SAN:D TEI~JVIINO:LOGY

ARTIFICIAL SAND: Product resulting Ji"0111crushing a rock to the size of sandgrains, the fracture often passing tluough the component grains.

BANK SAND: Sedimentary deposits, usually contail1ing less them 5% clay, oceun-ingin banl\:8or pits, used in core making and synthetic molding sands.

BLENDED ~/10LDING SANDS: Naturally bonded molding sands which havebeen mixed or modiJicd by the supplier to produce desirable properties.

BURNT SAND: Sand in wllich the binder or bond has been removed or impaired bycontact with mollcnmctaJ.

FACIN G SAND: Specially prepared molding sand mixhIre used in the mold adjacentto the pattern to produce a smooth casting surface.

NATURA.L SAND: One derived from a rock, in \'ihidl the grains separate along theirnatural boundaries. This includes unconsolidated sand, or a soft sandstone where littlepressure is required to separate the individual grains.

NATURALLY -BONDED J\10LDING SAND: A sand containing sufficientbonding material as mined to be suitable for molding purposes.

SAND: A loose, granular material resulting from the disintegration of rock. The namesand refers to the size of grain and not to mineral composition. Diameter of the individualgrains can vary from approximately 6 to 270 mesh. Most foundry sands are made upprincipally of the mineral quartz (silica).

GATING SYSTElvI: The cOlllplete asselnbly of sprues, rulUlcrs, gates and individualcasting cavities in the mold.

SPRUE: The vertical channel COIUlcctingthe pouring basin with the skimming gate, ifany, and the runner to the mold cavity, all of which together may be called the gate.

SPRUE: Sometimes used as a genetic tean to cover aU gates, risers, etc. returned to themelting unit for re-melting.

RUNNER: A channel through which molten metal or slag is pa.o;;sedfrom Olll.lreceptacleto another; in a mold, the portion of the gate assembly that connect the downgate or spruewith the casting ingate or riser.

GATE: End of the runner in a mold where the molten tnetal enters the casting or moldcavity; sometimes npplied to the entire assembly of connected channels, to the patternparIs which fc.mn Ihem or 10 Ihe mclal whidl JiJls them, and sometimes is reslricted 10mean the first or main channel.

POURING BASIN: The enlarged mouth of the sprue into which the molten metal isfIrst poured.

SKIM GATE: A gating arrangement which changes the direction of flow of moltenmetal and prevents the passage of slag and other undesirable materials.

BOTTOl\rl RUNNING OR POURING: Filling of the mold cavity from thebottom by means of gates tram the runner.

CHOKE: A restriction in the gating system for the purpose of keeping dirt" dross or slagfrom entering the casting proper.

FINGER GATE: Gate used on thin castings to allow rapid filling of mold. It iswedge-shaped with thin edge divided vertically to produce several members or fmgers.Metal flows into mold in several thin streams. Facilitates breaking gate tram a thin ordelicate casting.

HORl~ GATE: A semicircular gate to convey a molten metal over or under certainparts of a castings that it will enter the mold at or near the center; also used as a skim gate.

SLOT GATE: A gate used on vertical cylindrical castings in which the down sptue andcasting are connected over a large pal1 or all of the height of the casting.

PENCIL GATE: A series of small round gates entering the mold cavity iiom aboveand coming from a common pouring basin.

GATE RING: A gate so fOlmed that a number of small gates conduct the metal fi'om acircular tunnel' to a mold in the center.

GATE STRAINER: A gate designed to prevent dirt and slag iiom entering the moldand also to control the rate at which metal enter!'>the mold cavity.

SWHlL GATE: 1\ gale used wilh a feeder and runner designed 10 swirllhe .metal inthe feeder to remove impurities.

POURING: Transfer of molten metal from furnace to ladle, ladle to ladle, or ladle intomolds.

RELIEF SPRUE: In a mold a vertical channel, the approximate size of thedownsptue cormected to the tunnel' to relieve pressure surge during pouring. It functionslike a standpipe in a plumbing system.

RUNNER BOX: Device for distributing molten metal around a mold by dividing itinto several streams.

RUNNER EXTENSION: In a mold, that part of a runner which extends beyond thefarthest ingate as a blind end. It acts as a dirt trap since the fIrst rush of metal along therunner will pick up any loose particles of sand or dirt and cany them into the extensionand not into the mold cavity.

