Aluminium castings rules
Get the complete knowledge on aluminium castings rules with the book “Castings practice: the 10 rules of casting” by John Campbell, including background, holding pouring, melt treatments, and degassing.
The book offers the perfect starting point for learning about metal castings rules, including aluminium castings rules. Master background, pouring, melt treatments and degassing with one source!
In the book
“Castings practice: the 10 rules of castings”
by John Campbell:
“This rules have been applied to many different alloy systems including aluminium.”
Brief contents
1 Rule 1 – Achieve a good quality melt
- Background
- Melting
- Holding
- Pouring
- Melt treatments
- Degassing
- Additions
- Filtration
- Packed beds
- Alternative varieties of filters
- Practical aspects
2 Rule 2 – Avoid turbulent entrainment (the critical velocity requirement)
- Maximum velocity requirement
- The ‘no fall’ requirement
- Filling system design
- Gravity pouring of open-top moulds
- Gravity pouring of closed moulds
- Horizontal transfer casting
- Counter-gravity
- Surface tension controlled filling
- Inclusion control: filter sand traps
- Practical calculation of the filling system
3 Rule 3 – Avoid laminar entrainment of the surface film
(the non-stopping, non-reversing condition)
- Continuous expansion of the meniscus
- Arrest of vertical progress
- Waterfall flow
- Horizontal stream flow
- Hesitation and reversal
4 Rule 4 – Avoid bubble damage
- Gravity-filled running systems
- Pumped and low-pressure filling systems
5 Rule 5 – Avoid core blows
- Background
- Prevention
6 Rule 6 – Avoid shrinkage damage
- Feeding systems design background
- Gravity feeding
- Computer modelling of feeding
- Random perturbations to feeding patterns
- Dangers of solid feeding
- The non-feeding roles of feeders
- The seven feeding rules
- rule 1: Do not feed
- rule 2: Heat-transfer requirement
- rule 3: Mass-transfer requirement
- rule 4: Junction requirement
- rule 5: Feed path requirement
- rule 6: Pressure gradient requirement
- rule 7: Pressure requirement
- The new feeding logic
- Background
- The new approach
- Active feeding
- Freezing systems design
- External chills
- Internal chills
- Fins
7 Rule 7 – Avoid convection damage
- Convection: the academic background
- Convection: the engineering imperatives
- Convection damage and casting section thickness
- Countering convection
8 Rule 8. Reduce segregation damage
9 Rule 9 – Reduce residual stress (the ‘no water quench’ requirement)
- Residual stress from casting
- Residual stress from quenching
- Distortion
- Heat treatment developments
10 Rule 10 – Provide location points
- Datums
- Location points
- Rectilinear systems
- Cylindrical systems
- Trigonal systems
- Thin-walled boxes
- Location jigs
- Clamping points
- Mould design: the practical issues
- Casting accuracy
- Tooling accuracy
- Mould accuracy
- Summary of factors affecting accuracy
- Metrology
Appendix
- The 1.5 factor
- The Bernoulli equation
- Rate of pour of steel castings from a bottom-pour ladle
- Running system calculation record
- Design methodology for investment castings
