takes spherical rather than flake form. Ductile iron is produced by adding magnesium. The spherical form of the graphite provides greater tensile strengths and flexibility than other types of iron. An iron/graphite composite in which the graphite exists in spheres or nodules, allowing the material to deform rather than fracture when placed under mechanical stress. Also called Nodular Iron. Iron in which carbon is in the form of spherical nodules. See Nodular Iron.

Ductility

The property permitting permanent deformation by stress in tension with out rupture.

Duplexing

Term usually used in reference to melting metals or alloys in one type of furnace and transferring to another for holding, refining, etc. Common in the malleable field, where charges are melted in a cupola and transferred to air or electric furnaces for slight reduction of carbon and an increase in temperature.

Dust

Small solid particles created by the breaking up of larger particles by a process.

Dye Penetrant

Penetrant is used to crack detection, which has a dye added to make it more readily visible under normal or black-lighting conditions. In the case of normal lighting, the dye is usually red and nonfluorescent. With black lighting, the dye is fluorescent and yellow-green in color.

Glossary of Foundry Terms - E

Eddy Current Testing

The detection of discontinuities by observation of the interaction between electromagnetic fields and metals.

Ejector Marks

Marks left on die castings by the ejector pins, which may be raised or depressed from the surface of the casting. See Die Casting, Ejector Pins.

Ejector Pins

Movable pins in pattern dies which help remove patterns from the die.

Ejector Plate

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Movable plate beneath a shell molding pattern containing the pins for lifting or ejecting the hardened, resin-bonded shell mold from the pattern. See Shell Molding.

Elastic Limit

Maximum stress that a material will withstand without permanent deformation. See Yield Strength.

Elasticity

The property of recovering original shape and dimensions upon removal of a deforming force.

Electric Arc Furnace

A crucible furnace that uses an electric arc, similar to an electric arc welding operation, to melt metal. See Crucible Furnace.

Electrical Precipitator

In air pollution control, the use of electrodes in stack emissions emitting high voltage; particles 0.1 micron and smaller can be attached and collected at discharge electrode.

Electrochemical Corrosion (Contact Corrosion, Electrolytic Corrosion, Galvanic Corrosion)

Localized corrosion from exposure of an assembly of dissimilar metals in contact or coupled with one another, i.e., electrochemical action.

Electrode

Compressed graphite or carbon cylinder or rod used to conduct electric current in electric arc furnaces, arc lamps, carbon arc welding, etc.

Electron Microprobe Analyzer

An instrument for selective analysis of a microscopic area, in which an electron beam bombards the point of interest in Vacuo at a given energy level. Intensity of backscatter is measured to interpret which chemical elements are present, and by scanning a large area the microprobe can analyze chemical composition and indicate the distribution of an element.

Elongation

A measure of a material's ductility. Given in a percent, it indicates the amount a material will deform before permanent deformation. The higher the number, the more ductile. See Ductility.

Embrittlement

Loss of ductility of a metal due to chemical or physical change. See Acid Embrittlement, Ductility, Hydrogen Embrittlement.

Endothermic Reaction

The reaction which occurs with absorption of heat. See Exothermic Reaction.

End-Quench Hardenability Test

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A standardized method for comparing the hardenability of different steels.

Engineering Strain(e)

The average linear strain, obtained by dividing the elongation of the length of the specimen by the original gage length.

Engineering Stress(es)

The load divided by the original area.

EPC (Expendable Pattern Casting)

See Lost Foam Process.

Equilibrium

Dynamic condition of balance between atomic movements where the resultant is zero, a stable condition and the condition appears to be one of rest rather than change.

Ergonomics

The science which deals with the interaction between people, their work place and environment. It also considers the physiology of workers in the design of tools, equipment, and the work methods needed.

Erosion

Abrasion of metal or other material by liquid or gas, usually accelerated by pressure of solid particles of matter in suspension, and sometimes by corrosion.

Erosion Scab

Casting defect occurring where the metal has been agitated, boiled, or has partially eroded away the sand, leaving a solid mass of sand and metal at that particular spot.

Etchant

A solution for chemical etching the polished surface of a metal specimen to reveal macro- or micro-structures.

Ethyl Silicate

Light brown liquid consisting predominantly of tetraethyl silicate with some polysilicates which can be hydrolized with water to form alcohol and silicic acid. Used as a bonding agent in investment molding. See Investment Casting.

Eutectic

The alloy which has the lowest melting point possible for a given composition. See Alloy.

Eutectic Reaction

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Reaction in which a liquid solution solidifies or transforms at constant temperature to form a solid mass made up of tow kinds of crystals.

Eutectoid

A solid solution of any series which cools without change to its temperature of final composition.

Evaporation Pattern Casting / Expendable Pattern Casting / EPC

See Lost Foam Process.

Exothermic

Formed by or characterized by heat reaction as in oxidation.

Exothermic Reaction

Chemical reactions involving the liberation, or production, of heat. See Endothermic Reaction.

Expansion Scabs

Rough thin layers of metal partially separated from the body of the casting by a thin layer of sand, and held in place by a thin vein of metal.

Expansion, Sand

Dimensional increase that sand undergoes when subjected to elevated temperature conditions.

Expendable Pattern

In investment molding, the wax or plastic pattern that is left in the mold and later melted and burned out. This also called a disposable pattern.

Extensometer

An instrument used in the testing of metals to measure small increments of deformation.

External Chills

Various materials of high heat capacity such as metals, graphite, etc., forming parts of the walls of the mold cavity to promote rapid heat extraction from molten metal. See Mold Cavity.

Glossary of Foundry Terms - F

Fabrication

The joining, usually by welding, of two or more parts to produce a finished assembly. The components of the assembly may be a combination of cast and wrought materials.

Facing

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Refractory material applied to the face of a mold. See Mold, Refractory.

Facing Sand

Specially prepared molding sand used in the mold adjacent to the pattern to produce a smooth casting surface. See Molding Sand.

False Cheek

A cheek used in making a three-part mold in a two-part mold.

Fatigue

The loss of load-bearing ability of a material under repeated load application, as opposed to a single load.

Fatigue Crack

A fracture starting from a nucleus where there is an abnormal concentration of cyclic stress, and propagating through the metal. Surface is smooth and frequently shows concentric markings with a nucleus as the center.

Fatigue Limit (Endurance Limit)

Maximum stress that a material will endure without failure for an infinite number of load cycles.

Fatigue Strength

Maximum stress that a material will endure without failure for a specified number of load cycles.

Feed Head

A reservoir of molten metal provided to compensate for contraction of metal as it solidifies, by the feeding down of liquid metal to prevent voids. Also called a riser. See Riser.

Feed Material

The volume of molten metal from which a casting feeds as it shrinks (contracts) during solidification.

Feeder

Sometimes referred to as a riser. A vertical channel in the mould (part of the runner system) which forms the reservoir of molten metal necessary to compensate for losses due to shrinkage as the metal solidifies. See Riser.

Feeding

Supplying additional molten metal to a casting to make up for volume shrinkage during casting solidification. See Solidification.

Ferric Oxide

Red iron oxide, Fe2O3, commonly available as hematite ore. Used in ground form in cores and molds to increase hot compressive strength.

Ferrite

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Iron practically carbon-free. It forms a body-centered-cubic-lattice and may hold in solution considerable amounts of silicon, nickel, or phosphorus; hence the term is also applied to solid solutions in which alpha or delta iron is the solvent.

Ferritic steels

Steels in which ferrite is the predominant phase. These steels are magnetic.

Ferroalloys

Alloys consisting of certain elements combined with iron, and used to increase the amount of such elements in ferrous metals and alloys. In some cases the ferroalloys may serve as deoxidizers. See Alloy.

Ferromagnetic

The ability to become highly magnetic and have the ability to retain a permanent magnetic moment. The elementary magnetic dipoles inside the domain are all oriented in a direction parallel to each other.

Ferrophosphorus

An alloy of iron and phosphorus containing about 70% iron and 25% phosphorus. See Alloy.

Ferrostatic Pressure

Pressure induced by a head of liquid iron or steel.

Fettle

A British term meaning the process of removing all runners and risers and cleaning off adhering sand from the casting. Also refers to the removal of slag from the inside of the cupola and in Britain to repair the bed of an open hearth. See Casting, Risers, Runners.

Fillet

A concave corner piece, often a preformed strip of leather or wax, used on foundry patterns used at the intersection of two surfaces to round out a sharp corner.

Filter

The filtering out of unwanted gases in the casting, at pouring off portion of making the casting.

Fin

A thin projection of metal from the casting, formed as a result of imperfect mold or core joints. See Casting, Core.

Fines

Sand grain sizes substantially smaller than the predominating grain sized in a molding sand; also material remaining on 200- and 270-mesh sieves and pan after tests for grain size and distribution.

Finish (machine)

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Amount of metal allowed for machining.

Finish (verb)

The hand work on a mold after the pattern has been withdrawn. See Mold, Pattern.

Finish Allowance

The amount of stock left on the surface of a casting for machining.

Finish Mark

A symbol (f, f1, f2, etc.) appearing on the line of a drawing that represents the edge of the surface of the casting to be machined or otherwise finished.

Finish Welding

Production welding carried out in order to ensure the agreed quality of the casting.

Finite Difference Analysis (FDA)

A computerized numerical modeling approach for solving differential equations. Used primarily in solving heat transfer and solidification problems.

Finite Element Analysis (FEA)

A computerized numerical analysis technique used for solving differential equations to primarily solved mechanical engineering problems relating to stress analysis.

Firebrick

Brick made of refractory clay or other material which resists high temperatures.

Fireclay

A type of clay which is resistant to high temperatures.

Firecracker Core

See Pencil Core.

Flame Hardening

A surface hardening process involving localized flame heating to above the austenite transformation temperature, Ac3, followed by quenching. See Ac3.

Flaring

Term used in connection with zinc-bearing alloys, particularly manganese bronze, to denote evolution of zinc oxide fumes during melting.

Flash

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Thin fin or web of metal extending from the casting along the joint line due to the cope and drag not matching completely or where core and coreprint do not match.

Flask

A metal or wood rigid frame without top and without fixed bottom used to hold the sand of which a mold is formed; usually consisting of two parts, cope and drag. See Cope, Drag, Mold.

Flask Bar

A reinforcing member attached within either half of a flask to assist in holding the rammed sand in position. See Flask, Ramming.

Flask Clamp

A device for holding together the cope, drag, and cheek of a flask.

Flask Pin Guides

Guides used to accurately align the match plate pattern in the flask and flask to flask location.

Flask Pins

Assure proper alignment of cope and drag molds after the pattern is withdrawn. See Cope, Drag, Mold, Pattern.

Flask, Slip

A removable flask which can be stripped vertically from the mold. See Flask.

Flask, Snap

A hinged flask which can be removed from the mold after completion.

Flask, Tight

Flask which remains on the mold. See Flask.

Flat/Knife Gate

Wide gate with narrow opening into the mold.  It is used to pour thin, flat castings. See Gate.

Flat Back

A pattern with a flat surface at the joint of the mold. It lies wholly within the drag or cope, and this joint of the mold is a plane surface. See Cope, Drag, Mold, Pattern.

Flowability

Property of a foundry sand mixture which enables it to fill pattern recesses and move in any direction against pattern surfaces under pressure.

Flow-Off

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Large vent, usually located at the high point of a mold cavity. In addition to letting air and mold gases escape during a pour, the flow-off fills with metal and is allowed to run or flow during the final stage of pouring. See Mold Cavity.

Fluidity

Ability of molten metal to flow readily; usually measured by the length of a standard spiral casting.

Fluidize

To impart fluid like properties to powders or sands e.g. fluidized beds.

Fluorescent Crack Detection

Application of penetrating fluorescent liquid to a part, then removing the excess from the surface, which is then exposed to ultraviolet light. Cracks show up as fluorescent lines.

Flux

Any substance used to promote fusion. Also any material which reduces, oxidizes, or decomposes impurities so that they are carried off as slags or gases.

Follow Board

A board shaped to the parting line of the mold. See Mold, Parting Line.

Founding

The art and science of melting and casting of metals and alloys into useful objects that serve the needs of industry. It is better known as metal casting.

Foundry (Foundries, plural)

The act, process, or art of casting metals. The buildings and works for casting metals.

Foundry Ladle

A vessel for holding molten metal and conveying it from cupola to the molds. See Cupola, Mold.

Foundry Returns

Metal in the form of sprues, gates, runners, risers and scrapped castings, with known chemical composition that are returned to the furnace for remelting. Sometimes referred to as "revert ".

Foundry Sand

Foundry sand is used in creating cores and molds used in the casting of iron, steel, copper and aluminum products. In construction, steel and iron beams-known as girders-are used in the building of bridges, large office buildings and some homes. Copper pipes, aluminum supports and even the hardware and hand tools used in construction had their origins at the foundry. Foundry sand is the second largest industrial use of sand in terms of tons consumed. See Casting, Core, Molds.

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Free On Board (F.O.B.)

This is a historical transportation industry term. It deals with who pays the shipping charges on goods produced. The term is a pricing agreement which does not include the carriage charges, from the seller, to the buyer of a product. The seller absorbs the freight charges, the carriage charges, the destination charges, the shipping charges, etc., whatever you wish to call the expense to move the material from the seller to the buyer. There may well be third party billing of these carriage charges. The seller may well have incorporated these charges in the selling price, but does not invoice the buyer for that fee. Remember..."Free On Board," equates to a remembrance thought factor of ..."Free Onto The Buyer"...or F.O.B. as the early traffic managers so coined the term.

Freezing

Term used to denote the solidification process. See Solidification.

Frictional Wear

The displacement and/or detachment of metallic particles from a surface as a consequence of being in contact with another moving component.

Froude Number

Used in hydraulics as an analog to the Reynolds number. It is the ratio of inertial forces to gravitational forces.

Furans

Generic term for a family of chemical compounds including furfural and furfuryl alcohol sued as binders for core sands.

Fusion

Change from a solid to a fluid state caused by application of heat.

Glossary of Foundry Terms - G

Gage Length

The original length of that portion of the specimen over which strain or change of length is determined.

Gage Marks

Reference marks; in tensile testing, the marks which indicate the gage length, used in determination of tensile elongation.

Gagger

A metal piece of irregular shape (usually an L shape) used to reinforce and support sand in deep pockets of molds. There are two types; straight or hooked (cast or steel rods).

Gaging

Checking dimensional requirement by means of a gage.

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Gamma iron

One of the allotropic (polymorphic) forms of iron which crystallizes in the face-centered-cubic lattice form. When pure, its range of stability is from 1,670°F to 2,552°F (910°C to 1400°C).

Gannister

An acid (silicious) refractory often used in furnace linings.

Gas Holes

Rounded cavities caused by generation or accumulation of gas or entrapped air in a casting; holes may be spherical, flattened or elongated.

Gas Porosity

A condition existing in a casting caused by the trapping of gas in the molten metal, or by mold gases evolved during the pouring of the casting.

Gate

Specifically, the point at which molten metal enters the casting cavity. Sometimes employed as a general term to indicate the entire assembly of connected columns and channels carrying the metal from the top of the mold to that part forming the casting cavity proper. This term is also applied to pattern parts that form the passages, or to the metal that fills them.

Gated Patterns

One or more patterns with gating systems attached. See Gate, Pattern.

Gating System

The complete arrangement of gates, runners, and sprues through which molten metal flows into the cavity of the mold. See Cavity, Gate, Molds, Runners, Sprues.

Gilsonite

Natural black lustrous asphalt found in the Uinta Mountains in Utah and also known as uintaite. It is used as a carbonaceous addition to foundry sands.

Gooseneck

The pressure vessel or metal injection mechanism in a hot-chamber-type die-casting machine.

Gouging Abrasion

Abrasion involving gross surface indentation and possible removal of sizable metal fragments.

Grade

The grade of an iron, usually given by three successive numbers, the first being the tensile strength (KSI), the second the yield strength (KSI), and the third the elongation (%).

Grain Fineness Number

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A system developed by AFS for rapidly expressing the average grain size of a given sand. It approximates the number of meshes per inch of that sieve that would just pass the sample if its grains of uniform size. It is approximately proportional to the surface area per unit of weight of sand, exclusive of clay.

Grain Refiner

Any material added to a liquid metal or alloy or treatment which produces a finer grain size in the subsequent solid.

Grains

Crystals in metals and alloys.

Granular Fracture (Crystalline fracture)

A type of irregular surface produced when metal is broken.

Granular Pearlite

A structure formed from ordinary lamellar pearlite by long annealing at a temperature below but near to the critical point, causing the cementite to spheroidize in a ferrite matrix.

Graphite

Native carbon in hexagonal crystals, also foliated or granular massive, of black color with metallic luster, and soft. Used for crucibles, foundry facings, lubricants, etc. Also made artificially by passing alternating current through a mixture of petroleum coke and coal tar pitch. See Coke, Crucible.

Graphite, Primary

Carbon precipitated as graphite flakes while the iron cools through the freezing eutectic in which austenite, graphite, molten iron, and carbide exist together. Usually with reference to white fracture cast iron.

Graphite, Secondary

Graphite formed by decomposition of austenite during slow cooling of cast iron.