RUNNER RISER: A conventional runner, usually in the horizontal plane, whichpermits flow of molten metal to the ingate and is large enough to act as a reservoir to feedthe casting.

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SCREEN: A perf()rated metal plate placed between the gate and nmuer of a castingmold for the purpose of separating entrapped oxides, slag, etc., during the pouring.

SHOvVER GATE (PENCIL GATE, por GATE): In a mold, a gating systemby which metal sho"vers into the mold c:n,ity from a group of small gates at the top.

SKIlVI CORE (SKIlVll\r1ER): A 11atcore or tile placed in a mold to skim a flowingstream of metal. Cormnonly used in pouring basins, it holds back slag and dirt willie cleanmetal passes undemeath to the dovvnsprue.

SKIl\1 GATE: A gating anangement which changes the direction offlow of moltenmetal and prevents the passage of slag and other undesirable materials.

WHIRL GATE: A gate and sprue ammgement which tangentially introduces moltenmetal into a riser so the centrifugal action forces dirt or slag to the center of the liser andaway from the riser connection as the metal enlers the casting cavity.

SPRUE PLUG: Wood or metal tapered roll or pin used to tonn a sprue opening, or .:lmetal plug left in the sprue after pow'ing has begun to allow filling or the poming basinbefore the metal is allovved to enter the sprue.

LADLE: Metal receptacle frequently lined with refractors and used for transporting andpouring molten metal. Types include hand, bull, crane, bottom-pour, holding, teapot,trolley, shank, lip-pour, buggy, truck, mi'ting, reservoir.

LADLE, BOTTO~l POUR: L'ldle from which metal, usually steel, flows through anozzle in the bottom.

LADLE, BULL: A large ladle for carrying molten metal. Frequently used to designatea transfer ladle.

LADLE, CASTING: A clllcible or iron vessel lined with refractory matelial forconveying molten metal from the furnace and pouring it into the mold.

LADLE, TEAPOT: A ladle in which, by means of an external spout, iron is removedfrom the bottom rather than the top.

TRr-\NSFI~RLADLE: A ladle that may be supported 011 amonorail or carried in ashank and used to transler metal hom the melting llJrnace 10 the holding furnace, or fromfurnace to pouring ladles.

IUS:ER TEI~JVlINOLOGY

nOB: A riser or fceder, 118ua11yhlind, \0 provide molten metal to the casting duringsolidification, thereby preventing sluinkage cavities.

BREAK-OFF CORE: A thin core connecting the riser and casting which, while notimpeding the flow of metal, serws as a notch to assist in riser removal.

CHURN: Movement of mclall'Od up and dO\VlI ill Ihe riser of a large casting Lopreventiieezing over the top.

CORE BREAI(-OFF: A core designed to produce a sharp break line in the gate forease of removal of feeder.

DIRECTIONAL SOLIDIFICATION: The solidiJication of molten metal in acasting in such a manner that feed metal is always available for that pOliion that is justsolidifying.

DRA "V: A tenn sometimes used to denote a shrink ;JppeaIing on the surface of a castingor a rIser.

FEEDER, FEEDER HEAD: A reservoir of molLenmetal to compensate for thecontraction of metal as it solidifIes. J\tfoltcnmetal flowing from the feed head, also knownas a RISER, prevents voids in the casting.

FEEDING: Pouring additional molten metal into a freshly poured mold to compensatefor volume shrinkage while the casting is solidifYing. Also the continuous supply of moltenmeta~ as from a 1iser, to tile solidi{ying metal in a casting. Also refers to keeping risersopen by manipulation of feeding rods.

FEEDING ROD: An iron rod used for keeping open the head or tiser, to which hotmetal is added from time to time as the casting contracts in cooling.

NECK DO\VN (KNOCK-OFF, WASHBURN, or CAlvIERON CORE): A thin coreor tile used to restrict the riser neck, making it easier to break or cut off the riser from thecasting.

RISER: A reservoir of molten metal provided to compensate for the internal contractionof the casting as it solidifies.

RISER, BLIND: A riser which docs nol break tlu'ough the top of the cope mold, andis entirely sunoundecl by sand; often combined with ~pin gales, and together fanning aneffIcient method of gating and feeding a casting.

