Investment Casting Foundry

Casting of metals evolved first as witchcraft, gradually becamean art, then technology, and became only recently a science. Many ofthe processes used in a metal casting are still empirical in nature, but many others are deeply rooted in mathematics. In whatever form, casting of metals is an activity fundamental in the very existence ofour world, as we know it today.Foundry reports indicate that solidification modeling is not only acost-effective investment but also a major technical asset. It helpsfoundries move into markets with more complex and technicallydemanding work. However, to the best of the author's knowledge, therehave been no attempts to synthesize the information that can be usedfor engineering calculations pertinent to computational modeling ofcasting solidification.This book is based on the author's thirty years of experience withteaching, research and the industrial practice of solidificationscience as applied to casting processes. It is an attempt to describesolidification theory through the complex mathematical apparatus thatincludes partial differential equations and numerical analysis, whichare required for a fundamental treatment of the problem. Themathematics, however, is restricted to the element essential to attaina working knowledge of the field. This is in line with the main goalof the book, which is to educate the reader in the fast moving area ofcomputational modeling of solidification of casting. For the sake ofcompleteness, a special effort has been made to introduce the readerto the latest developments in solidification theory, even if thereader has no engineering applications at this time.The text is designed to be self-contained. The author'steachingexperience demonstrates that some of the students interested insolidification science are not fully proficient in partialdifferential equations (PDE) and/or numerical analysis.

Lost-foam casting - Lost foam casting (LFC) is a type of investment casting process that uses foam patterns as the investment. The method takes advantage of the properties of foam to simply and cheaply form castings that would be difficult or impossible, using normal "cope and drag" techniques.

Type foundry - A type foundry is a company that produces and/or distributes typefaces. Originally, type foundries manufactured and sold metal and wood typefaces and matrices for line-casting machines like the Linotype and Monotype machines designed to be printed on letterpress printers.

Casting flask - A Casting Flask is a wooden or metal frame, used in a foundry to contain molding sand used to make a mold. A simple flask has two parts, the cope and the drag, and more elaborate flasks may have three or even four parts.

Sprue (casting) - In foundry work, a Sprue is the passage through which metal is poured into a mold. The term can also refer to the excess metal on a rough casting, which solidified in the sprue hole.

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