Graphitization

The decomposition of carbide to give free carbon as graphite or as temper carbon.

Graphitizer

Any substance, such as silicon, titanium, aluminum, etc., which promotes the formation of graphite in cast iron compositions.

Gray Iron

Iron in which a large percentage of the carbon content is in the form of graphite flakes. Traditionally referred to as “Cast Iron”. The graphite flakes cause it to have low shock resistance, but high damping ability. It has a gray fracture. Gray Iron is by far the oldest and most common form of cast iron. As a result, it is assumed by many to be the only form of cast iron and the terms "cast iron" and "gray iron" are used interchangeably. Cast iron

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containing graphite in flake form and typically consisting of 2 to 4 percent carbon and 1 to 3 percent silicon. Gray iron is widely used for engine components in automobiles and trucks. See Cast Iron.

Gray Iron Meltimg

The process of melting gray iron, especially as it is done in a foundry on a commercial scale. See Gray Iron.

Gray Iron Quality Control

The application of quality control practices to the manufacture of gray iron. See Gray Iron.

Green Permeability

Property of a molded mass of sand in its tempered condition which is a measure of its ability to permit the passage of gases through it.

Green Sand

Natural sands combined with water and organic additives, such as clay, to proper consistency for creating molds. See Core, Molds, Natural Sand.

Green Sand Core

A core that is made of molding sand but not baked.

Green Strength

Tenacity (compressive, shear, tensile, or transverse) of a tempered sand mixture at room temperature.

Grinding

Removing gate stubs, fins, and other projections on castings by an abrasive wheel. See Casting, Gate, Fins.

Growth

With reference to cast iron, permanent increase in volume that results from continued or repeated cyclic heating and cooling at elevated temperatures. For unalloyed iron, temperature is in excess of 900° F, and growth is cause by decomposition or graphitization of carbides and by oxidation of the graphite. See Cast Iron.

Guide Pin

The pin on a flask used to locate the cope in the proper place on the drag; also used to locate cheeks. See Cope, Cheek, Drag, Flask.

Gypsum Cement

Calcined calcium sulfate, commonly called plaster of Paris.

Glossary of Foundry Terms - H

Hadfield Manganese Steel

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A specialty steel which is austenitic and usually contains approximately 12% Manganese. It is used in mining, earth- moving equipment and in railroad track work.

Hand Ladle Or Shank

A small ladle carried by one man. See Ladle.

Hard Sand Match (Match Plate)

A body of sand shaped to conform to the parting line upon which a pattern is laid in starting to make a mold. Sand is made hard by addition of linseed oil and litharge, Portland cement, etc. See Match.

Hardenability

In a ferrous alloy, the property that determines the depth and distribution of hardness induced by quenching.

Hardness

Resistance of a material to indentation as measured by such methods as Brinell, Rockwell, and Vickers. The term hardness also refers to stiffness of a material, or its resistance to scratching, abrasion, or cutting. See BHN, Brinell Hardness, Vickers Diamond.

Hardness/Brinell

Relative term referring to the resistance of a metal to plastic deformation from a given standard load applied on a standard penetration head. See BHN, Brinell Hardness, Vickers Diamond.

Head

The pressure exerted by a column of fluid, such as molten metal, water, etc.

Head Metal

The reservoir of metal in the feeder or riser of a mold. See Mold, Riser.

Heap Sand

Sand in piles on the foundry floor.

Hearth

That portion of a reverberatory furnace on which the molten metal or bath rests.

Heat

A single furnace charge of metal to be used for pouring directly into mold cavities; a heat may be all of part of a master heat. See Mold Cavity.

Heat Transfer

Transmission of heat from one body to another by radiation, convection, or conduction.

Heat Treatment

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A combination of heating and cooling operations timed and applied to a metal or alloy in the solid state in a manner which will produce desired properties.

Heel

Metal left in a ladle after pouring, or in a furnace after or between tapping.

High Pressure Mold

A strong high-density mold, made by air, hydraulic, or other squeeze process.

High Stress Grinding Abrasion

Abrasion that occurs when the abrasive is crushed between two opposing surfaces.

High-Alloy Steel

Ferrous alloy with more than 12 weight percent of noncarbon additions.

Hindered Contraction

Casting contraction during solidification and cooling which is hindered by mold or core restraints.

Holding Furnace

Usually a small furnace for maintaining molten metal at the proper pouring temperature, and which is supplied from a large melting unit.

Holding Ladle

Heavily lined and insulated ladle in which molten metal is placed until it can be used. See Holding Furnace.

Hollow Drill Test (Trepanning)

Removing a cylindrical sample from a metal section or structure to determine soundness of the section.

Homogenizing

A process of heat treatment at high temperature intended to eliminate or decrease chemical segregation by diffusion.

Horizontal Axis Casting Machine

A centrifugal casting machine in which the axis of rotation of the mold is horizontal.

Horn Gate

Curved gate in the shape of a horn arranged to permit entry of molten metal at the bottom of the casting cavity. See Casting, Cavity, Gate.

Hot Box Process

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Method of making and curing cores within a heated corebox. To form and cure the core, the corebox is heated to approximately 500 degrees F. The sand used in this process contains a catalyst which hardens the binders in the core upon contact with the hot corebox. Complete curing while the core is still in the box results from the residual heat in the core, eliminating the need for conventional dryers or ovens. Frequently, cores created with the Hot Box process are shell cores. See Core.

Hot Deformation (Sand)

Change of form of a sand specimen which accompanies the determination of hot strength.

Hot Shortness

Brittleness in metal at elevated temperature.

Hot Spots

Areas of extra mass usually found at the junction of sections.

Hot Strength (Sand)

Tenacity (compressive, shear or transverse) of a sand mixture determined at any temperature above room temperature.

Hot Tear

Irregularly shaped fracture in a casting formed prior to completion of metal solidification resulting from stresses set up by steep thermal gradients within the casting during solidification and too much rigidity of the core or mold material. See Core, Solidification.

Hot Tears

Cracks in metal castings formed at elevated temperatures by contraction stresses. See Casting.

Hotbox Process

A furan resin based process which uses heated metal coreboxes to produce cores. See Core Box, Furans.

HSLA

Abbreviation for high strength low alloy steel. Steel with relatively high strength and impact properties. The carbon level is low and the alloying additions are significantly less than 5 weight percent.

Hunter Molding

Hunter molding is a sand molding process used to make sand molds. Hunter molding is yet another sand molding process named after the company that makes the machine, Hunter Automated Machinery Corporation. Hunter molding machines are horizontally parted matchplate molding machines, as opposed to the Disamatic vertically parted machines. See Disamatic Molding.

Hydrogen Embrittlement

A condition of low ductility resulting from the absorption of hydrogen. A time dependent fracture process which results in a loss of ductility. See Ductility.

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Hypereutectic Alloy

An alloy containing more than the eutectic amounts of the solutes. Analogous to hypereutectiod. See Alloy.

Hypereutectoid

An alloy containing more than the eutectic composition. See Alloy, Eutectic.

Hypereutectoid Steel

A steel containing more than the eutectoid percentage of carbon (0.83 wt. %). See Eutectic.

Hysteresis (Cooling Lag)

Difference between the critical points on heating and cooling due to tendency of physical changes to lag behind temperature changes.

Glossary of Foundry Terms - I

ID Grinding

Term for internal dimension grinding.

Ideal Critical Diameter, D1

The largest diameter of a bar which, upon quenching in an ideal quench, will exhibit 50% martensite at the center of the bar. See Quenching.

Ideal Quench

A quench in which the temperature of an object being quenched instantaneously drops to that of the quench bath and remains constant. See Quenching.

Illinois Inclusion Count Method

A determination of the index number of cleanliness of steel. See Inclusion.

Illite

A mineral, typically KAl 3Si 3O 10(OH)2, found in many clays, large working of which are found in Illinois and Michigan.

Impact Strength

The resistance to impact loads; usually expressed as the foot pounds of energy absorbed in breaking a standard specimen. See Charpy Impact Test.

Impact Value

Total energy needed to break a standard specimen by a single blow under standard conditions; e.g. Charpy Impact Test.

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Impoverishment

Loss of any constituent from an alloy or from localized areas of an alloy by oxidation, liquidation, volatilization, or changes in the solid state. The term depletion is also used, particularly in referring to the lowering of the concentration of solute in a solid solution, around particles precipitated from solid solution.

Impregnation

A treatment process using a sealing medium for salvaging leaky castings by injecting under pressure liquid synthetic resins, tung oil, etc., into the porous area. This material is then solidified in place by heating or baking. Other mediums used include silicate of soda, drying oils with or without styrene, plastics, and proprietary compounds.

Impression

Cavity in a die-casting die or in a mold. See Cavity, Mold.

Impurity

An element unintentional allowed in a metal or alloy. Some impurities have little effect on properties; others will grossly damage the alloy.

Inclusion(s)

Particles of slag, refractory materials, sand or deoxidation products trapped in the casting during solidification. See Dirty Casting, Solidification.

Inconel

An oxidation-resistant alloy, 80% Ni, 14% Cr, and 6% Fe.

Indentation Hardness

The resistance of a material to indentation. This is the usual type of hardness test, in which a pointed or rounded indenter is pressed into a surface under a substantially static load. See BHN, Brinell Hardness, Hardness.

Indirect-Arc Furnace

An AC, Alternating Current, electric-arc furnace in which the metal is not one of the poles. An electric furnace in which the arc is struck between two horizontal electrodes, heating the metal charge by radiation.

Induction Furnace

An AC melting furnace which utilizes the heat of electrical induction.

Induction Hardening

A surface hardening process involving the localized use of pulsating magnetic currents to achieve heating above the austenite transformation temperature, Ac3, followed by quenching. See Ac3, Quenching.

Induction Heating

Process of heating by electrical resistance and hysteresis losses induced by subjecting a metal to the varying magnetic field surrounding a coil carrying an alternating current.

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Inert Gas

A gas that will not support combustion or sustain any chemical reaction; e.g., argon or helium.

Infrared Dryer

A core or mold dryer employing infrared lamps. See Core Dryers.

Infrared Radiation Pyrometer

This instrument which uses the ratio of the radiated energy from a body in two wavelength bands and then is a measure of the body's surface temperature. Temperatures down to 200°C (392°F) may be measured. See Pyrometer.

Infrared Rays

Pertaining to or designating those rays which lie just beyond the red end of the visible spectrum, such as are emitted by a hot non-incandescent body. They are invisible and nonactinic and are detected y their thermal effect. Their wave lengths are longer than those of visible light and shorter than those of radio waves. Can be applied in the foundry for drying or core baking operations and for heating dies. Infrared radiant heat are synonymous. See Foundry.

Infusorial Earth (Diatomite, Fossil flour, Mountain meal, Mountain flour, Tripolite, Kieselguhr)

A very fine whitish powder composed of the siliceous skeletons of infusorians (Protozoa).

Ingates

The channels through which molten metal enters the mold cavity. See Gate.

Ingot

Casting to be later forged or hot worked.  Also, a form used for convenient handling of cast iron, aluminum, and other commercial metals. i.e., Pigs. See Cast Iron.

Ingot Iron

Iron of comparatively high purity produced in open-hearth furnace under conditions that keep down the carbon, manganese, and silicon content; e.g., Armco Iron. See Cast Iron.

Injection

Forcing molten metal into a die-casting die. Also refers to forcing oxygen, nitrogen, and other gases, as well as solids such as calcium carbide and graphite, into molten metal.

Injection Molding

The injection of molten metal or other material under pressure into molds. See Molds.

Inoculant

Materials, which when added to molten metal, modify the structure and thereby change the physical and mechanical properties.

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Inoculation

A process of adding some material to molten metal in the ladle for the purpose of controlling the structure to an extent not possible by control of chemical analysis and other normal variables.

Insert

A part usually formed from metal, which is placed in a mold and may become an integral part of the casting. See Casting, Mold.

Institue of Scrap Iron and Steel, Inc.

See Trade Name for address.

Insulating Pads And Sleeves

As opposed to chills, insulating material, such as gypsum, diatomaceous earth, etc., used to lower the rate of solidification. As sleeves on open risers, they are used to keep the metal liquid, thus increasing the feed efficiency. See Solidification.

Insulating Sleeve

Hollow cylinders or sleeves formed of gypsum, diatomaceous earth, pearlite, vermiculite, etc. Placed in the mold at sprue and riser locations to decrease heat loss and rate of solidification of the metal contained in them. See Riser, Sprue.

Integral Dose (Volume Dose)

A measure of the total energy absorbed by man or any object during exposure to radiation.

Intensity (Radiology)

Amount of energy per unit time passing through a unit area perpendicular to the line of propagation at the point in question. Often this term is used incorrectly in the sense of dose rate.

Intercast Process

A patented procedure for die casting "cast-assemble" units with moving parts.

Intercrystalline Failure

Cracks or fractures that follow along the grain boundaries in the microstructure of metals and alloys.

Interdendritic Attack

A type of electrochemical corrosion that sometimes occurs in as-cast alloys or alloys that have had very little working.

Intergranular Corrosion

Corrosion in a metal taking place preferentially along the grain boundaries.

Internal Chills

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Solid pieces of metal or alloy, similar in composition to the casting, placed in the mold prior to filling it with molten metal. They increase the rate of solidification in their areas and are employed only where feeding is difficult or impossible.

Internal Friction

Ability of a metal to transform vibratory energy into heat; generally refers to low stress levels of vibration; damping has a broader connotation since it may refer to stresses approaching or exceeding yield strength.

Internal Shrinkage

A void or network of voids within a casting caused by inadequate feeding of that section during solidification. See Solidification, Void.

Internal Stresses (or Thermal stresses)

Generally stresses which occur during the cooling of a part.

International Molders & Allied Workers Union of America

International Molders & Allied Workers Union of America - see trade associations.

Interrupted Quench

Removing the casting from a quenching bath before it has reached the temperature of the bath. See Quenching.

Invar

An alloy having practically no expansion when heated; 36% Ni, 0.5% Mn, 0.2% C, and the balance Fe.

Inverse Chill

A condition in an iron casting section in which the interior is mottled or white while the outer sections are gray. This condition is also called reverse chill, internal chill, or inverted chill.

Inverse Segregation

A concentration of certain alloy constituents that have lower melting points in the region corresponding to that first solidifying; caused by interdendritic flow of enriched liquid through channels where the pressure drops with contraction of dendrites. The internal evolution of hydrogen may also give a positive pressure, aiding this flow and causing a liquidated surface as tin sweat. See Segregation.

Inversion

A change in crystal form without change in chemical composition, as from quartz to cristobalite.

Inversion Casting

The metal is fed through a bottom feeder, the mold being inverted for pouring.

Investing

The process of pouring the investment slurry into the flask surrounding the pattern to form the mold. See Flask, Mold.

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Investment

A flowable mixture of a graded refractory filler, a binder and a liquid vehicle which when poured around the patterns conforms to their shape and subsequently set hard to form the investment mold. See Investment Casting.

Investment Casting

A pattern casting process in which a wax or thermoplastic pattern is used. The pattern is invested (surrounded) by a refractory slurry. After the mold is dry, the pattern is melted or burned out of the mold cavity, and molten metal is poured into the resulting cavity. See Lost Wax Process.

Investment Casting Process

A pattern casting process in which a wax or thermoplastic pattern is used. The pattern is invested (surrounded) by a refractory slurry. After the mold is dry, the pattern is melted or burned out of the mold cavity, and molten metal is poured into the resulting cavity. See Mold Cavity.

Investment Molding

Method of molding using a pattern of wax, plastic, or other material which is "invested" or surrounded by a molding medium in slurry or liquid form. After the molding medium has solidified, the pattern is removed by subjecting the mold to heat, leaving a cavity for reception of molten metal. This is also called the lost-wax process or precision molding. See Lost Wax Process, Investment Casting.

Investment Precoat

An extremely fine investment coating applied as a thin slurry directly to the surface of the pattern to reproduce maximum surface smoothness. The coating is surrounded by a coarser, cheaper, and permeable investment to form the mold. See Dip Coat.

Inwall Brick

Refractory lining of the inwall section of blast furnace or cupola. See Blast Furnace, Cupola, Refractory.

Ionization

The process or the result of any process by which a neutral atom or molecule acquires either a positive or a negative charge.

Ionization Chamber

An instrument designed to measure quantity of ionizing radiation in terms of the charge of electricity associated with ions produced within a defined volume.

Iridium

A noble metal of the platinum group. Usually extensively as a radiation source. For radiography of thin walled castings.

Iron

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A metallic element, mp 1535°C (2795°F). Also irons that do not fall into the steel categories, such as Gray Iron, Ductile Iron, Malleable Iron, White Iron, Ingot, and Wrought Iron. See Gray Iron, Ductile Iron, Malleable Iron, White Iron, Ingot.

Iron Carbide

See Cementite.

Iron Oxide

This material as prepared for foundry use generally contains about 85% ferric oxide and is produced by pulverizing a high grade of pure iron ore. It can be added to core sand mixes to assist in keeping the core from cracking before the metal solidifies during the casting operation and also helps to resist metal penetration during this period. Added to molding sand mixtures for control of finning and veining. Also may reduce carbon pick up.

Iron Sand

See Iserine.