RISER-GATING: Practice ofrun1l.ing metal for the casting tlu'ough the riser to helpdrrcctionalsolidrlication.

RISER HEIGHT: The distance from the top of the riser when liquid to the top of theriser neck. Riser height when solid may be several inches less than when liquid because ofloss of feed metal to the casting.

RISER NECK: The cOlUleetingpassage between the tiser and the casting. Only theheight and width, or diameter, of the tiser neck usually are reported, although the shapemay be equally imp0l1ant.

RISER, OPEN: Conventional i{)rlll of"riser usually located at the heaviest section ofthe casting and extending through the entire height of the cope.

RISER PAD (RISER CONTACT): An enlargement of the riser neck where itjoins the casting. The pUllJose of the pad is to prevent "breaking in" of the riser when it isstruck or eHtfrom the cHsting.

\VHIRL GATE: A gate and sprue anangcmcnt which tangentially introduces moltenmetal into a riser so the centrrlugal action forces diJ.1or slag to the center of the riser andaway from the riser cotillection as the metal enters the casting cavity.

MOLD/CORE l~ERMINOLOGY

ARBORS: M.etal shapes embedded in and used to support either green or dry sandcores.

BARS: Ribs of metal or wood placed across the cope portion of a flask. Sometimescalled "cleats". In some C:lsesused

CASTING, PERl\!lANENT lVlOLD: A casting produced in a re-useable metal orrefractory mold.

CASTING, SAND: 1\ casting produced in a mold made of green sand, dried sand, ora core sand.

CHAPLETS: 1\-1ctalsupports or spacers used in molds to maintain cores, or parts ofthe mold which are not self-supporting in their proper positions during the casting process.

CHEEK: Intennediate section of a flask that is inserted between cope and drag todecrease the ditficulty of molding unusual shapes or 10 fill a need for more than oneparting line

CHILL: 1) Addition of solid metal to molten metal in ladle to reduce temperature beforepouring; 2) depth to \vhich chilled structure penelrates a casting.

CHILL BLOCK.: A cast iron test block in vvhich the depth of chill, as determined byfracture, is used as :'Inestilnate of the cast iron's qU

CORE IRONS: An irolJ, sleel bar, \vire, or other shape used within a core forstrengthening it in the green sand state to prevent distortion.

CORE JIG: A devise for setting core assemblies outside of the mold and placing the'Vvholeassembly in the mold.

CORE l\1ARKER: A core seat so shaped or arranged that the core will registerconectly in the mold; also termed locator, indicator, register, tell-tale.

CORE PRINT: Projections attached 10 a pallern in ordcr to form recesses in the moldat points where cores are to be supported.

CORE, RAlVI-UP 'VING: A core used to form a projection on a side of the casting.The core print is wedge shaped and extends tu the pmting line.

CORES, LEFT AND RIGHT-HAND: Cores made in separate whole boxes, alikeexcept that one has projection and bevel on opposite side.

CORE "'IRES OR ROnS: Reinrorcing wires or rods for fr:lgilc cores, OOCHprefOlmed into spedal shapes.

CRUSH STRIP OR BEAD: An indentation in the patting line of a pattern platewhich insures that cope and drag shall have good contact by producing a ridge of sandwhich crushes against the other sutface of the mold or core.

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

DAUBING: Filling of cracks in molds or cores by specially prepared pastes or coatingsto prevent a mechanical penetration of metal into these cracks during pouring.

DIE CASTING: A casting process by which the molten metal is forced under greaterthan atmosphelic pressure into the metal mold cavity.

DOWEL: A pin of various types used in the parting surface ofpalted patterns or coreboxes to assure conect regularity.

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DR.A",VPLATE: A plate attached to a pattern to l~lci1itatedrawing of pattern lrDIu themold.

FLASK: Metal or wood frame without top or fixed bottom used to hold the sand ofwhich a mold is formed; usually consists of two parts, cope and drag.

FLASK PIN: Guides to assure proper alignment of the cope and drag of the mold afterthe pattem is withdravvll.

FLASK, TIGHT: A type of flask which remains on the mold during pouring. Lugsare normally provided for clamping cope and drag together for POUling.