Iron, Hard Or White

Irons (Fe3C) possessing white fracture because all or substantially all of the carbon is in the combined form. Irons to be malleablized are cast white, as are many abrasion-resistant irons.

Iron, Malleable

A mixture of iron and carbon, including smaller amounts of silicon, manganese, phosphorus, and sulfur, which after being cast (white iron, carbon in combined form as carbides) is converted structurally by heat treatment into a matrix of ferrite containing nodules of temper carbon (graphite).

Iron, Pearlitic Malleable

A malleable iron having a more or less pearlitic matrix.

Iron, White Or Hard

Iron of suitable composition in which the castings, later to be malleableized, are originally cast. Carbon is in the combined form; hence it’s white fracture and name.

Iron-Carbon (Graphite) Diagram

A diagram representing stable equilibrium conditions between iron and graphite (pure carbon) phase over the entire range of iron and steel.

Iron-Iron Carbide Diagram

A phase diagram representing metastable equilibrium conditions between Fe and Fe3C over the entire range of carbon steels and cast irons.

Iserine

A black sand which consists mainly of magnetic iron ore but also contains a considerable amount of titanium.

Isocure

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Trade name of a binder system developed for use in the cold box process of core construction.

Isocyanate Acid

Isomeric cyanic acid (HNCO).

Isomorphous

Phases with crystal structures of the same type.

Isothermal

Pertaining to changes or other phenomena occurring at a constant temperature.

Isothermal Annealing

A process in which a ferrous alloy is heated to produce a structure partly or wholly austenitic, and is then cooled to and held at a temperature that causes transformation of the Austenite to a relatively soft ferric-carbide aggregate. See Austenite, Annealing.

Isothermal Transformation

The process of transforming Austenite in a ferrous ally to Ferrite or a ferrite-carbide aggregate at any constant temperature within the transformation range. The transformation of one phase in an alloy system to another phase at any constant temperature.

Isotope

One of several different nuclides having the same number of protons in their nuclei, and hence having the same atomic number, but differing in the number of neutrons and therefore in the mass number.

Glossary of Foundry Terms - J

J

Symbol for a 1-gram equivalent weight.

Jack Arch

A spring arch, flat or horizontal on the underside.

Jacket, Mold

A wood or metal form slipped over a mold made in a snap or slip flask, to support the four sides of the mold during pouring. Jackets and mold weights are shifted from one row of molds to another during the pouring period. See Flask.

Jamb

Usually an upright structural member forming the side of an opening in a refractory or furnace wall.

Jamb Brick

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A brick modified so one corner is rounded.

Jar Ramming

Packing sand in a mold by raising and dropping on a table the sand, pattern, and flask. Jolt squeezers, jarring machines, and jolt rammers are machines using this principle. See Jolt Ramming, Jolt Squeezer Machine, Jolt Machine.

Jarring Machine

A molding machine that packs the sand by jarring. See Jar Ramming.

Jersey Fireclay Brick

Highly siliceous clay brick, semisilica brick.

Jet Scrubber

A high velocity water jet directed into the throat of a venture section of a cupola to separate out particulates in air pollution control.

Jet Tapping

A method of tapping a melting furnace by firing a small explosive charge instead of using an oxygen lance. The tapper consists of an explosive charge enclosed in a plastic case surrounded by a hollow bullet-shaped body.

Jib

Projecting part of crane from which lifting chain or gear is suspended.

Jig

A device arranged to expedite a hand or machine operation.

J-Integral

A mathematical expression used to characterize the fracture toughness of a material having appreciable plasticity prior to fracture. The J-integral eliminates the need to describe the behavior of the material near the crack tip. Units are MN/m or in in-lb/in 2.

Jobbing Foundry

A foundry engaged in the manufacture of numerous types of castings and is not a part of a manufacturing plant, and produces castings for sale that usually makes a wide variety of castings in small lots or quantities. See Casting, Foundry.

Joint Welding

Production welding used to weld cast components together to obtain an integral unit.

Jolt

To raise the flask filled with sand and allow it to drop, thereby compacting the sand against the pattern. See Flask, Sand.

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Jolt Machine

Molding machine which packs or rams the sand around the pattern by raising the table on which the flask, sand, and pattern are mounted a few inches and allowing the whole to drop suddenly. The table is raised pneumatically, and the operation is repeated until the desired sand density is reached.

Jolt Ramming

Packing sand in a mold by raising and dropping the sand, pattern, and flask on a table. Jolt squeezers, jarring machines, and jolt rammers are all machines that use this method.

Jolt Squeezer Machine

A combination machine that employs a jolt action followed by a squeezing action to compact the sand around the pattern. See Jar Ramming.

Jominy Test

See End-Quench Hardenability Test.

Glossary of Foundry Terms - K

K

Symbol used in linear elastic fracture mechanics to describe the intensification of applied stress at the tip of a crack of known size and shape. At the onset of rapid crack propagation, the factor is call the critical stress-intensity factor (KIc) or fracture toughness. Various subscripts denote loading conditions or fracture toughness. Units are Mpa/mm or ksi/in.

K Factor

Tensile strength in pounds per square inch divided by the Brinell Hardness number. See BHN, Brinell Hardness.

Kahlbaum Iron

An iron of more than 99.975% purity, produced in Germany.

Kalling-Dommarfvet process

A desulfurizing process using powdered burnt iron.

Kaolin

The purest form of China clay consisting of silicate of aluminum.

Kaolinite

Hydrated silicate of alumina represented by the formula Al2O3 · 2 SiO2 2 H2O. It is a white, pearly mineral, crystallizing in a monoclinic system in the form of small, hexagonal plates. Constituent of kaolin, white china clay, used for porcelain, etc.

Kappa Carbide

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A carbide of iron (Fe23,C6) in which all or part of the iron may be replaced by chromium, molybdenum, and/or tungsten.

Kayser Hardness Test

A method for determining the true hardness of metals at high temperatures.

KC (Plane-stress fracture toughness)

The value of stress intensity at which crack propagation becomes rapid in sections thinner than those in which plane-strain conditions prevail. Units are MPa/m or ksi/in.

Kelvin Temperature Scale

One in which the unit of measurement equals that of the centigrade degree and according to which absolute zero is 0 degrees, equivalent to -273.16°C.

Kerf

The width of a cut.

Keyhole Specimen

A type of notched impact test specimen which has a hole-and-slot notch shaped like a keyhole.

Kic (Plane-Strain Fracture Toughness)

The minimum value of KC. Represents the fracture toughness of a material independent of crack length, or loading system. Units are MPa/m or ksi/in.

Kieselguhr

Diatomaceous earth, a finely porous material used for thermal insulation to 1100°C (2012°F).

Killed Steel

Molten steel held in a ladle, furnace, or crucible (and usually treated with aluminum, silicon, or manganese) until more gas is evolved and the metal is perfectly quiet. See Crucible, Ladle.

Kiln

An oven or furnace for burning, calcimining or drying a substance.

Kiln Marks

Irregularities on the surface of refractors caused by deformation under load during burning.

Kiln-Dried

Lumber artificially dried in a specially designed enclosure or lumber kiln.

Kilovolt (kV)

Unit of electrical potential equal to 1,000 volts.

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Kilovolts Constant Potential

The potential in kilovolts of a constant voltage generator.

Kilovolts Peak

The crest value of the potential wave in kilovolts. When only one half of the wave is used, the crest value is to be measured on this half of the wave.

Kip

A term sometimes used to represent a unit load of 1,000 pounds.

Kish

Graphite thrown out by liquid cast iron in cooling.

Kissing (Touching)

Gating with minimum metal left at casting breakoff point, having a gate just "kiss" the surface. See Gate.

Knock Out

To remove sand and casting from a flask.

Knock-Off Riser

Riser with a small attachment and can be knocked off with a hammer.

Knock-Out Pins

Small pins on die-casting machines, permanent molds, and shell-molding machined for ejection of castings, etc. See Ejector Pins.

Knoop Hardness Number (HK)

A number related to the applied load and to the projected area of a rhombic-based diamond indentor, with edge angles of 172 1/2° 30' and 130 1/2°.

Glossary of Foundry Terms - L

Ladle

Metal receptacle frequently lined with refractories used for transporting and pouring molten metal. Different types of ladles include hand bull, crane, bottom-pour, holding, teapot, shank, lip-pour.

Ladle, Bottom-Pour

Ladle from which metal flows through a nozzle in the bottom.

Ladle, Bull

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Large ladle for transporting and pouring molten metal.

Ladle, Lip-Pour

Ladle in which the metal is poured over a lip.

Ladle, Teapot

A ladle in which, by means of an external spout, metal is removed from the bottom rather than the top of the ladle. See Ladle.

Lance, Oxygen

Long steel pipe or tube, usually covered with refractory, used to inject oxygen into molten steel to reduce the carbon content. Also may be used to open up frozen tap holes in cupolas, etc. See Cupola.

Lap-Gate

When the connection point of ingate to casting overlaps onto the cope surface.

Lateral Expansion

A measured property used in Charpy Impact Testing. Refers to the increase width of the specimen after fracture. See Charpy Impact Testing.

Leaker

Foundry term for castings which leak under liquid or gaseous pressure.

Linear Elastic Fracture Mechanics (LEFM)

A method of fracture analysis that can determine the stress required to induce fracture instability in a structure with a crack like flaw of know size and shape.

Lining

Inside refractory layer of firebrick, clay, sand, or other material in a furnace or ladle.

Lining, Monolithic

A lining made without the customary layers and joints of a brick wall. Usually made by tamping or casting refractory material into place, drying, and then burning in place on the job.

Linseed Oil

Drying-type oil expressed from flax seeds and used as a binder for core sand. See Binder, Core Sand.

Liquid Contraction

Shrinkage or contraction in molten metal as it cools from one temperature to another while in the liquid state.

Liquid Penetrant Testing

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A nondestructive testing method suitable for evaluating the surface integrity of non-magnetic and ferro-magnetic parts.

Liquidus

The temperature at which solidification of metal begins on cooling and the temperature at which the last portion of solid metal becomes liquid on heating.

Loam

A coarse, strongly bonded molding sand used for loam and dry-sand molding.

Loam Mold

A mold built up of brick, covered with a loam mud, and then baked before being poured.

Loam Molding

A system of molding, especially for large castings, wherein the supporting structure is constructed of brick. Coatings of loam are applied to form the mold face.

Locating Pad

A projection on a casting that helps maintain alignment of the casting for machining operations.

Locating Surface

A casting surface to be used as a basis for measurement in making secondary machining operations.

Logo

The sign, mark, or distinguishing letter designating the manufacturer.

Loose Molding

The molding process utilizing unmounted patterns. Gates and runners are usually cut by hand. See Gates, Runners.

Loose Piece

Part of a pattern so attached that it remains in the mold, and is removed after the body of the pattern is drawn. In die-casting, a type of core, (which forms the undercuts, positioned in, but not fastened to, a die and so arranged as to be ejected with the die-casting, from which it is removed and used repeatedly for the same purpose. See Core Box, Pattern.

Loose Pieces

Part of a core box or pattern which remains embedded in the core or mold and is removed after lifting off the core box or drawing the pattern. Backdraft is avoided by this means. See Core Box, Pattern.

Lost Foam Process

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Casting process in which a foam pattern is removed fro the cavity by the molten metal being poured. See Mold Cavity.

Lost Wax Process

A method for changing a sculpture made of soft clay into a harder material, such as bronze.

Low Stress Scratching Abrasion

Abrasion involving near zero impingement angle for the striking particle, also parallel flow erosion.

Glossary of Foundry Terms - M

Machinability

The capability of being cut, turned, broached, etc., by machine tools.

Machine Allowance

Stock added to the part to permit machining of the part to final dimensions.

Machine Drawing

An engineering drawing which depicts the final size and shape of the part for its end use. See Computer Aided Design (CAD).

Machine Finish

Allowance of stock on the surface of the pattern to permit the machining of the casting to the required dimensions.

Magnaflux™

Trade name for a method of magnetic crack detection.

Magnaglo™

Trade name for a method of magnetic crack detection in which the magnetic particles are treated so that they fluoresce in ultraviolet light.

Magnetic Crack Detection

Method of locating cracks in materials which can be magnetized; done by applying magnetizing force and applying finely divided iron powder which then collects in the region of the crack.

Magnetic Particle Inspection

A nondestructive method of inspecting the surface integrity of ferromagnetic materials.

Malleability

The property of being permanently deformed by compression without rupture.

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Malleable Iron

Iron that may be altered in shape by hammering or by the pressure of rollers without exhibiting fracture or brittleness. The majority of the carbon content is in the form of graphite nodules rather than flakes. See Nodular Iron.

Malleableization

Annealing or heat-treating operation performed on white iron castings to transform the combined carbon into temper carbon.

Manganese

One of the elements; its chemical symbol is Mn. It’s formula weight is 54.93; specific gravity 7.2, and melting point is 1260°C. Metallic manganese is used in the nonferrous industry both as a deoxidizing agent and as an essential constituent to improve physical properties of certain alloys.

Manganese Briquets

Crushed ferromanganese bonded with a special refractory in briquet form, and containing 2-lb metallic manganese and ½-lb metallic silicon.

Manganese Steel (Austenitic)

See Hadfield Manganese Steel.

Maraging Steel

A high alloyed steel that is hardened by both martensite transformation and by age hardening. See Age Hardening, Martensite.

Martempering (Interrupted Quenching)

A hardening treatment of a steel involving a slow cool through the martensitic transformation range to reduce stresses associated with the quenching of austenite. An important aspect of martempering is that no transformation product other than martensite should form. See Austenite, Martensite, Quenching.

Martensite

A generic term used for microstructures formed by diffusionless phase transformations. A constituent found in hardened steel; has a needle like microstructure. See Mf, Ms.

Martensitic Stainless Steels

A corrosion-resistant ferrous alloy with a predominant martensitic phase.

Mass Effect

The effect that the mass of a component has on the properties of the material from which the part is made. In castings, such effects may arise due to the effect of mass on the solidification rate and on the rate of temperature change during heat treatment.

Master Pattern

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An original pattern made to produce castings which are then used as metal patterns. See Casting.

Match

A form of wood, plaster of Paris, sand or other material on which an irregular pattern is laid or supported while the drag is being rammed.

Matchplate

A metal or other plate on which patterns split along the parting line are mounted back to back with the gating system to form an integral piece.

Meallographic Structure

The nature, distribution, and amounts of the metallographic constituents in a metal.

Mechanical Properties

Those properties of a material that reveal the elastic and inelastic reaction when force is applied, or that involve the relationship between stress and strain; for example, the modulus of elasticity, tensile strength, and fatigue limit. This term should not be used interchangeably with "physical properties."

Melting Pot

Metal, graphite-clay, or ceramic vessel in which metal is melted.

Melting Range

Pure metals melt at one definite temperature, but constituents of alloys melt at different temperatures, and the variation from the lowest to the highest is called the melting range. See Alloy.

Melting Rate

Amount of metal melted in a given period of time, usually one hour.

Melting Zone

Portion of the cupola above the tuyeres in which the metal melts. See Cupola, Tuyeres.

Metal Lot

A master heat that has been approved for casting and given a sequential number by the foundry.

Metal Penetration

Defect in the casting surface which appears as if the metal has filled the voids between the sand grains without displacing them.

Metalloid

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An element intermediate between metals and nonmetals possessing both metallic and nonmetallic properties, as arsenic, sometimes applied to elements commonly bonded in small amounts in steel, as carbon, manganese, boron, silicon, sulfur, and phosphorus.

Metallstatic Pressure

A compound phase referring to hydrostatic pressure, substituting "Metall" since "Hydro" connotes water.

Metallurgical Bond

The bond between two metals whose interface is free of voids, oxide films, or discontinuities.

Metallurgy

Science dealing with the constitution, structure, and properties of metals and alloys, and the processes by which they are obtained from ore and adapted to the use of man.

Metalock

A method of cold repair of castings and forgings.

Metals Comparator

An instrument for testing or identifying metallic and nonmetallic parts. Parts are placed in an electromagnetic field and a standard parts in a matched electromagnetic field. Distortions of the magnetic fields are compared on an oscilloscope.

Metamic

A metal ceramic high in Cr-Al 2O3.

Metastable (Unstable)

A state of pseudo-equilibrium.

Mexico Bay Sand

A sand similar to Michigan City dune sand mined at Selkirk Beach, near Mexico, NY, on Lake Ontario. It has a silica content of 90% and over.

Meyer Hardness Test

A test to determine tendency of a metal to harden when deformed plastically. A series of indentations are made in the metal using a fixed-diameter ball and progressively increasing loads. See Brinell Hardness, Charpy Impact Test.

Mf

The temperature at which martensite formation finishes during cooling. See Martensite, Ms.

Mica Schist

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A type of micaceous refractory rock used for lining cupolas and other melting furnaces.

Mica Strainer

A skim core made of thin mineral silicates crystallizing in monoclinic form.

Michigan Sand

Core sands of dune or lake sand and bank sands found in Michigan.

Micro Pipes (British) (Microshrinkage)

Tiny cavities, a fraction of a millimeter in diameter, with irregular outlines, which occur in castings. Etching shows they occur at intersections of convergent dendritic directions.

Microcast Process

A patented method of precision-casting alloys, as Vitallium, Monel, Inconel and the Haynes Stelite alloys. See Inconel, Monel.

Microetching

Etching of metal samples for examination under the microscope.

Microformer

A type of extensometer for measuring elongation of test piece in a tensile test.

Micrography

Examination by means of a microscope.

Microhardness

The hardness of microconstituents of a material. See Hardness.

Microinch

0.000001 (1/1,000,000th) of an inch. A common unit of measurement in surface measurement research and in standard roughness (surface) unit values of performance of machinery.

Microlug

A test coupon used to give rapid indication of the effectiveness of magnesium treatment of ductile iron. See Ductile Iron.

Microporosity

Extremely fine porosity in castings caused by shrinkage or gas evolution and apparent on radiographic film as mottling. See Microshrinkage.

Microradiography

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Process of passing x-rays through a thin section of an alloy in contact with photographic film, and then magnifying the radiograph 50 to 100 diameters to observe the distribution of alloying constituents, of voids, and of other microstructural features. See X-rays.

Microscopic

Minute object or structures which are invisible or not clearly distinguished without the use of a microscope.

Microsection

A metal specimen whose surface has been polished and etched to reveal the microstructure. See Microstructure.

Microshrinkage

Very finely divided porosity resulting from interdendritic shrinkage resolved only by use of the microscope; may be visible on radiographic films as mottling. Etching shows they occur at intersections of convergent dendritic directions.

Microspectroscopy

A method of identifying metallic constituents using spectrographic arc. See Spectography.

Microstructure

The structure and characteristic condition of metals as revealed on a ground and polished (etched or unetched) specimen at magnifications above 10 diameters. See Microsection.

Micro-Tester

A low load hardness tester, suitable for both Vickers and Knoop tests, working with loads of between 10 to 3000 grams. See Knoop Hardness, Vickers Diamond.

Microtone (British)

An instrument for cutting thin sections of soft specimens.

Migra Iron (British)

A special pig iron for high quality castings.

Mikro-Tester

A low load hardness tester, suitable for both Vickers and Knoop tests, working with loads of between 10 to 3000 grams. See Knoop Hardness, Vickers Diamond.

MIL STD

Designation for the United States Government military standards, specifications, usually requiring rugged, exacting, testing equal to the exigencies of combat usage.

Mild Steel

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Plain carbon steel of about 0.25% carbon or less.

Mill Sale

Iron oxide scale formed on steel during hot working processes, cooled in air.

Mill Stars

Multi-pointed white iron or hard iron bodies used in a Tumbling Barrel to assist in polishing and cleaning.

Milling

Removing metal with a milling cutter.

Milliroentgen (mr)

A sub-multiple of the roentgen equal to one-thousandth (1/1000th) of a roentgen.

Milliscope (British)

An instrument which gives an electrical warning when melt reaches a predetermined temperature.

Mineral

Natural inorganic substance which is either definite in chemical composition and physical characteristics or any chemical element or compound occurring naturally as a product of inorganic processes.

Mischmetal

Alloy of rare-earth metals containing about 50% cerium and 50% lanthanum, neodymium, and similar elements.

Miscibility

Solubility; ability of two or more liquids to form a homogeneous solution.

Misrun

Denotes an irregularity of the casting surface caused by incomplete filling of the mold due to low pouring temperature, gas back-pressure from inadequate venting of the mod, and inadequate gating.

Mitis Casting

Casting of very mold steel.

Mock-Up

A full-size model built accurately for study, testing or display.

Model

A proportional representation of an object in any scale.

Modell Number

99

A value giving a measure of wear resistance.

Modification

A process in which the eutectic temperature, structure, and composition of aluminum-silicon alloys are apparently altered by the addition of small amounts of a third element, such as sodium. A similar phenomenon can be effected by chill casting.

Modulus Of Elasticity (E)

In tension it is the ration of stress to the corresponding strain within the limit of elasticity (Yield Point) of a material. For carbon and low alloy steels any composition and treatment, the value is approximately 30,000,000 psi.

Modulus of Resilience ( ur )

The amount of strain energy per unit volume required to tress a material from zero to the yield stress limit. The modulus of resilience is proportional to the area under the elastic portion of the stress-strain diagram. Units are Pa or psi.

Modulus of Rigidity

In a torsion test the ratio of the unit shear stress to the displacement caused by it per unit length in the elastic range. See Shear Modulus.

Modulus of Rupture

Used in both bending and torsion testing. In bending, the modulus of rupture is the bending moment at fracture divided by the section modulus. In torsion, modulus of rupture is the torque at fracture divided by the polar section modulus.

Modulus of Toughness (ut)

Amount of work per unit volume of a material required to carry that material to failure under static loading. Equal to the area under the entire stress-strain curve. Units are Pa or psi.

Mogullizer

Equipment for sealing by vacuum impregnation of small pores in castings. See Porosity.

Moh's Scale

A scratch hardness test for determining comparative harness using ten standard minerals, from talc to diamond.

Moisture Content

The amount of water contained in a substance that can be driven off by heating at 220°F - 230°F (104.4°C - 110°C).

Moisture Teller

A patented apparatus for the rapid determination of moisture content of molding sand.

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Molasses Water

A solution of water and molasses sprayed on sand molds to strengthen mold surface and yield a fine finish layer. See Sand Molding.

Mold

Normally consists of a top and bottom form, made of sand, metal, or any other investment material which contains the cavity into which molten metal is poured to produce a casting of definite shape and outline. See Mold Cavity.

Mold Blower

Molding equipment for blowing sand mixture onto the pattern with compressed air; allows for faster production than gravity rollover dump.

Mold Board (Follow Board)

The board upon which the pattern is placed to make the mold.

Mold Cavity

The impression in a mold produced by removal of the pattern. It is filled with molten metal to form the casting. Gates and risers are not considered part of the mold cavity. See Casting, Gates, Risers.

Mold Coating

Coating to prevent surface defects, i.e., metal penetration and improve casting finish. See Core Wash.

Mold Conveyor

Power-driven unit on which molds are conveyed from the molding station to pouring station to shakeout.

Mold Cover Half (Cover Die)

The top half of the mold, the cope. In die casting, the front half of the die, which remains stationary as the die is opened. See Cope.

Mold Facing

See Mold Coating.

Mold Hardener

In sand molds in which sodium silicate is the binder, injection of CO2 causes a chemical reaction which results in a rigid structure.

Mold Jacket

A wooden or metal form slipped over a mold to support the side during pouring.

Mold Oven

Oven or furnace in which molds are dried.

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Mold Shift

Casting defect resulting when the two cavities in the cope and drag molds do not match properly. See Cavity, Mold Cavity, Cope, Drag.

Mold Wash

Usually an aqueous emulsion, containing various organic or inorganic compounds or both, which is used to coat the face of a mold cavity. Materials include graphite, silica flour, etc. This guards against penetration of metal into sand walls.

Mold Weights

Weights placed on top of molds to offset internal or ferrostatic pressure.

Moldability

Ability of sand to flow into a flask and around a pattern measured in the amount of sand falling through an inclined screen or slot. See Flask, Pattern.

Moldabilty Controller

A patented device for controlling water additions to sand mix to maintain a consistent moldability index.

Molding Bench

The making of sand molds from loose or production patterns at a bench.

Molding Floor

Making sand molds from loose or production patterns at a floor. Patterns are usually too large to be handled satisfactorily on the bench. See Sand Molding, Molding Sand.

Molding Gravel

The coarser and more permeable grades of molding sand generally used in production casting of exceptional size and weight.

Molding Machine

Hand or pneumatically operated machine on which molds are made and which rams the sand by squeezing or jolting or both.

Molding Material

A material suitable for making molds into which molten metal can be cast.

Molding Sand

Mixture of sand and clay suitable for mold making.

Molding Sand Mixture

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A sand mixture suitable for making molds into which molten metal can be cast.

Molding Sands

Sands containing over 5% natural clay, usually between 8 and 20%. See Naturally Bonded Molding Sand.

Molding, Bench

Making sand molds by hand tamping loose or production patterns at a bench without assistance of air or hydraulic action.

Molding, Floor

Making sand molds from loose or production patterns of such size that they cannot be satisfactorily handled on a bench or molding machine, the equipment being located on the floor during the entire operation of making the mold.

Molding, Machine

Making sand molds from production patterns on molding machines. See Sand Molding.

Molding, Pit

Molding method in which the drag is made in a pit or hole in the floor. See Drag.

Molecular Weight

Weight of the smallest quantity of a substance processing all its normal physical properties.

Molecule

The smallest particle of a substance that can exist in the free state and which has the same composition as any larger mass of the substance.

Molybdenum

A metal used widely in alloying of other metals. It is used as hardening element for steel, and for diecasting dies. The melting point is 2,620°C (4,748°F), and the atomic number is 42.

Molybdic Oxide

The oxide of molybdenum; added to the furnace in briquetted form as an important finishing constituent in nitriding steels.

Monel

A high nickel alloy, approximately 67% Ni, 28% Cu, the balance Fe, Mn, Si and other elements. Monel metal is resistant to corrosion and is widely used to resist the action of acids. See Inconel.

Monitoring

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Periodic or continuous determination of the does rate in an occupied area (area monitoring) or the does received by a person. See Monitoring, Personnel.

Monitoring, Personnel

Monitoring any part of any individual, his breath, or excretions, or any part of his clothing.

Monitoring Area

Routine monitoring of the level of radiation or of radioactive contamination of any particular area, building, room or equipment. Usage in some laboratories or operation distinguishes between routine monitoring and survey activities.

Monkey Cooler (British)

In a blast furnace, the smaller of a series of three water coolers protecting the cinder notch. The largest is the cooler, while the in-between cooler is the intermediate cooler.

Monocast Process

A patented application of resin-bonded sand to line the flask in the production of centrifugal cast pipe. The resin-bonded layer is thinner than the conventional sand lining. See Flask.

Monotectic

An isothermal reversible reaction in a binary system, in which a liquid on cooling, decomposes into a solid and a second liquid of different composition. Compare with Eutectic.

Monotron

An instrument for measuring indentation hardness. It is fitted with two dials, one to measure depth of penetration, the other the load.

Montmorillonite

A very plastic clay, more siliceous than kaolinite; the principal constituent of bentonite. See Bentonite.

Moore, R. R., Fatigue Machine

A constant load rotating bending type fatigue testing machine.

Moisture, Workable

That range of moisture content within which sand fills, rams, draws, and dries to a satisfactory mold, and within which the sand does not dry out too fast to mold and patch.

Mother Metal

The molten alloy just before final solidification and freezing out of the solid. See Alloy, Solidification.

Motorized Variac

An autotransformer for stepless voltage control in shell molding.

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Mottled

White iron structure interspersed with spots or flecks of gray.

Mottled Cast Iron

Iron which consists of a mixture of variable proportions of gray iron and white cast iron. Mottle cast ironhas a mottled fracture. See Gray Iron, White Cast Iron.

Mould (British)

Normally consists of a top and bottom form, made of sand, metal, or any other investment material which contains the cavity into which molten metal is poured to produce a casting of definite shape and outline. The American spelling of this word is "mold". See Mold.

Mould Cavity (British)

The impression in a mould produced by removal of the pattern. It is filled with molten metal to form the casting. Gates and risers are not considered part of the mould cavity. See Mold Cavity.

Mould Coating (British)

Coating to prevent surface defects and improve surface finish. See Mold Coating.

MP

Abbreviation for melting point.

Ms

The temperature at which transformation of austenite to martensite starts during cooling.

Mud

A term frequently used to designate plastic lining materials. See Daubing.

Mud daub

See Daubing.

Muffle Furnace (Kiln)

A furnace in which the heating is indirect; the material to be heated is contained in a refractory container heated from the outside.

Muliductor Power Source

A device to convert standard 3-phase, 60 cycle current to single- phase, 180-cycle current, so-called medium frequency; produces a strong, controlled stirring action for induction melting.

Muller

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Type of foundry-sand-mixing machine. See Foundry Sand.

Mulling

The thorough mixing of sand, water and binding ingredients to form tempered ready-to-use molding or core sand. See Core Sand.

Mulling and Tempering

The thorough mixing of sand with a binder, either natural or added, with lubricant of other fluid, as water.

Multiple Mold

Composite mold made up of stacked sections. Each section produces a complete gate of castings. All castings are poured from a central downgate.

Multiple-Cavity Die

A die-casting die having more than one impression of the same part. See Combination Die.

Mushet Steel

An air hardened steel containing about 2% C, 2% Mn, and 7% W, developed by Scotsman Robert Musket in 1870.

Mushy Stage

The state between sold and liquid in alloys which freeze over a wide range of temperatures.

Glossary of Foundry Terms - N

Nail, Chill

Steel nail with a heavy head which is inserted in the mold wall to hasten cooling of the metal at that point.

Natural Aging

See Aging.

Natural Sand

Unconsolidated sand, sand derived from a rock in which grains separate along their natural boundaries. This includes soft sandstone where little pressure is required to separate the individual grains. See Molding Sand, Naturally Bonded Molding Sand.

Naturally Bonded Molding Sand

A sand containing sufficient bonding material as mined to be suitable for molding purposes. Seldom used today in the metalcasing industry. See Molding Sand.

Navy (USA) Tear Test

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A method of evaluating the susceptibility of ship plate to brittle or cleavage type fracture.

Neat Brick

Brick with faces arranged so one of the flat faces in inclined toward the other, almost eliminating one end face.

Neat Cement

Portland Cement mixed with water only.

Neck Down (Knock-Off, Wafer Core, Washburn, Cameron Core)

A thin core or tile used to restrict the riser neck, making it easier to break or cut off the riser from the casting. See Core.

Necking

Reducing the cross sectional area of the metal in an area by stretching.

Necking Down

Reduction in area concentrated at the subsequent location of fracture when a ductile metal is stressed beyond it yield point in tension.

Needles

Elongated acicular crystals, tapering at each end to a fine point, as martensite.

Needling Agents

Special agents such a boron which markedly increase the hardness of steel.

Negative Quenching (Negative Hardening)

Accelerated cooling in water or oil, from a temperature below the critical range. See Quenching.

Negative Thermoie Heat Exchange

In shell molding, improving the mass-surface ratio by simulating profile geometry of pattern or core cavity on the underside; will boost running temperature of high projections by 25%. See Shell Molding.

Nesh (Hot Short)

A British term applied to metal that is weak and ruptures easily under not working conditions.

Network Structure

A structure in which the grains or crystals of one constituent are partly or entirely enveloped in another constituent; an etched section through the crystals resembles a network.

Neumann Band

A mechanical twin in ferrite.

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Neutral Refractories

A loose term designating refractories which presumably will not react with so-call acid or basic refractories and slags. See Refractory, Slag.

Neutron

Elementary nuclear particle with a mass (1.00893 mass units) approximately the same as that of a hydrogen atom. It is electrically neutral.

New Jersey Sand

A large number of grades of foundry sands mined in southern New Jersey.

Nichrome

Oxidation-resistant alloy 65% Ni, 20% Fe, and 15% Cr.

Nickel

An element used for alloying iron and steel as well as nonferrous metals; melting point 1455°C (2651°F). Nickel is also a base metal for many casting alloys resistant to corrosion and high temperature oxidation. Nickel’s chemical symbol is Ni. Its formula weight is 58.69, the specific gravity is 8.90, and nickel’s melting point 1,452°C. See Monel, Nimonic, Inconel, Ni-Hard.

Ni-Hard

Hard white cast iron containing 4% Ni and 2% Cr. See White Cast Iron.

Nil Ductility Transition Temperature (NDDT)

Determined in the dropweight test. Refers to the absence of the ductile fracture appearance and any reduction in area due to the brittle behavior of the steel. See Ductility.

Nimonic

Class of nickel-base cast alloy resistant to stress and to oxidation at high temperatures. See Inconel.

Nine-Inch Equivalent

Standard unit of volume in refractories industries; 9 x 4-1/2, 2-1/2 in brick.

Nipple

A pipe coupling consisting of a short piece of threaded tubing.

Nital

A solution of nitric acid in alcohol use as an etching agent in ferrous metallography.

Nitriding

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A surface hardening process involving heating in a atmosphere of ammonia or in contact with a nitrogen-bearing material so as to promote the absorption of nitrogen.

Nitrogen Flush

Bubbling nitrogen gas through a metal melt under vacuum (as with valve bronze) to improve tensile properties and pressure tightness.

Nobake Binder

A synthetic liquid resin sand binder that hardens completely at room temperature, generally not requiring baking, used in the Cold Setting process. See Cold Setting Process.

No-Bake Process

Molds/cores produced with a resin bonded air setting sand. Also known as the air set process because molds are left to harden under normal atmospheric conditions. See Core, Mold.

Noble Metals

Metallic elements with surfaces that do not readily oxidize in air; e.g., gold, silver, platinum.

Nodular Fireclay (Burley, Burley Flint)

Rock containing aluminous or ferrogenous nodules, or both, bonded by fireclay.

Nodular Graphite

Graphite or carbon in the form of spheroids, characteristically in malleable and nodular iron.

Nodular Iron

Cast iron, normally gray cast iron, which has the major part of its graphitic carbon in nodular from. See Ductile Iron.