FLOOR~10LDER: Craftsman employed on the main foundry floor in makingmolds for large castings generally from loose pattems.

FOLLO"V-BOARD: A board which conforms to the form of the pattern and defmesthe parting surface of the drag.

FOUNDRY NAILS: Coated steel nails with heavy heads, inserted in the mold wall tohasten chilling action of the metal at that particular point, as well as to aid in holding thesand-metal interface and prevent it from spalling; used to prevent cuts, washes, scabs at thegate.

GAGG ERS: Metal pieces of inegular shape used to reinforce and supp0l1 sand in deeppockets of molds.

GUIDE: A ship or other suitable device used to locate the cope in the proper place onthe drag.

INGOT: A mass of metal cast to a convenient size and shape for re-melting or hotworking.

JO DB IN G FOUNDRY: A foundry engaged in the manufacture of numerous typesof castings not intended for use in its own product. Usually refers to a foundry makingcastings for many other companies.

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LIFTERS: Ivletal tool used for removing loose sand from cope or drag before closingmold. Also, a device which is attached to the cope, to hold the sand together when thecope is lifted.

LOOSE PIECE: 1) Core box; part of a core box ,,,hich remains embedded in thecore, and is removed after lifting off the core box. 2) Pattern; laterally-projecting part of apattem so attached that it remains in the mold until the hody of the pattern is withdrawn.back-draft is avoided ,,,ith this means. 3) Part of a pcnrwncnl mold which remains on thecasting, and is removed ailer casting is ejected from the mold.

MASTER PATTERN: A pattem embodying a contraction allo"vance in itsconstmction, used for making castings to be employed as paltr.;rns in production work. Ininvestment casting, the object from which a die can be made, generally a metal mold of thepart to be cast, with process shrinkage added.

lVIOLD CAVITY: In a mold, the hole which, when filled ,,,-ithmetal becomes thecasting. Gates and risers are not considered pal1 of the mold cavity,.

lVIOLD 'VASH: UsualJy an a

RAISINGS: Sections of flasks, without bars, used together with flasks to give variousdepths of flasks desired.

RIDDLE: A screening devll;e, manually or mechallil;ally operated, for removing coarseparticles and contamination from molding sand.

RIGGING: Process of tooting pattem equipment for production-- as mounting pattemson boards integrally vvith skimmers, gales, risl.:1's,ele.

RODDING: Reinforcing the sand in a core with metal rods or shapes to strengthenparts of the core.

ROLL-OVER BOARD: A wood or metal plate on which the pattem is laid top facedownward for ramming the drag half of the mold, the plale and half mold being tumedover together before the joint is made.

SAILORS: An object hanging [ro.m a (Ope bar or other structural member and used tosupport the sand.

SHOT AND GRIT: These two tenus refer to the metallic tY!leof abrasive commonlyused for cleaning castings. The shot is formed by blowing hut tHetal into a quenching tankand subsequently screening into various sizes. The gIlt is produced by breaking up the shotin either a ball or hanuner mill. A large percentage of the shot produced today is heattreated to improve toughness.

SHRINKAGE: Change in size as the metal passes from the fluid to the solid state inthe mold.

SLICK, SLICKER, Si\-100THER: A tool used for mending and smoothing thesurface of a mold after withdrawal of pattern and before closing the mold.

STICKER: A lump on the surface of a casting caused by a portion of the mold facesticking to the pattem. Also, a fanning tool used in molding.

STOCK CORES: Cores of standard diameters usually made 011 a core machine andkept on himd, sawed to required lengths.

STRESS RAISERS: Factors such as sharp changes in contour or surface defects,which concentrate stresses locally.

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8\VAD: A sponge or piece of waste, hemp, or other material used in dampening sandaround a pattem before withdrawing it. ~omctjmes use in blacking molds which might bebroken by a brush.

S\VEEP: A template cut to the profile of the desired mold shape, which when revolvedaround a stake or spindle, produces that mold.

TIE PIECE: Bar or rod-shaped piece built into a pattern and made a part ofthe castingto prevent distortion caused by uneven contraction between separated members.

TRYOFF: Procedure usually associated with mold assembly. It is a test for clearance,bearing, and metal thickness. Performed by placing daubs of clay in position beforeclosing the mold.