Noise Radiator

A device creating noise.

Noise Spectrum

The various frequencies making a noise.

Nomogram (Graph)

A graph that enables one by the aid of a straight-edge to read off the value of a dependent variable when the value of two or more independent variables are given.

Nondestructive Testing (Inspection)

Testing or inspection that does not destroy the object being tested or inspected.

Nonferrous

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A negative term, refers to alloy in which the predominate metal or solvent is not iron. See Alloy.

Nonferrous Metal Casting

Metal casting done with a nonferrous metal, in which the molten metal is poured into a mold, cooled, and allowed to solidify. See Nonferrous.

Nonferrous Metal Processing

The processing of a nonferrous metal, such as by melting, alloying, or casting. See Nonferrous.

Normal Segregation

Concentration of alloying constituents that have low melting points in those portions of a casting that solidify last.

Normal Steel

Steel in which the pearlite is completely laminated. See Pearlite.

Normalizing

Heating a ferrous alloy to a suitable temperature above the transformation temperature Ac3, followed by cooling at a suitable rate, usually in still air to a temperature substantially below the transformation range.

Notch Bar

Small size ingot with notches to facilitate breakage for remelting.

Notched Bar

A test specimen which is notched. Used in impact or fatigue tests.

Novalak

A two-step basic flake resin with no thermosetting properties, applied to sand in shell molding process as a mold or solution. See Shell Molding.

Nowel

The lower section of the flask, commonly called the drag. See Drag, Flask.

Nozzle

Pouring spout of the bottom-pour ladle. See Ladle.

Nozzle Brick

A thick-walled tubular refractory shape set in bottom of a ladle through which steel is teemed.

Nozzle Pocket Brick

A refractory shape set in bottom of a ladle containing a recess in which nozzle is set. See Ladle.

NTP

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Abbreviation for normal temperature and pressure reference point, zero centigrade 760 mm mercury pressure.

Nucleus

The first structurally determinate particle of anew phase or structure that may be about to form. Applicable in particular to solidification, recrystallization, and transformations in the solid state.

Glossary of Foundry Terms - O

Oddsides

Semi-permanent molds of plaster of paris, graphite, or dry sand, tarred and dried and used for repetitive work in the foundry.

Off Iron

Pig iron that is not of the desired composition. See Pig Iron.

Off-Dimension

A casting defect caused by any incorrect dimension resulting from improper setting of cores, using wrong core, shifts, swells, etc. See Core.

Off-Gage (Off-Size)

Core defect caused by improper gagging of dimensions.

Off-Grade Metal

Metal whose composition does not correspond to the designated or applicable specification.

Oil And Whiting Test

A method of detecting fine cracks by applying a penetrating oil and painting the tested metal surface with a mixture of whiting and a thinner. Oil in the cracks emerges to stain the whiting.

Oil Core

A core bonded with oil.

Oil Mold

A mold in which the sand is bonded by an oil binder.

Oil Furnace

Furnaces fired with oil.

Oil Quenching

Quenching in oil. See Quenching.

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Oil Sand Core

Core in which sand mass is bound by an oil-based binder.

Oil Sands

Sand bonded with such oils as linseed and the synthetics.

Oil Shot

In die casting, a sponge like whirl on the surface of casting resulting from an excess of oil applied to the sprue hole before the shot was made.

Oil-Oxygen Binder (Cold-Setting, Air-Setting Binders)

A synthetic auto-oxidizing liquid, oil-based binder that partially hardens at room temperature, using an oxygen releasing agent. Baking is needed to complete the hardening.

Olive

(Mg2Fe2SiO4) A naturally occurring mineral composed of fosterite and fayalite, crushed and used as a molding sand. Usually the sand of choice in manganese steel casting due to its basicity. See Molding Sand.

Olivine

Magnesium-iron-orthosilicate composed of forsterite and fayalite. Does not contain free silica. Possible molding material.

One-Piece Pattern

A solid pattern, not necessarily made from one piece of material. The pattern may have one or more loose pieces.

One-Screen

A distribution of a clean sand or a sand with two maximum screens separated by a minimum screen. These high-expansion problem sands are also referred to as camel back distributions.

Open Face Mold

See Open Sand Casting.

Open Flame Furnace

As opposed to the crucible furnace; in the open-flame furnace the metal charge is confined in the refractory lining, with the flame and products of combustion coming in direct contact with the metal.

Open Grain Structure

A defect wherein a casting, when machined or fractured, appears to be coarse grained and porous; usually due to a shrink area.

Open Riser

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Riser whose top is open to the atmosphere through the top of the mold. See Riser.

Open Sand Casting

A casting poured into a mold which has no cope or other covering.

Open-Hearth Furnace

A furnace for melting metal, in which the bath is heated by the combustion of hot gases over the surface of the metal and by radiation from the roof. The furnace fuel may be producer gas, coke-oven gas, powdered coal, or oil.

Open-Hearth Steel

Steel made in open-heart furnace.

Optical Pyrometer

A temperature measuring device through which the observer sights the heated object and compares its incandescence with that of an electrically heated filament whose brightness can be regulated; or the intensity of the light admitted from the object may be varied through filters and compared with a constant light source. See Pyrometer.

Optimum Moisture

That moisture content which results in developing the maximum of any property of a sand mixture.

Orange Peel

A pebble-grained surface that develops in the mechanical forming of sheet metals with coarse grains.

Orange Peel Bucket

A bottom-drop bucket used for charging cupolas; the drop-bottom is divided into a number of sections that appear to peel back as the bucket opens.

Ore

A mineral from which a metallic element may be extracted profitably.

Oriffice

An opening of controlled size used to measure or control the flow of gases.

Oriffice Plate

In a cupola a device used to measure the volume of air delivered to the windbox.

Oscillating Trough Cooler

A steel trough conveyor within a plenum where reclaimed sand is cooled prior to reuse.

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Osmondite

An obsolete term once used to designate a ferrous microstructure not so well defined as Troosite.

Ottawa Sand

A sand originating near Ottawa, IL. Also know as St. Peter sandstone.

Oven, Drying

A furnace or oven for drying molds or cores.

Ovens

See Continuous Annealing Furnace.

Overaging

Aging a precipitation-hardening alloy under conditions of time and temperature greater than those required to obtain maximum strength or hardness. See Aging.

Overfiring

Heating refractories to a temperature sufficient to cause pronounced vitrification, deformation, or bloating.

Overflows (Overflow wells)

Separated cavities cut into the face of die casting dies adjacent to the main cavity and connected to it by a channel, ensuring filling of cavity.

Overhand

Extension of the end surface of the cope half of a core print beyond that of the drag to provide clearance for closing of the mold. See Cope, Mold.

Overhang

The extension on the vertical surface of a core print, providing clearance for closing the mold over the core, also known as "shingle."

Overheated

A term applied when, after exposure to an excessively high temperature, a metal develops an undesirable coarse grain structure, but is not necessarily damaged permanently. Unlike burned structure, the structure produced by overheating can be corrected by suitable heat treatment, by mechanical work, or by a combination of the two.

Overstressing

Permanently deforming a metal by subjecting it to stresses that exceed the elastic limit.

Owen Jet Dust Counter

An instrument similar to the Konimeter, using the humidification factor.

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Oxidation

Any reaction whereby an element reacts with oxygen.

Oxidation losses

Reduction in amount of metal or alloy through oxidation. Such losses usually are the largest factor in melting loss.

Oxide

A compound of oxygen with another element.

Oxidizing Atmosphere

An atmosphere resulting from the combustion of fuels in an atmosphere where excess oxygen is present, and with no unburned fuel lost in the products of combustion.

Oxidizing Flame

A flame produced with excess oxygen.

Oxygen Bomb Calorimeter

An instrument to measure the heats of combustion of solid and liquid fuels.

Oxygen Impingement Process

Pure oxygen is blown down on the bath to refine Pig Iron.

Oxygen Lance

See Lance, Oxygen.

Glossary of Foundry Terms - P

P1

In production, the acceptable quality level.

P2

In production, lot tolerance.

Pack Hardening (Park Carburizing)

See Case Hardening.

Packing Or Packing Material

Sand, gravel, mill scale or similar materials used to support castings packed in annealing pots, to prevent possible warpage under high temperatures. See Annealing, Casting, Warpage.

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Pad

Metal added deliberately to the cross section of a casting wall, usually extending from a riser, to ensure adequate feeding to a localized area in which a shrink might occur without the addition.

Padding

The process of adding extra material to a cross-section of a casting wall, usually extending from a riser to ensure adequate feed to a localized area where sharing would occur if the added material were not present. It must be machined off of casting.

Panel Spalling Test

A test using a panel of the refractory being tested to provide a reference to spalling behavior.

Panoramic Analyzer

An instrument for analyzing sounds and displaying the results either on an oscilloscope or a graph.

Papping Plate

A metal plate attached to a pattern to prevent injury to the pattern and assist in loosening it from the sand.

Parkerizing

A proprietary method of producing a protective phosphate coating on ferrous metals. Parker A treatment involves immersing in a bath of acid manganese phosphate. The Parker D is a modification using acid zinc phosphate with a nitrate iron as accelerator.

Parlanti Casting Process

A proprietary permanent mold process using dies of aluminum with a controlled rate of heat transfer.

Parsons Duncan Process

A method of casting steel ingots wherein the top layer of the mold is heated and the last to solidify.

Parted Pattern

A pattern made in two or more parts.

Partially Graphitized Cast Iron

A blackheart malleable casting only partly graphitized in annealing, giving a mixture of black and white. Sometimes termed salt and pepper fracture. See Cast Iron.

Particulate Matter

In air pollution control, solid or liquid particles, except water, visible with or without a microscope, that make up the obvious portion smoke.

Parting

The joint, dividing line, where mold separates to permit removal of the pattern.

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Parting Agent

See Release Agent.

Parting Compound

Material dusted or sprayed on a pattern or mold to prevent adherence of sand.

Parting Line

A line on a pattern or casting corresponding to the separation between the cope and drag portions of a sand mold. The joint where mold separates to permit removal of pattern. See Casting, Cope, Drag, Mold, Pattern.

Parting Sand

A bondless sand dusted on the parting to prevent the parts of the mold from adhering to each other.

Passivator

An inhibitor which changes the potential of a metal to a more cathodic value.

Passivity

The property of some metals to become abnormally inactive towards certain reagents.

Patching

Repair of a furnace lining or repair of a mold core.

Pattern

An original used as a form to produce duplicate pieces. Pattern dimensions are slightly enlarged to counteract the shrinkage of the casting as it solidifies and cools in the mold. Although patterns can be made in one piece, a complicated casting may consist of two or more parts.  The pattern may be made out of wood, plastic, metal, or other material. See Casting, Mold, Solidification.

Pattern Coating

Coating material applied to wood patterns to protect them against moisture and abrasion of molding sand.

Pattern Draft

The taper allowed on the vertical faces of a pattern to permit easy withdrawal of pattern from the mold or die.

Pattern Layout

Full-sized drawing of a pattern showing its arrangement and structural features.

Pattern Letters

Metal or plastic letters or figures in various sizes which are affixed to patterns for identification purposes.

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Pattern Shrinkage

The shrinkage allowance made on all patterns to compensate for the change in dimensions as the solidified casting cools in the mold from freezing temperature to room temperature. Pattern is made larger by the amount of shrinkage characteristic of the particular metal in the casting and the amount of resulting contraction to be encountered. Rules or scales are available for use. See Casting, Shrinkage, Pattern.

Pattern, Split

Pattern usually made in two parts, sometimes in more than two.

Patternmaker(s)

A craftsman engaged in production of foundry patterns from wood, plastic, or metals, such as aluminum, brass, etc. See Pattern.

Patternmaker's Shrinkage

The shrinkage allowance made on all patterns to compensate for the change in dimensions as the solidified casting cools in the mold from freezing temperature of the metal to room temperature. Pattern is made larger by the amount of shrinkage characteristic of the particular metal in the casting and the amount of resulting contraction to be encountered. Rules or scales are available for use.

PCE

Abbreviation for Pyrometric Cone Equivalent.

Pearlite

A microconstituent of iron and steel consisting of alternative layers of ferrite and iron carbide or cementite.

Pearlitic Malleable Iron

A malleable iron in which the iron matrix is made higher strength/lower ductility through heat treatment. See Pearlite.

Peel

Free removal of burnt molding sand from casting.

Peen

Peening action obtained by impact of metal shot, often used to improve fatigue properties by putting the surface in compression. Also the small end of a molder's hammer.

Pencil Core

A core projecting to the center of a blind riser allowing atmospheric pressure to force out feed metal. See Blind Riser.

Penetrameter

A strip of metal with stepped thickness variation and with holes at varying depths; used in radiography to indicate the sensitivity of the radiograph.

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Penetration, Metal

Condition where molten metal has penetrated into the sand, resulting in a mixture of metal and sand adhering to the casting.

Periclase

Natural magnesia in nodular form, formed by heating.

Perlite

A highly siliceous volcanic rock which can be expended by heating into a porous mass of particles. Perlite can be used as an insulation in foundry sand mixtures. Not to be confused with Pearlite.

Permanent Mold

A long-life mold into which metal is poured by gravity.  It is used repeatedly to produce many castings from the same mold.  It is not an ingot mold. See Mold.

Permeability

The property of a mold material to allow passage of gases. The property in sand molds which permits the passage of gases.

pH

A symbol denoting the negative logarithm of the concentration of the hydrogen ion in gram-atoms per liter, used in expressing both acidity and alkalinity; pH=log 1/H per liter. An important factor in foundry sand control, pH7 is neutral; values less than 7 acid, and higher than 7, basic. At 25°C, the neutral value is 7. Acidity increases with decreasing values below 7, and basicity increases with increasing values above 7.

Phase

A constituent which is completely homogeneous, and is both physically and chemically separated from the rest of the alloy by definite bounding surfaces; for example, austenite, ferrite, cementite. Not all constituents are phases; pearlite for example. See Austenite, Cementite, Pearlite.

Phase Diagram

(1) A graphic representation of the equilibrium temperature and composition limits of phase fields reactions in an alloy system. In a binary system, temperature is usually the ordinate and composition the abscissa. Ternary and more complex systems require several two-dimensional diagrams to show the temperature-composition variables completely. In alloy systems, pressure is usually considered constant, although it may be treated as an additional variable. (2) Graphical representation of the equilibrium temperatures and the composition limits of phase fields and phase reactions in an alloy system.

Phenolic Resin (One-step)

A resin made by the polymerization of a phenol with an aldehyde; used a binder for cores and sand molds. See Urea-Formaldehyde Resin.

Phosphorus

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One of the elements; its chemical symbol is P. Its formula weight is 123.92; specific gravity 1.82, and melting point 44.1°C.

Photomicrograph

A photograph of the grain structure of a metal as observed when optically magnified more than 10 diameters. The term micrograph may be used.

Physical Metallurgy

The science concerned with the physical and mechanical characteristics of metals and alloys.

Physical Properties

Properties of matter such as density, electrical and thermal conductivity, expansion, and specific heat. This term should not be used interchangeably with "mechanical properties."

Picral

An etchant for ferrous alloys; 4% picric acid in alcohol.

Pig Iron

Blocks of iron to a known metal chemical analysis used for melting, with suitable additions of scrap, etc., for the production of ferrous castings. See Ingot.

Pig Iron, Basic

A grade of iron made from the basic open-hearth process of steelmaking; P, 0.40% maximum for Northern iron, 0.70 to 0.90% for Southern iron; S 0.05% maximum and Si, 1.50%.

Pig Iron, Chateaugay

Pig iron from Chateaugay (New York State). Ores that very low in phosphorus, copper-free, and containing appreciable amounts of titanium.

Pilot Casting Or Sample Casting

A casting made from a pattern produced in a production die to check the accuracy of dimensions and quality of castings which will be made in quantity. See Casting.

Pinhole

Small hole under the surface of a casting. See Casting.

Pins, Fask

Hardened steel locating pins used on flasks to ensure proper register of cope and drag molds. See Cope, Drag.

Pipe

A cavity formed by shrinkage of the metal during solidification of the last portion of liquid metal, usually occurring in a riser having feeder metal for the casting. See Cavity, Casting.

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Pit Mold

Mold in which the lower portions are made in a suitable pit or excavation in a foundry floor. See Foundry.

Pitch

Usually coal-tar pitch obtained in manufacture of coke and distilled off at about 350°F. Used as a binder in large cores and molds. Melting range is 285°F to 315°F.

Pitting

A form of wear characterized by the presence of surface cavities, the formation of which is attributed to processes such as fatigue, local adhesion, cavitation or corrosion.

Plane Strain

A stress condition in linear elastic fracture mechanics (see LEFM) in which there is zero strain in a direction normal to both the axis of applied tensile stress and the direction of crack growth. Under plane strain conditions, the plane of fracture instability is normal to the axis of the principal tensile stress.

Plasma Refining

Process used to reduce sulfur and oxygen to very low levels.

Plaster Molding

Molding method wherein gypsum or plaster of Paris is mixed with fibrous talc, with or without sand, and with water to form a slurry that is poured around a pattern. In a short period of time, the mass air-sets or hardens sufficiently to permit removal of the pattern. The mold so formed is baked at elevated temperature to remove all moisture prior to use. One variation is the Antioch process.

Plaster of Paris

A semi-hydrated form of calcium sulfate made by sintering gypsum to 120°C-130°C (248°F-266°F).

Plastic Deformation

Permanent distortion of a material under the action of applied pressure.

Plastic Pattern

Pattern made from any of the several thermosetting-type synthetic resins such as phenol formaldehyde, epoxy, etc. Small patterns may be cast solid, but large ones are usually produced by laminating with glass cloth.

Plates, Bottom

Plates, usually of metal, on which molds are set for pouring.

Plates, Core Drying

Flat plates of metal on which cores are placed for baking.

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Plumbago

Powdered graphite.  See Printing Back.

PMMA

Abbreviation for Polymethymethacralate. Foam used in the lost foam process, does release as much carbon as polystyrene.

Pneumatic Tools

Grinders, rammers, drills, etc., operated by compressed air.

Pocket

A body of sand surrounded on all but one side by molten metal.

Pohland Method

A technique for the ultrasonic testing of steel in which a visible image of the defects present in the steel can be shown on a screen.

Polystyrene

A polymer of styrene used in making molding products. In particular, used in the lost foam process.

Porosity

Unsoundness in castings appearing as blowholes and shrinkage cavities.

Porosity (Blow-Holes)

Holes in the casting due to gases trapped in the mold, reaction of molten metal with moisture in the molding sand, or imperfect fusion of chaplets with molten metal. (Surface porosity may be due to overheating of the mold or core faces, but should not be confused with sand inclusions.) See Blow Hole, Blow Holes, Inclusion, Molding Sand.

Postheating

A process used immediately after welding whereby heat is applied to the weld zone either for tempering or for providing a controlled rate of cooling, in order to avoid a hard or brittle structure.

Pot

Term usually applied to cast iron containers used in melting aluminum-base alloys; also used to describe steel crucibles for melting magnesium-base alloys, as well as graphite crucibles. See Alloy, Crucible.

Pour

Discharge of molten metal from the ladle into the mold.

Poured Short

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Casting which lacks completeness due to the cavity not being filled with molten metal.

Pouring

Filling the mold with molten metal. Transfering the molten metal from the furnace to the ladle, ladle to ladle, or ladle into the molds. See Molds, Ladle.

Pouring Basin

Reservoir on top of the mold to receive the molten metal.

Pouring Basin, Cup

Located on top of sprue or downgate. That portion of the gating.

Pouring Cup

The flared section of the top of the downsprue. It can be shaped by hand in the cope, or be a shaped part of the pattern used to form the downsprue; or may be baked core cup placed on the top of the cope over the downsprue. See Baked Core.

Pouring Device

Mechanically operated device with a ladle set for controlling the pouring operation.

Pouring Ladle

Ladle used to pour metal into the mold. See Casting, Ladle, Mold.

Pouring Off

The task of ladling, or mechanically pouring, of the molten metal into the molds, forming the casting. See Casting.

Powder Cutting

Introducing iron powder in an oxygen stream to hasten oxygen torch cutting by the combination of fluxing and oxidation. Generally used for cutting stainless steel.

Powdered Coal

Finely ground, high-volatile coal used for heating furnaces and annealing ovens in the malleable foundry industry.

Precipitation Hardening

A process of hardening an alloy in which a constituent precipitates from a supersaturated solid solution.

Precipition Heat Treatment

Any of the various aging treatments conducted at elevated temperatures to improve certain mechanical properties through precipitation from solid solution. See Heat Treatment.

Preheating

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A general term for heating material, as a die in die casting, as a preliminary to operation, to reduce thermal shock and prevent adherence of molten metal.

Pressure Die Casting

A British term. See Die Casting.

Pressure-Tight

A term describing a casting free from porosity of the type that would permit leaking.

Primary Choke (Choke)

That part of the gating system which most restricts or regulates the flow of metal into the mold cavity. See Gate.

Primary Crystals

The first dendritic crystal that form in an alloy during cooling below the liquid's temperature.

Print

Part of the core used to locate and support-part of a pattern to form area in mold for same purpose; part of mold and part in core box for the same purpose. See Core, Mold, Core Box.

Print Back

After the surface of a mold is dusted with graphite facing, the pattern is replaced, rapped into position and again removed.

Printing Back

To dust the cavity with Plumbago and reprint pattern. It smoothes the cavity surface by filling voids. See Plumbago.

Process Capability

The amount of variation in the output of a controlled manufacturing process, the range defined by plus or minus three standard deviations.

Product Analysis

In castings, the analysis of the actual part as opposed to the analysis of the steel from which the casting was poured.

Production Foundry

Highly mechanized foundry for manufacturing large quantities of repetitive castings. See Foundry.

Production Welding

Any welding carried out during manufacturing before final delivery to the purchaser. This includes joint welding of casting and finishing welding.

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Proeutectoid

The constituent that separates out of a solid solution before the formation of eutectoid. See Eutectoid.

Profile Tolerances

A system of locating and tolerancing developed to control the orientation of rough parts in machine fixtures. From locating points on the casting a "perfect profile" is established for all surfaces and features. A tolerance envelope surrounding that profile defines the limitations of an acceptable part.

Progressive Solidification

See Directional Solidification.

Protection Tube

A metal, graphite, or ceramic tube which shrouds and protects the wires of a thermoelectric pyrometer.  See Pyrometer.

Psi

Abbreviation for pounds per square inch.

Pugnill

A mill for mixing foundry sands and sand mixtures consisting essential of a shaft fitted with plows or paddle wheel which revolve in a tub or vat. See Foundry Sand.

Punchout Machines

A machine used to force the entire sand and casting contents from the molding box in one motion, without the use of vibration.

Purging

Elimination of air and other undesirable gases from furnaces or heating boxes.

Purifiers, Flux

Various materials added to molten metals and alloys for the purpose of removing impurities, gases, etc.

Push-Up

An indentation in the casting surface due to displacement (expansion) of the sand in the mold.

Pyrometallurgy

Chemical metallurgical process dependent upon heat.

Pyrometer

An instrument for determining elevated temperatures.

Pyrometric Cone

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A slender trihedral pyramid made of a mixture of minerals similar in composition to that of a clay or other refractory being tested. Each cone is assigned a number indicating its fusion temperature.

Pyrometric Cone Equivalent (PCE)

An index of refractoriness obtained by heating on a time-temperature schedule a cone of the sample material and a series of standardized pyrometric cones of increasing refractoriness.

Pyrometry

A method of measuring temperature with any type of temperature indicating instruments. See Pyrometer.

Glossary of Foundry Terms - S

SAE Specifications

A set of materials specification issued by the Society of Automotive Engineers, Inc.

Sag

A decrease in metal section in casting due to sagging of the cope or core. See Core, Cope.

Salamander

A heating device, usually of drum shape, in which fuel is burned in the open air by natural draft. Iron material which has collected in the bottom of a blast furnace during a blow. See Blast Furnace, Blow.

Salt Bath

A bath of molten salts used for heating steels, for hardening or tempering.

Sand

In metalcasting, a loose, granular material high in SiO2, resulting from the disintegration of rock. The name sand refers to the size of grain and not to mineral composition. Diameter of the individual grains can vary from approximately 6 to 270 mesh. Most foundry sands are made up principally of the mineral quartz (silica). Reason for this is that sand is plentiful, refractory, and cheap; miscellaneous sands include zircon, olivine, chromite, CaCO3, black sand (lava grains), titanium minerals and others.

Sand Blast

Sand driven by a blast of compressed air (or steam). It is used to clean castings, to cut, polish, or decorate glass or other hard substances, and also to clean building fronts, etc.

Sand Casting

Metal castings produced in sand molds. See Casting.

Sand Conditioning

Preparation of used molding sand for reuse, which includes additions of bond, additives, moisture, etc.

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Sand Control

Procedure whereby various properties of foundry sand, such as fineness, permeability, green strength, moisture content, etc., are adjusted to obtain castings free from blows, scabs, veins, and similar defects. See Foundry Sand.

Sand Control Equipment

Testing instruments such as moisture determinators, permeability air-flow apparatus, etc., for determining the various physical properties of sands.

Sand Dryer

Apparatus for removing moisture from sand.

Sand Holes

Cavities of irregular shape and size whose inner surfaces plainly show the imprint of granular material.

Sand Inclusions

Cavities or surface imperfections on a casting caused by sand washing into the mold cavity. See Mold Cavity.

Sand Molding

Process in which moist sand is compressed into a hollow form. Molten metal is then poured into the form to fill the cavity. When the metal has solidified, the sand is broken away by vibration leaving the metal casting.

Sand Muller

A machine for mixing sand by kneading and squeezing. See Muller.

Sand Mulling

A method of evenly distributing the bond around the sand grain by a rubbing action.

Sand Plow

A bladed device used to divert sand from a belt conveyor into a sand hopper.

Sand Porosity

Volume of the pore spaces or folds in a sand. (Not synonymous with permeability).

Sand Reclaimer

Equipment for removing extraneous material from used sand and reconditioning it for further use.

Sand Reclamation

Processing of used foundry sand grains by thermal, attraction or hydraulic methods so that it may be used in place of new sand without substantially changing current foundry sand practice. See Foundry Sand.

Sand Slinger

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Molding machine which throws sand into a flask or corebox, by centrifugal action. See Flask, Core Box.

Sand Tempering

Dampening and cutting over or otherwise mixing sand to produce uniform distribution of moisture, and allowing time for migration of water molecules.

Sand Toughness

Indication of molding sand workability, particularly with reference to ramability, because the tougher the sand, the harder it is to ram tightly against the pattern. It is usually given as a number obtained by multiplying deformation by green compressive strength times 1000. See Molding Sand.

Sand Wall

Temporary independent wall separated from a slag pocket wall; facilitates slag removal and protects permanent wall.

Sand, Backing

Sand in a mold back of the facing.

Sand, Bank

Sand from a bank or pit.

Sand, Blast

Sand used in an abrasive blasting machine for cleaning castings.

Sand, Core

Sand used in making cores.

Sand, Facing

Prepared sand used next to the pattern.

Sand, Floor

Sand used in floor molding.

Sand, Heap

Sand prepared on foundry floor.

Sand, Lake

Sharp sand from vicinity of lakes.

Sand, Molding

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Sand used to make molds.

Sand, Natural

Naturally bonded sand as distinguished from that which is formed synthetically. See Naturally Bonded.

Sand, Open

Sand through which gases can pass freely.

Sand, Silica

Sand composed of almost pure silica.

Sand, Synthetic

Molding sand prepared by adding clay or other bond to the sand which is practically free of those materials. See Natural Sand.

Scab

A blemish on a casting caused by eruption of gas from the mold face.

Scaling (Scale)

Surface oxidation, partially adherent layers of corrosion products, left on metals by heating or casting in air or in other oxidizing atmospheres.

Scanning Electron Microscope (SEM)

An instrument used for obtaining microstructure images using an electron beam. The micrographs obtained give depth perception of the metal being observed.

Scarfing

Cutting off surface projections such as gates and risers from casting by means of gas torch.

Scrap

Any scrap metal melted, usually with suitable additions, to produce castings.

Scrap Metal

Metal to be remelted; includes scrapped machinery fabricated items such as rail or structural steel and rejected castings (metal to be re-melted, castings that have to be re-melted).

Screen Sand

A sieve or riddle with openings of definite size used to separate one gain size from another or to remove lumps from sand.

Screen Analysis (Sieve Analysis)

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Distribution of particle size sand expressed in terms of the percentage of weight retained on each of a series of standard screens decreasing in mesh size and the percentage passed by the screen of finest mesh.

Scrubbers

See Wet Scrubbers.

Sea Coal

Term applied to finely ground bituminous coal which is mixed with sands for foundry uses.

Sealed Source

Any radioactive material that is encased in and is to be used in a container in a manner intended to prevent leakage of the radioactive material.

Seam

A surface defect on a casting related to but of lesser degree than a Cold Shut; a ridge on the surface of a casting caused by a crack in the mold face. See Cold Shut.

Segregation

A concentration of alloying elements at specific regions, usually as a result of the primary crystallization of one phase with the subsequent concentration of other elements in the remaining liquid.

Selenium

A metalloid melting 220°C (428°F) added to stainless steel to improve machinability.

Separator

A mechanical unit which separates or grades ground materials into constituent parts, used in the foundry to remove fines from the system sand and dust from the air.

SG Iron

Term used in Britain and continental Europe for ductile or nodular iron. SG means spherulitic or spheroidal graphite.

Shakeout

The process of separating the solidified casting from the mold material. The stage in the casting process where the sand from the mold is cleaned off of the newly formed castings through vigorous vibration. See Casting, Molds, Vibrator.

Shakeout Machinery

Equipment for mechanical removal of castings from molds.

Shank

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The handle attached to a small ladle. See Ladle.

Sharp Sand

Sand free from binders, i.e., new, clean sand of angular shape. The term does not refer to grain shape. See Binder.

Shaw (Osborn-Shaw) Process

A precision casting technique in ceramic molds which do not require wax or plastic investment. See Lost Wax Process, Investment Casting.

Shear

A type of deformation in which parallel planes in the metal crystals slide so as to retain their parallel relation.

Shear Modulus (G)

In a torsion test, the ratio of the unit shear stress to the displacement caused by it per unit length in the elastic range. Units are Pa or psi.

Shear Strain

Elastic displacement produced by pure shear loading.

Shear Strength

Maximum shear stress a material is capable of withstanding without failure.

Shear Stress

Load per unit area parallel to the plane of contact.

Shell Molding

A process for forming a mold from resin-bonded sand mixtures brought in contact with pre-heated (300°F - 500°F) metal patterns, resulting in a firm shell with a cavity corresponding to the outline of the pattern. See Cavity, Pattern.

Shell Process

Process in which clay-free silica sand coated with a thermosetting resin or mixed with resin is placed on a heated metal pattern for a short period of time to form a partially hardened shell. The bulk of the sand mixture inside the resulting shell is removed for further use. The pattern and shell are then heated further to harden or polymerize the resin-sand mix, and the shell is removed from the pattern. Frequently, shell cores are made using the Hot Box process. See Hot Box Process.

Shewed Tolerances

Tolerances which are non-symmetrically distributed about the design parameter.

Shift

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A casting defect resulting form a mismatch of cope and drag. Sometimes there is a Core Shift, which also produces defective casting. See Core Shift.

Shortness (Hot)

Brittleness in a metal at an elevated temperature.

Shot

Metallic abrasive commonly used for cleaning casting surfaces. In die-casting, it is the phase of the die-casting cycle when molten metal is forced into the die.

Shotblasting (Shot peening)

Casting cleaning process employing a metal abrasive (grit or shot) propelled by centrifugal or air force.

Shrink

The difference in volume between liquid metal and solid metal or the void (shrink hole) left in a casting because of it.

Shrink Hole

A cavity in a casting due to insufficient feed metal. See Cavity.

Shrink Rule

Patternmaker's rule graded to allow for metal contraction.

Shrinkage

Difference in volume between liquid metal and solid metal in a given cavity. Contraction of metal in the mould during solidification. The term is also used to describe the casting defect, i.e. shrinkage cavity. This results from poor design, insufficient metal feed, or inadequate feeding.

Shrinkage Cracks

Cracks that form in metal as result of the pulling apart of grains by contraction before complete solidification. See Solidification.

Shrinkage, Centerline

Shrinkage occurring in the center of casting sections, particularly with platelike or barlike contours, which solidify simultaneously from two faces and cut off feeding in the central portion.

Shrinkage, Patternmakers

A linear scale or ruler, typically in inches or millimeters which has been lengthened by the percentage of linear shrinkage by which liquid metal contracts during solidification and cooling. See Solidification.

Sieve

A device with meshes of wire or other material for separating fine material from coarse material.

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Sieve Analysis

See Screen Analysis.

Silica

Silicon dioxide, SiO2, occurring in nature as quartz, opal, etc. Molding and core sands are impure silica. The prime ingredient of sand and acid refractories.

Silica Brick

Refractory material of ganister, bonded with hydrated lime, and fired at high temperature.

Silica Flour

Silica in finely divided form.

Silica Gel

A colloidal form of silica used as a drying agent.

Silica Sand

Sand with a minimum silica content of 95% used for forming casting molds.

Silica Wash

Silica flour mixed with water and other materials to form a brushable or sprayable facing material.

Silicon

An abundant element, chemically classed as a nonmetal, metallurgically a metal, used extensively in ferrous and nonferrous alloys; melting point 1423ƒC (2593.4ƒF).

Silicon Brass

A series of alloys containing 0.5-6% silicon, 1-19% zinc and a substantial amount of copper. See Alloy.

Silicon Bronze

A series of alloys containing 1-5% silicon, 0.5-3% iron, under 5% zinc, under 1.5% manganese, and the remainder being substantially copper.

Silicon Carbide Briquets

Silicon carbide in briquet form used as an inoculant and deoxidizer in cupola-melted gray iron.

Silicon-Aluminum

An alloy of 50% silicon and 50% aluminum used for making silicon additions to aluminum alloys; also called an intermediate or hardener alloy. Melting point is 1070ƒF. See Alloy.