TUCKING: Pressing sand with the fmgers under tlask bars, around gaggers, and otherplaces where the rmmner does not give the desired density.

VENT: A small opening or passage in a mold or core to facilitate escape of gases whenthe mold is poured.

VENTING: Perforation with a venting wire of the sand over and around a mold cavityto assist in the escape of the gases.

VENT \VlRE: A wire used to make vents or small holes in the mold to allow gas toescape.

'VHISTLER: A small vent opening from isolated mold cavities, usually high points, toallow trapped gases to escape quickly.

HACK DRAFT: ;\ reverse lapel' which prevcllts removal of the pallem from themold.

BATTENS: Wooden bars or strips fastened to bottom or follow board for rigidity or toprevent distortion during ramming of the mold.

CENTER LINE: Well defined gage-line placed on a geometric center of the work toserve as a hasis from which dimensions are to be measured.

FINISH ALLO'VANCE: Amount of stock left on the surface of a casting formachine finish.

PARTING LINE: A line on a paLtem or casting corresponding to the separationbetween the cope and drag portions of a sand mold.

PATTER.~:A foam of wood, metal, or other materials, around which molding materialis placed to make a mold for casting metals.

PATTERN BOARD: Board having a tme sUIface upon which a pattem is placedpreparatory to making a mold of the paLLem.

PATTERJ.~CHECI(ING: Verifying dimensions of the paUem with those of thedrawing.

PATTERN COATING: Materials applied to wood pattems to protect them againstmoistme and abrasion of molding sand.

PATTERN DRAFT: Taper allowed on vertical faces of a pattern to permit easywithdrawal of pattem from the mold.

PATTE&~, GRAND ~ilASTER: Pattem constructed with triple slrrinkageallowance from which metal master pattetnc; are made.

PATTERN LAYOUT: Full-size drawing of a pattem showing its alTangement andstructural features.

PATTERNMAK.ER' S SHRINKAGE: Shrinkage allowance made on all patternsto compensate for the change in dimensions as the solidified casting cools in the mold fromfreezing temperature of the metal to room temperature. Pattem is made larger by the

nmount of shrinkage characteristic of the pmticular metal in the casting and the amount ofresulting contraction to be encountered. Rules or scales are available for use.

PATTERN1\;IAKIN G: SkilJed craft of modeling in wood, metal, or other materialsobjects to be cast in metal.

PATTER1\T, lVIASTER: Pattem constructed with double sluinkage allowance fromwhich production pattems are to be made.

PATTERN PLATES: Straight flat metal or other plates on which patterns aremounted.

PATTERN, TI~NIPORARY: A ptlttern used to produce a limited number ofcastings and made as cheaply as the case will pelmit..

RAPPING: Knocking or janing the pattern to loosen it from the sand in the moldbefore \vithdrawing the pattcm.

RAPPING BAR: :t\letal rod used to rap the draw spike to loosen the pattern in thesand for drawing.

RAPPING PLATE: A metal plate attached to a pattern to prevent injury to thepattern and assist in loosening it from the sand.

SHRINKAGE, PATTERN~1AKER'S: A scale divided in excess of standardmeasurement to allow for the difference in size between the casting and the correspondingmold cavity. Used by patternmakers to avoid calculations for shrinkage.

SKELETON PATTERt~: A framework or skeleton of ribs representing the interiorand exterior fmm and the metal thickness of the required casting.

STANDARD PATTERN: A pattern of high-grade material and workmanship indaily use or used at frequent intervals. A pattern used as a master to make or checkproduction patterns.

CASTING DEFECTS

BLEEDER: A defect wh~rein a casting lacks completeness due to molten metaldraining or leaking out of some part of the mold cavity after pouring has stopped.

BLISTER: A shallow blow with a thin fum of metal over it appearing on the sUlface ofa casting.

BLOWHOLE: Inegular shaped cavities with smooth walls produced in a casting whengas, entrapped when the mold is being lilled, or evolved during solidification of the meta~fails to escape and is held in pockets.

BUCKLE: An indentation in a castulg, resulting from expansion of the sand, may betermed the start of an expansion defect.

BURNING-ON: Repailing a defective part of a casting by pouring fluid metal on ituntil the defective part has become fluid, the whole masslhus fusing together. Should notbe confused with "burning-in."