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Silicon-Copper

An alloy of silicon and copper, used as a deoxidizer and hardener in copper-base alloys, which is available in tow types containing 10 and 20% silicon.

Silvery Iron

A type of pig iron containing 8-14% silicon, 1.50% carbon max., 0.06% sulfur max., and 0.15% phosphorus max. See Pig Iron.

Simultaneous Engineering

Refers to the process where user/designer and producer interact to reduce lead time and improve the efficiency of a part. This process is faster and more efficient than the traditional sequential process of design and manufacture.

Sintering

The bonding of adjacent surfaces of particles of a mass of powder or a compact by heating to a suitable temperature and cooling.

Sintering Point

That temperature at which the molding material begins to adhere to the casting, or in a test when the sand coheres to a platinum ribbon under controlled conditions. Also, the temperature at which sand grains begin to adhere to one another.

Sizing

A primary coating of glue applied to the end grain of wood to seal the pores.

Skeleton Pattern

A framework representing both the exterior and interior of the shape of the casting.

Skim Bob

Small upward bulge in the grating system, near the casting cavity, which functions as a dirt trap.

Skim Core (Skimmer)

A flat core or tile placed in a mold to skim a flowing stream of metal. Commonly used in pouring basins, it hold back slag and dirt while clean metal passes underneath to the downsprue.

Skim Gate

A gating arrangement which changes the direction of flow of molten metal and prevents the passage of slag and other undesirable materials into the mold cavity. See Mold Cavity, Slag.

Skimmer

A device or tool for removing slag and dross from the surface of molten metal. See Dross, Slag.

Skimming

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Removing or hold back dirt or slag from the surface of the molten metal before or during pouring.

Skin

A thin surface layer different chemically or structurally from the main mass of a metal object. The surface of a mold or casting. See Casting, Mold.

Skin-Drying

Drying the surface of the mold by direct application of heat.

Slab Core

A plain flat core.

Slag

A fused nonmetallic material used to protect molten metal from the air and to extract certain impurities. The nonmetallic covering on molten metal resulting from the combination of impurities in the initial charge like ash from fuel, and any silica and clay eroded from the refactory lining. It is skimmed off prior to pouring the metal.

Slag Inclusions

Casting surface imperfections similar to sand inclusions, but containing impurities from the charge materials, silica and clay eroded from the refractory lining, ash from the fuel during the melting process. May also originate from metal-refractory reactions occurring in the ladle during pouring of the casting. See Inclusions.

Slag Trap

An enlargement, dam or protrusion in the gating or runner system in a mold for the purpose of preventing molten slag particles from entering the mold cavity. See Dirt Trap.

Slicking (Sleeking)

Smoothing the surface of molds.

Slip Casting

In ceramics, a pouring slip, a water suspension of finely ground clay, into a plaster of Paris mold. After it hardens it is dried and fired.

Slurry

A flow able mixture of refractory particles suspended in a liquid. Thin watery mixture such as the gypsum mixture for plaster molding, the molding medium used for investment casting, core dips, and mold washes. See Dip Coat.

Slush Casting

Casting made by pouring an alloy into a metal mold, allowing it to remain sufficiently long to form a think solid shell, and then pouring out the remaining liquid metal. See Alloy, Casting.

Smelter

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An individual or firm which wins metals from cores, or which melts, treats or refines scrap metals and alloys for further use.

Smelting

A metallurgical thermal process in which a metal is separated in fused form from nonmetallic materials or other undesired metals with which it is associated.

Smoke

A type of emission resulting from incomplete combustion and consisting predominantly of small gas borne particles of combustible material present in sufficient quantity to be observable independently of the presence of other solids in the gas stream.

Snag

Removal of fins and rough places on a casting by means of grinding. See Casting, Fins, Grinding.

Snap Flask

A flask that has hinges and latches so that it may be removed from the mold prior to the pouring.

Soaking

Prolonged heating of a metal, furnace or ladle at a selected temperature.

Sodium Silicate (CO2 Process)

Molding sand is mixed with sodium silicate and the mould is gassed with carbon dioxide gas to produce a hard mold or core. See Water Glass.

Softening

A process used to soften metals through annealing or tempering. See Annealing.

Sold

That material which has a tendency to resist any attempt to change its size or shape.

Soldering

Joining metals by fusion of alloys that have relatively low melting points- most commonly, lead-based or tin-based alloys, which are the soft solders. Hard solders are alloys that have sliver, copper, or nickel bases, and use of these alloys with melting points higher than 800°F (426.7°C) is generally termed brazing. The sticking or adhering of molten metal to portions of a die.

Soldiers

Wooden pegs used to reinforce a body of sand or hold it in place.

Solid Contraction

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Shrinkage or contraction as a metal cools from the solidifying temperature to room temperature.

Solid Solution

A single solid homogeneous crystalline phase containing two or more chemical species.

Solidification

Process of metal (or alloy) changing from the liquid to the solid state.

Solidification Range

Only pure metals solidify or freeze at one definite temperature. Alloys contain different constituents which solidify at different temperatures, and the various temperatures from that of the first constituent to solidify to that of the last to constituent to freeze is called the solidification range. See Solidification.

Solidification, Shrinkage

The decrease in size accompanying the freezing of a molten metal.

Solidifying Contraction

Shrinkage or contraction as metal solidifies. See Shrinkage.

Solidus

Temperature at which freezing is completed. Below that temperature all metals are completely solid.

Sonic Testing

Using sound waves above audible frequency via a supersonic reflectoscope to measure time sound waves take returning from opposite sides of casting. Defects return the waves in more or less time. See Defects.

Sorbite

Tempered martensite that has a micro-structure of distinctly granular appearance. Further tempering causes the appearance of clearly resolvable carbide particles (spheroidite).

Spalling

Buckling or flaking off of the surface material.

Spary Quenching

After solution heat treating, a mode of quenching in which a spray of water is directed upon material just removed from the furnace.

Specific Gravity

A numerical value representing the weight of a given substance as compared with the weight of an equal volume of water at 39°F (3.9°C), for which the specific gravity is taken as 1,000 kg/m3. See Density.

Specific Heat

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Equivalent to thermal capacity, or the quantity of heat required to produce a unit change in the temperature of a unit mass.

Specific Volume

Volume of one gram of a substance at a specific temperature, usually 68°F (20°C).

Spect-O-Graph

Optical instrument for determining the concentration of metallic constituents in a metal (or alloy) by the intensity of specific wavelengths generated when the metal or alloy is thermally or electrically excited.

Spectography

Process for determining the concentration of metallic constituents in a metal or alloy by the intensity of specific wavelengths generated when the metal or alloy is thermally or electrically excited.

Spheroidite

A cementite aggregate of globular carbide and ferrite.

Spheroidized Vementite (Divorced Pearlite)

The globular condition of iron carbide after a spheroidizing treatment.

Spiegeleisen (Spiegel)

Alloy of iron and manganese used in basic and acid open hearth steelmaking practice A high manganese pig iron containing 15-30% manganese and used in bessemer and open-hearth steel production. See Pig Iron.

Spiral Test

A method of interpreting the fluidity of an alloy by pouring molten metal into a mold with a long narrow channel. The length of such casting, under standardized conditions, is taken as the fluidity index of that alloy.

Splash Core

A core of tile placed in a mold to prevent erosion of the mold at places where metal impinges with more than normal force. Splash cores are commonly used at the bottom of large rammed pouring basins, at the bottom of long downsprues, or at the ingates of large molds.

Split Pattern

A pattern that is parted for convenience in molding.

Spongy Casting

A casting in which the metal is porous and dendritic.

Spout

A trough through which the metal flows from the furnace to the ladle.

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Sprue

A vertical passageway that takes the molten metal from the pouring basin to the runner. See Runners.

Sprue (Downsprue Downgate)

(1) The channel, usually vertical, which the molten metal enters: so-called because it conducts metal down into the mold. (2) The vertical channel connecting the pouring basin with the runner system and terminates in the sprue well at the bottom. See Runners.

Sprue Base (or well)

Rectangular or cylindrical block that receives metal from the Sprue, reduces the velocity of the falling stream of metal and provides the transition from the vertical to the horizontal and send the metal into the runner system. See Runners.

Sprue Bottom

A print attached to the top or squeeze board of a mold to make an impression in the cope indicating where the sprue should be cut. See Cope, Molds.

Sprue Cutter

A metal tool used in cutting the pouring aperture, the sprue hole.

Sprue Hole

The opening through which the metal is poured into the cope to run into the casting cavity. See Cope.

Sprue Pin

In die-casting, a tapered pin with a rounded end projecting into a sprue hole, acting as a core that deflects the metal and aids in removal of the sprue from the die-casting. See Core, Sprue Hole.

Sprue Plug

A tapered metal or wood pin used to form the sprue opening in a mold. Also a metal or other stopper used in pouring basin to prevent molten metal from flowing into the sprue until a certain level has been reached. It prevents entry of dirt and dross. See Dross.

Spruing

Removing gates and risers from castings after the metal has solidified.

Squeeze Board

A board used on the cope half of the mold to permit squeezing of the mold.

Squeeze Head

In certain type of molding machines, a stationary or movable plate against which a filled mold is compressed, in order to complete the compacting of the sand.

Squeeze Pressure

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The pressure applied by a molding machine to press the flask and contained sand against the fixed squeeze head or board on a molding machine.

Squeezer Machine

A power-operated, usually pneumatic, device used to pack sand into a flask. See Flask.

Stack Molding

Molding method in which the half-mold forms the cope and drag. They are placed one on top of the other and poured through a common sprue. Cavities on the bottom side of one half-mold rest on the flat side of the half-mold beneath. When the cavities are in both sides of the half-molds, the method is called multiple molding. See Multiple Mold.

Stainless Steel

A wide range of steels containing chromium or chromium and nickel, exhibiting high resistance to corrosion.

Standard Deviation

A statistical quantity used to describe the variation of a measurable attribute about some average value.

Standard Pattern

A pattern of high-grade material and workmanship in daily use or at frequent intervals. A pattern used as a master to make or check production patterns.

Standard Samples

A sample of know composition used to calibrate an instrument or method of analysis.

Standard Shapes

Refractory units stocked by manufacturers or made from stock molds.

Stave Construction

Attaching staves to polygonshaped heads in the building of cylindrical bodies; also, standard method used in making semicircular core boxes.

Steel

An alloy of iron and carbon, containing no more than 1.74% carbon. It must be malleable at some temperature while in the as-cast state. See As-Cast.

Steels, SAE

Common designation for the standard grades of steel approved by the Society of Automotive Engineers.

Steeped Construction

In patternmaking, the courses of material that when fastened together resemble steps. See Pattern.

140

Stellite

Proprietary name of a group of complex alloys retaining their hardness strength and resistance to oxidation at high temperatures; contains W, Co, Cr and C.

Step Gate

A vertical sprue containing a number of side branches or entries at different levels into the casting cavity. See Cavity, Gates, Sprue.

Stereolithography Apparatus (SLA)

Equipment used for computerized building of three-dimensional models and patterns. Enables the data representation of a CAD solid model to be directly converted into a plastic model of a casting.

Sticker

A lump on the surface of a casting caused by a portion of the mold face sticking to the pattern. Also, a forming tool used in molding.

Stock Allowance

Material added to a part to allow for surface preparation or precise dimensioning by machining.

Stock Cores

Standard cores of common diameters which are kept "in stock" for general use. See Cores.

Stool

Device used on molding machine to hold pattern plate or refractory block used to support a crucible in a crucible furnace. See Crucible, Crucible Furnace.

Stool Plate

Plate on a mold machine on which stools are mounted.

Stooling

Supporting green sand cores in machine molding while pattern is being withdrawn. See Green Sand, Core.

Stop Off

To shorten or change a mold.

Stop Off Strip

Reinforcing members on frail patterns. Impressions later filled with sand.

Stopper Head

A refractory shape at the end of a stopper rod, usually clay and graphite, seated in a ladle's nozzle.

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Stopper Rod

A device in a bottom-pour ladle for controlling the flow of metal through the nozzle into the casting. The stopper rod consists of a steel rod, protecting sleeves, and a graphite stopper head. It may also be a single piece manufactured from graphite.

Stopping Off

Closing off a part of the mold that is not wanted to be cast.

Strained Casting

A phrase used to describe the result when molten metal is poured into the mold at too fast a rate or under too great metallstatic pressure, causing the cope to rise slightly from the drag and resulting in an oversize casting. See Casting, Cope, Drag, Mold.

Strainer Core

A perforated core placed at the bottom of a sprue or in other locations in the grating system to control the flow of the molten metal. To some extent, it prevents coarse particles of slag and dross from entering the mold cavity. See Core Strainer.

Strains, Casting

Strains produced by internal stresses, resulting from unequal contraction of the metal as the casting cools.

Streamline Flow

Steady flow of liquid without turbulence. Generally, not experienced in metal casting.

Strength, Baked

Compressive, shear, tensile, or transverse strength of a molded sand mixture when baked at a temperature above 230°F (110°C) and then cooled to room temperature.

Strength, Compressive

See Compressive Strength.

Strength, Impact

See Impact Strength.

Strength, Retained

Compressive, shear, tensile, or transverse strength attained by a sand mixture after being subjected to a cycle or cycles of heating and cooling which approximate foundry practice.

Strength, Shear

See Shear Strength.

Strength, Tensile

142

See Tensile Strength

Strength, Yield

See Yield Strength.

Stress Raisers

Factors such as sharp changes in contour or surface defects which concentrate stresses locally. See Defects.

Stress, Relieving

A heat treatment to reduce residual stresses followed by sufficiently slow cooling to minimize development of new residual stresses. See Heat Treatment.

Stress, Residual

Those stresses setup up in a metal as a result of nonuniform plastic deformation or the unequal cooling of a casting.

Stress-Corrosion Cracking

Spontaneous failure of metals by cracking under combined conditions of corrosion and stress, either residual or applied.

Strike Off (noun)

A straight edge, or metal bar, to cut the sand level with the top of the drag or cope flask. See Cope, Drag, Flask.

Strike Off (verb)

Operation of removing excess sand from top of core box or flask. See Core Box, Flask.

Stripper Pins

On certain molding machines, a series of pins (usually four in number) which support the rammed flask-half at the parting surface so that the mounted pattern may be drawn by lowering.

Stripping

Removing the pattern from the mold or core from core box. See Core, Core Box, Mold, Pattern.

Stripping Machine

A device for removing the pattern from a mold or a core from the core box.

Stripping Plate

A plate, formed to the contour of the pattern, which holds the sand in place while the pattern is drawn through the plate.

Stripping Time

143

In oil-oxygen and nobake mixture, the moment when the core box may be satisfactorily drawn from the core, or pattern from the sand.

Structure (Cast Structure)

The size and disposition of the constituents of a metal as cast.

Styroform Pattern

Expendable pattern of foamed plastic, especially polystyrene, use in manufacturing casting by the Full Mold process.

Subcutaneous Blowhole

Blowholes at or near the surface of solidified metal, covered with a thin layer of metal. May also be called pinhole porosity.

Subzero Treatment

Refrigeration of steel to promote transformation of retained austenite.

Sulfur

A nonmetallic chemical element, with a melting point of 444°C (831.2°F) occurring as an undesirable tramp (trace) element in most ferrous alloys.

Sulfur Prints

A macrographic method of examining for the distribution of sulfide impurities, in which a sheet of wet acidified bromide paper is placed on the polished surface to be examined.

Superalloy

An alloy developed for very high temperature use where relatively high stresses are encountered and where oxidation resistance is needed. See Alloy.

Supercooling

Lowering the temperature of a molten metal below its liquidus during cooling. See Liquidus.

Superduty Fireclay Brick

Having pce above 33 with less than 1.0 percent linear shrink in the 1599°C (2910°F) reheat test, and less than 4.0 percent loss in panel spalling test preheated at 1649°C (3000°F).

Superheat

Any increment of temperature above the melting point of a metal; sometimes construed to be any increment of temperature above normal casting temperatures introduced for the purpose of refining, alloying or improving fluidity.

Superheating

144

Theoretically, the temperature above the liquidus. In practice, it usually means temperature above the usual pouring range. See Liquidus.

Supersaturated

Metastable solution in which the dissolved material exceeds the amount the solvent can hold in normal equilibrium at the temperature and under the other conditions that prevail.

Supersonic Reflectoscope

An instrument for sending, receiving, and measuring sound waves over 20,000 cycles per second.

Supramor

An electromagnetic flaw detection ink for the rapid detection of subcutaneous and surface flaws in ferrous metals.

Surface Finish

Condition or appearance of the surface of a casting.

Surface Hardening

Conferring a superficial hardness to a steel while maintaining a relatively soft core. See Hardening.

Surface Protection Air Liquide (SPAL)

The use of liquid argon, liquid nitrogen, or carbon dioxide snow to minimize the reaction of air and molten metal that normally occurs in an induction furnace. The liquid or snow is fed onto the surface of the molten metal where it vaporizes, displacing the air thus reducing slag and oxygen levels.

Surface Texture

The roughness, waviness, lay or other characteristics of the surface of a part.

Surfacing

Depositing a filer metal on a metal surface by any method to obtain certain desired properties or dimensions.

Sweep (verb)

To form a mold or core by scraping the sand with a form sweep having the desired profile. See See Core, Mold.

Sweep or Skree (noun)

A board shaped to a required profile. It is used to remove excess material from a mold or core. See Core, Mold.

Sweep Work

Forming molds or cores by the use of jigs or templates instead of patterns. See Core, Jigs, Mold, Patterns.

Swell

145

A casting defect consisting of an increase in metal section due to the displacement of sand by metal pressure. See Defect.

Swing Frame Grinder

A device for grinding large castings where the work remains stationary. This grinder, too large to be hand lifted, is usually suspended from a hoist.

Synthetic Molding Sand

Any sand compounded from selected individual materials which, when mixed together, produce a mixture of the proper physical and mechanical properties from which to make foundry molds. See Molding Sand, Natural Sand.

Synthetic Sands

Synthetic mixture of silica sand and exact proportions of binders and additives instead of using natural sands. See Natural Sand.

System Sand

Foundry sand used in making molds and which eventually becomes the bulk of the sand used in the mechanical system or mechanized unit. See Sand.

Glossary of Foundry Terms - T

Tap

To withdraw a molten charge from the melting unit.

Tap Hole

Opening in a furnace through which molten metal is tapped into the forehearth or ladle. See Ladle.

Teapot Ladle

Ladle with external spout wherein the molten metal is poured from the bottom rather than from the top. See Ladle.

Tear, Hot

Same meaning as hot crack, but developing before the casting has solidified completely. See Hot Crack.

Tear-Ups

Defect caused by backdraft, damaged pattern or uneven drawing of pattern. See Defect.

Telltale

Any distinguishing mark, projection, groove, etc. on a pattern, core box, mold or core which acts as a guide mark for assembling matching parts. See Core, Core Box, Mold.

Temper

146

Reheating hardened, normalized or mechanically worked steel to a temperature below the critical range to soften it and improve impact strength. The moisture content of a sand at which any certain physical test value is obtained, i.e., temper with respect to green compressive strength, permeability, retained compressive strength, etc. To mix material with enough liquid to develop desired molding properties.

Temper Brittleness

Brittleness that results when certain steels are held within or cooled slowly through a certain range of temperature below the transformation range. The brittleness is revealed by notched-bar impact tests at room temperature or lower temperatures.

Temper Carbon

Carbon in nodular form, characteristic of malleable iron.

Temper Stressing

Quenching in water from the tempering temperature to improve fatigue strength.

Temperature

Degree of warmth or coldness in relation to an arbitrary zero measured on one or more of accepted scales, as Centigrade, Fahrenheit, etc.

Temperature, Holding

Temperature above the critical phase transformation range at which castings are held as a part of the heat treatment cycle. The temperature maintained when metal is held in a furnace, usually prior to pouring.

Temperature, Pouring

The temperature of the metal as it is poured into the mold.

Tempered Martensite

Martensite that has been heated to produce to BCC iron and a fine dispersion of iron carbide. See Martensite.

Tempering (Sand)

Addition of water to and mixing molding sand to obtain uniform distribution of moisture. See Molding Sand.

Tensile Strength (Ultimate Tensile Strength, UTS)

A measure of the amount of mechanical stress a material can withstand before it fractures. Measured in pounds per square inch (PSI), or thousands of pounds per square inch (KSI).

Ternary Alloy

An alloy that contains three principal elements.

Test Bar

147

Standard specimen bar designed to permit determination of mechanical properties of the metal from which it was poured.

Test Lug

A lug cast as a part of the casting and later removed for testing purposes.

Thermal Conductivity

The property of matter by which heat energy is transmitted through particles in contact. For engineering purposes, the amount of heat conducted through refractories is usually given in Btu per hour for one square foot of area, for a temperature difference of one degree Fahrenheit, and for a thickness of one inch, Btu/hr·ft·F/in.

Thermal Contraction

The decrease in a linear dimension and volume of a material accompanying a change of temperature.

Thermal Expansion

The increase in a linear dimension and volume of a material accompanying a change of temperature.

Thermal Fatigue

Failure resulting from rapid cycles of alternate heating and cooling.

Thermal Shock

Stress developed by rapid and uneven heating of a material.

Thermal Spalling

Breaking up of refractory from stresses which arise during repeated heating and cooling.

Thermal Stability

Resistance of a material to drastic changes in temperature.

Thermit Reaction

Exothermic, self-propagating processes in which finely divided aluminum powder is used to reduce metal oxides to free metals by direct oxidation of aluminum to aluminum oxide, with accompanying reduction of the less stable metal oxide. See Exothermic Reaction, Endothermic Reaction.

Thermocouple

A device for measuring temperatures by the use of two dissimilar metals in contact; the junction of these metals gives rise to a measurable electrical potential which varies with the temperature of the junction. Thermocouples are used to operate temperature indicators or heat controls.

Thermography

The technique of obtaining a photographic record of heat distribution in a solid or fluid.

Tie Bar

148

Rod-bar or rod-shaped part of the casting added to prevent distortion caused by uneven contraction between separated members.

Tight Flask

A type of flask which remains on mold during pouring. Lugs are normally provided for clamping cope and drag together for pouring. See Cope, Drag, Flask.

Tin

A chemical element having symbol Sn, formula weight 118.70, specific gravity 7.31, and melting point 231.85°C.

Tin Sweat

Beads or exudations of a tin-rich low-melting phase found on the surface of or on risers of bronze castings, which are usually caused from absorption of hydrogen by the molten metal.

Titanium

A white metallic element, melting point 1660°C (3020°F), having a high strength-to-weight ratio; useful in aircraft parts.

Tolerance

The permissible deviation of a dimension from the nominal or desired value. Minimum clearance between mating parts.

Tongs

Metal instrument with two legs joined by a hinger for grasping and holding things, e.g., crucible tongs.

Tool Steel

Any high-carbon or alloy steel used to make a cutting tool for machining metals and for metal-casting dies.

Tooling Points

The fixed positions on the casting surfaces used for references during layout and machining.

Top Board

A wood board on the cope half of the mold to permit squeezing the mold. See Squeeze Board.

Toughness

The ability of the metal to absorb energy and to deform plastically during fracture. Toughness values obtained in testing depend upon the test temperature, the rate of loading, the size of the test specimen, as well as the presence of a notch and its acuity.

Tower Oven

Vertical, continuous core oven with suspended shelves attached to sprocket-driven chains.

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Tramp Element (Trace)

Contaminant in the components of a furnace charge, or in the molten metal or casting, whose presence is felt to be either unimportant or undesirable to the quality of the casting.

Transfer Ladle

A ladle that may be supported on a monorail or carried in a shank and used to transfer metal from the melting furnace to the holding furnace or from furnace to pouring ladles. See Ladle, Shank.

Transformation (Temperature) Range

The critical temperature at which a change in phase occurs. To distinguish between the critical points in heating and cooling those in heating are referred to as the Ac points (c for Chauffage or heating) and those in cooling, Ar (r for Refroidissement).

Trim Die

Die for shearing (or shaving) flash from a die-casting.

Trimming

Removing fins, gates, etc. from castings. See Casting, Gate, Fins.

Trowel

Tool for sleeking, patching, and finishing a mold.

Tucking

Manual pressing of sand under the flask bars, in pockets and around gaggers where ramming alone fails to give desired density to ensure firm placement. See Sand, Ramming, Flask.

Tumbling Barrel

A revolving metal, wood box, or barrel in which castings are cleaned.

Tungsten

Steel-gray, metallic element, mp 3380°C (6116°F) used for electric lamp filament, x-ray tube target, and as alloy element in high-speed steels.

Turntable

The base on which a centrifugal casting mold rests.

Tuyere

Opening in the cupola where the air blast enters. See Cupola.

Glossary of Foundry Terms - U

150

Ultrasonic Cleaning

Immersion cleaning aided by ultrasonic waves which cause microagitation.

Ultrasonic Testing

A nondestructive method of testing metal for flaws based on the fact that ultrasonic waves are reflected and refracted at the boundaries of a solid medium. Ultrasonic testing is used to detect flaws in materials.

Undercooling

See Supercooling.

Undercut

Part of a mold or die requiring a drawback. See Drawback.

Unkilled Steel

A wild steel insufficiently deoxidized so that it evolves gas and blowholes during solidification. See Killed Steel.

Upgrading

In castings, the removal and repair of discontinuities to raise the quality level of the casting beyond that which can be economically achieved by good foundry practice. See Casting, Foundry.

Upper Yield Point (Also Yield Point)

Denoted in yield point phenomenon as a distinct break from the elastic region accompanied by a drop in load, yet prior to plastic deformation in the stress-strain curve in a low-carbon steel.

Upset

An addition to any flask part to increase height or depth.

Urea Formaldehyde Resin

A thermosetting product of condensation from urea or thio-urea and formaldehyde, soluble in water and used as a sand binder in core and mold compounds.

Glossary of Foundry Terms - A

Vacuum Casting

A casting in which metal is melted and poured under very low atmospheric pressure; a form of permanent mold casting where the mold is inserted into liquid metal, vacuum is applied, and metal drawn up into the cavity. See Cavity, Mold, Mold Casting.

Vacuum Degassing

151

The use of a vacuum technique to remove dissolved gases such as hydrogen, oxygen, and nitrogen from molten alloys.

Vacuum Melting

Melting, usually by induction heating, in a closed container which is subjected to a vacuum.

Vacuum Refining

Melting in a vacuum, usually by electrical induction, to remove gaseous contaminants from the metal.

Value Analysis

In manufacturing, an analysis to determine the most economical method of manufacturing, taking into account the cost and the process capability of alternate manufacturing systems under consideration, their degree of variation, the benefits of the resultant product, and desired quality and production quantity and rate.

Vanadium

A white, hard, metallic element, mp 1800°C (3272°F), used as an alloy in iron and steel; a powerful carbide stabilizer and deoxidizer.

Vegetable Oils

Oils extracted from plants, used as drying oils in oil core manufacture. Linseed oil is an example.

Veining

Surface defect on castings appearing as veins or wrinkles, which results from cracks in the sand due to elevated temperature conditions and occurs mostly in cores. See Casting, Cores, Defect.

Veins

A discontinuity on the surface of a casting appearing as a raised, narrow, linear ridge that forms upon cracking of the sand mold or core due to expansion of the sand during filling of the mold with molten metal. See Defect.

Vent

Small opening or passage through which gases can escape during the pouring of a mold. It is alco called a vent hole.

Vent Rod

A piece of wire or bar to form the vents in the sand.

Vent Wax

Wax in rod shape placed in the core during manufacture. In the oven the wax is melted out, leaving a vent or passage.

Venting

Perforation with a vent wire of the sand over and around a mold cavity to assist in the escape of the gases.

152

Vertical Axis Casting Machine

A centrifugal casting machine in which the axis of rotation of the mold is vertical.

Vibrator

A mechanical device, operated by compressed air or electricity, used to loosen a pattern from a mold by jarring or vibration as it is withdrawn from the sand.

Vickers Diamond

The diamon pyramid used in Vickers Hardness Testing. See Vickers Hardness Test.

Vickers Diamond Pyramid Hardness Tester

Patented indentation hardness machine. See Hardness.

Vickers Hardness Test

A method of determining the hardness of steel using a diamond pyramid that is pressed into the polished surface of the specimen and the diagonals of the impression are measured with a microscope fitted with a micrometer eye piece. The rate of application and duration are automatically controlled and the load can be varied. See Vickers Diamond.

Virgin Metal (Primary Metal)

Metal extracted directly from the ore; not previously used.

Viscosity

The resistance of fluid substance to flowing, quantitatively characteristic for an individual substance at a given temperature and under other definite external conditions.

Void

A shrinkage cavity produced in casting during solidification. See Casting, Cavity, Shrinkage, Solidification.

V-Process

A casting technique.

Glossary of Foundry Terms - W

Warm Box Process

Coremaking method in which the corebox is warm when the core sand is introduced. The warmth of the corebox initiates curing but does not complete it. Cores finish curing outside the corebox (sometimes in a separate dryer), allowing for faster core production cycles than with the Hot Box process. Cores created using this process must be solid- they cannot be shell cores. See Cores, Core Box, Hot Box Process.

Warpage

153

Deformation other than contraction that develops in a casting between solidification and room temperature; also, distortion occurring during annealing, stress relieving, and high-temperature service.

Wash

A casting defect resulting from erosion of sand by metal flowing over the mold or corded surfaces. They appear as rough spots and excess metal on the casting surface. Also call cuts. See Cut, Defect.

Washburn Core

Thin core which constricts the riser at the point of attachment to (Neck-Down Core) the casting. See Casting, Cores, Risers.

Washes

Refractory coating applied to molds and cores to provide protection against penetration from molten metal. See Cores, Molds.

Water Glass

Sodium silicate (an inorganic binder system), a viscous liquid which when mixed with powered fireclay forms a refractory cement.

Water Test

To subject a casting to water pressure in such a manner that any porous areas will show leakage.

Wax

Class of substances of plant, animal, or mineral origin, insoluble in water, partly soluble in alcohol, either, etc., and miscible in all proportions with oils and fats. They consist of esters, free fatty acids, free alcohols, and higher hydrocarbons. Common waxes are beeswax, bayberry, paraffin wax, ozokerite, ceresin, and carnauba. Their mixtures are formed into rods and sheets and used for forming vents in cores and molds, repairing patterns, etc.

Wax Pattern

A precise duplicate, allowing for shrinkage, of the casting and required gates, usually formed by pouring or injecting molten wax into a die or mold. Wax molded around the parts to be welded by a termite welding process.

Weak Sand

Sand lacking in the proper amount of bond. See Bond.

Wear

The undesired deterioration of a component by the removal of material from its surface.

Weld Bead

The built-up portion of a fusion weld, formed either from the filler metal or the melting of the parent metal.

Welding

154

A process used to join metals by the application of heat. Fusion welding, which includes gas, arc, and resistance welding, requires that the parent metals be melted.

Welding Electrode

A metal or alloy in rod or wire forms used in electric arc welding to maintain the arc and at the same time supply molten metal or alloy at the point where the weld is to be accomplished.

Welding Flash

Skin exposed too long to the ultraviolet rays of welding or melting arcs will burn as in a sunburn. Though temporary blindness can result, it is not permanent, as is popularly believed.

Welding Shielded-Arc

Electric-arc welding in which the molten weld metal is protected from the atmosphere. An inert gaseous atmosphere or fluxcoated electrode may be employed.

Welding Stress

That stress resulting from localized heating and cooling of metal during welding.

Welding, Arc

Welding accomplished by using an electric arc that can be formed between a metal or carbon electrode and the metal being welded; between two separate electrodes, as in atomic hydrogen welding or between the two separate pieces being welded, as in flash welding.

Welding, Autogenous

Method of uniting two pieces of metal by melting their edges together without solder or any added welding metal, as by the thermite process that employs a medium of finely divided aluminum powder and oxide or iron by which a temperature of some 2982.2°C (5400°F) is obtained.

Well (Cupola)

Lower portion of a cupola, between the sand bottom and the slaghole, which forms a reservoir for the molten metal. See Cupola.

Wet Scrubber (Gas Washer)

In air pollution control, a liquid (usually water) spray device for collecting pollutants in escaping foundry gases.

Wetting Agent

Surface-active agent which by reducing surface tension of the wetting liquid causes a material to be wetted more easily.

Whirl Gate

Gating system in which the metal enters a circular reservoir at a tangent, and so whirls around, leaving dirt and slag behind before passing into the mold cavity.

Whistlers

155

Small openings from isolated mold cavities to allow gases to escape easily. See Vent.

White Cast Iron

Cast iron in which substantially all the carbon is present in the form of iron carbide, and which has a white fracture.

Widmanstatten Structure

Plate-like structure seen in grains of steel in the course of transformation of a solid solution.

Wild Steel

Steel which has not been completely deoxidized and reacts violently after casting due to liberation of gases of cooling.

Wood Flour

Finely ground wood, usually hardwood, low in resin.

Glossary of Foundry Terms - XYZ

X-Ray

A form of radiant energy with extremely short wave length which has the ability to penetrate materials that absorb or reflect ordinary light. X-Rays provide a form of Non-Destructive testing.

Yield

Comparison of finished casting weight verses total weight of metal poured in a mold. A value expressed as a percentage indicating the relationship of the weight of a casting to the total composite of the casting and its gating system.

Yield Ratio

The ratio of yield strength to ultimate tensile strength.

Yield Strength

A measure of the amount of mechanical stress a material can withstand before it permanently deforms.

Young's Modulus (E)

See Modulus of Elasticity.

Zinc

A chemical element having symbol Zn, formula weigh 65.38, specific gravity 7.140, and melting point 419.4°C.

Zircon

156

Natural zirconium silicate, ZrSiO4 containing 67.23% zirconium oxide, ZrO4, and 32.77% silica, SiO2, is used as a molding medium in steel foundries.

Zirconia

ZrO2 an acid refractory up to 2,500°C (4,532°F) having good thermal shock resistance and low electrical resistively.

Zirconium

Silvery-white, metallic element, mp 1,860°C (3,380°F), a powerful deoxidizer when added to molten steel.

BIBLIOGRAPHY:

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