CASTING STRAINS: Strains resulting from the cooling of a casting and sometimesaccompanied by residual stresses.

CENTERLINE SHRINKAGE: Shrinkage or porosity occurring along the centralplane or axis of a cast pad.

COLD SHOT: Small globule of metal embedded in but not entirely fused with thecasting.

COLD SHUT: A casting defect caused by irnpelfect fusing of molten metal comingtogether from opposite directions in a mold, or due to folding of the surface.

CONTRACTION CRACKS: Cracks formed by the restriction of the metal while itis contracting in the mold; may occur just after solidification (called a hot tear) or a shorttime after the casting has been removed from the mold.

CORE BLOW: A gas pocket in a casting adjacent to a cored cavity and caused byentrapped gases from the core.

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CORE RAISE: A casting defect caused by 11otation of a core toward the cope surfaceof a mold causing a variation in wall thickness.

CORE SHIFT: A variation from specified dimensions of a cored section due to achange in position of the core or misaligruncnt of cores in assembling.

CRACK, HOT TEAR: A rupture in a casting OCCUlTingat or just below thesolidifYing temperature by a pulling apart of the soft metal.

CRUSH: Buckling or breaking of a seclion of mold due 10 incorrect register whenclosing. Also, an indentation in the casting sur1~lcedue to displacement of sand in the moldwhen the mold was closed.

CUTS: Defects in a casting resulting from erosion of the sand by metal flowing over themold or core surface.

DRA'V: A tenll sometimes used to denote a shrink appearing on the surface of a castingor rIser.

DROP: A mold defect caused by sand dropping from the cope or other overhangingsection, which results in a defect knmvn as a drop if the casting is poured.

EROSION SCAn: A casting defect which occurs when the molten metal has beenagitated, boiled, or partially eroded the sand, in the mold, leaving a solid mass of sand andmetal at that point.

EXPANSION SCAB: Rough thin layer of metal partially separated from the body ofthe casting by a thin layer of sand, and held in place by a thin vein of metal, usuallyresulting in a thin indentation in the casting, caused by spalling of the mold face.

FIN: A thin projection of metal from the casting, formed as the result of imperfect moldor core joints.

GAS HOLES: Rounded cavities, either spherical, flattened, or elongated, in a casting,caused by the generation and/or accumulation of gas or entrapped air during thesolidification of a casting.

HARD SPOTS: Dense inclusions in a casting, i.e., oxides, iron particles, sand, etc.which are harder than the surrounding metal and cause machining difficulties.

HOT TEAR: Surface discontinuity or fracture caused by either extemalloads orinternal stresses or a combination of both acting on a casting during solidification, andsubsequent contraction at tt:lUpi..:raturesnear the solidus.

INCLUSIONS: Particles of impurities (usually oxides, sulphides, silicates and such)that are held mechanically, or are fonned during solidification or by subsequent reactionwithin the solid metal.

INTERNAL SHRINKAGE: 1\ void or network 0fvoids within a casting caused byimproper feeding of that section during solidilication.

lVIE'I'AL PENETRATION: A casting sudace defect which appears as lithe metalhad filled the voids between the sand grains \vithout displacing them.

~IICROPOROSITY: EXlremdy fine porosity caused in castings by slu"inkagcor gasevolution and apparent on radiographic film as mottling.

IvnCROSHRINKAGE: VelY finely divided porosity resulting from interdendriticshrinkage resolved only by use of a microscope: may be visible on radiographic filins asmottling ..

~IISRUN: Casting not hIlly formed resulting from metal poured so cold that it solidifiedbefore filling the mold completely.

MOLD SHIFT: A casting defect which results when a mold does match at partinglines.

OPEN GRAIN STRUCTURE: A defect wherein a casting, when machined orfractured, appears to be coarse grained and porous; usually due to a shrink area.

PINHOLE POROSITY: Very small holes scattered through a casting, possiblycaused by rnicroshrinkage or gas evolution during solidification.

PIPE: A cavity fanned by contraction in metal during solidification, and occurringwhere the last pOliion of liquid metal freezes, as in a riser.

POURED SHORT: Casting which lacks completeness due to the mold not beingfilled.

PULL DOWN: A buckle in the cope, sometimes severe enough to cause a scab; also,a shrinkage defect, as a draw.

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