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Complete Casting Handbook

Metal Casting Processes, Metallurgy, Techniques and Design

Campbell’s Complete Casting Handbook: Metal Casting Processes, Techniques and Design, Second Edition provides an update to the first single-volume guide to cover modern principle… Read more

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Description

Campbell’s Complete Casting Handbook: Metal Casting Processes, Techniques and Design, Second Edition provides an update to the first single-volume guide to cover modern principles and processes in such breadth and depth, while also retaining a clear, practical focus.

The work has a unique viewpoint, interpreting the behavior of castings, and metals as a whole, in terms of their biofilm content, the largely invisible casting defects which control much of the structure and behavior of metals.

This new edition includes new findings, many from John Campbell’s own research, on crack initiation, contact pouring, vortex gates, and the Cosworth Process.

Key features

  • Delivers the expert advice that engineers need to make successful and profitable casting decisions
  • Ideal reference for those interested in solidification, vortex gates, nucleation, biofilm, remelting, and molding
  • Follows a logical, two-part structure that covers both casting metallurgy and casting manufacture
  • Contains established, must-have information, such as Campbell’s ‘10 Rules’ for successful casting manufacture
  • Includes numerous updates and revisions based on recent breakthroughs in the industry

Readership

Metallurgists, metals solidification and foundry professionals in industry and academia; cast metal product and process designers; MS&E researchers; government, corporate and academic researchers and libraries

Table of contents

Chapter 1. The Melt

  • 1.1. Reactions of the Melt with its Environment
  • 1.2. Transport of Gases in Melts
  • 1.3. Surface Film Formation
  • 1.4. Vaporisation

Chapter 2. Entrainment

  • 2.1. Entrainment Defects
  • 2.2. Entrainment Processes
  • 2.3. Furling and Unfurling
  • 2.4. Deactivation of Entrained Films
  • 2.5. Soluble, Transient Films
  • 2.6. Detrainment
  • 2.7. Evidence for Bifilms
  • 2.8. The Importance of Bifilms
  • 2.9. The Four Common Populations of Bifilms

Chapter 3. Flow

  • 3.1. Effect of Surface Films on Filling
  • 3.2. Maximum Fluidity (The Science of Unrestricted Flow)
  • 3.3. Extended Fluidity
  • 3.4. Continuous Fluidity

Chapter 4. Moulds and Cores

  • 4.1. Moulds: Inert or Reactive
  • 4.2. Transformation Zones
  • 4.3. Evaporation and Condensation Zones
  • 4.4. Mould Atmosphere
  • 4.5. Mould Surface Reactions
  • 4.6. Metal Surface Reactions
  • 4.7. Mould Coatings

Chapter 5. Solidification Structure

  • 5.1. Heat Transfer
  • 5.2. Development of Matrix Structure
  • 5.3. Segregation

Chapter 6. Casting Alloys

  • 6.1. Zinc Alloys
  • 6.2. Magnesium Alloys
  • 6.3. Aluminium
  • 6.4. Copper Alloys
  • 6.5. Cast Iron
  • 6.6. Steels
  • 6.7. Nickel-Base Alloys
  • 6.8. Titanium

Chapter 7. Porosity

  • 7.1. Shrinkage Porosity
  • 7.2. Gas Porosity
  • 7.3. Porosity Diagnosis

Chapter 8. Cracks and Tears

  • 8.1. Hot Tearing
  • 8.2. Cold Cracking

Chapter 9. Properties of Castings

  • 9.1. Test Bars
  • 9.2. The Statistics of Failure
  • 9.3. Effect of Defects
  • 9.4. Tensile Properties
  • 9.5. Fracture Toughness
  • 9.6. Fatigue
  • 9.7. Elastic (Young's) Modulus and Damping Capacity
  • 9.8. Residual Stress
  • 9.9. High Temperature Tensile Properties
  • 9.10. Oxidation and Corrosion Resistance
  • 9.11. Leak-Tightness
  • 9.12. Surface Finish
  • 9.13. Quality Indices
  • 9.14. Bifilm-Free Properties

Section 1 Casting Manufacture: Introduction to the Casting Manufacturing Industry

Chapter 10. The 10 Rules for Good Castings

  • 10.1. Rule 1: Use a Good-Quality Melt
  • 10.2. Rule 2: Avoid Turbulent Entrainment (The Critical Velocity Requirement)
  • 10.3. Rule 3: Avoid Laminar Entrainment of the Surface Film (The Non-Stopping, Non-Reversing Condition)
  • 10.4. Rule 4: Avoid Bubble Damage
  • 10.5. Rule 5: Avoid Core Blows
  • 10.6. Rule 6: Avoid Shrinkage Damage
  • 10.7. Rule 7: Avoid Convection Damage
  • 10.8. Rule 8: Reduce Segregation Damage
  • 10.9. Rule 9: Reduce Residual Stress
  • 10.10. Rule 10: Provide Location Points

Section 2. Filling System Design

Chapter 11. Filling System Design Fundamentals

  • 11.1. The Maximum Velocity Requirement
  • 11.2. Gravity Pouring: The ‘No-Fall’ Conflict
  • 11.3. Reduction or Elimination of Gravity Problems
  • 11.4. Surface Tension Controlled Filling

Chapter 12. Filling System Components

  • 12.1. Pouring Basin
  • 12.2. Sprue (Down-Runner)
  • 12.3. Runner
  • 12.4. Gates
  • 12.5. Surge Control Systems
  • 12.6. Vortex Systems
  • 12.7. Inclusion Control: Filters and Traps
  • 12.8. Filters

Chapter 13. Filling System Design Practice

  • 13.1. Background to the Methoding Approach
  • 13.2. Selection of a Layout
  • 13.3. Weight and Volume Estimates
  • 13.4. Pressurised versus Unpressurised
  • 13.5. Selection of a Pouring Time
  • 13.6. Thin Sections and Slow Filling
  • 13.7. Fill Rate
  • 13.8. Pouring Basin Design
  • 13.9. Sprue (Down-Runner) Design
  • 13.10. Runner Design
  • 13.11. Gate Design

Section 3. Processing (Melting, Moulding, Casting, Solidifying)

Chapter 14. Melting

  • 14.1. Batch Melting
  • 14.2. Continuous Melting
  • 14.3. Holding, Transfer and Distribution
  • 14.4. Melt Treatments
  • 14.5. Cast Material
  • 14.6. Re-melting Processes

Chapter 15. Moulding

  • 15.1. Inert Moulds and Cores
  • 15.2. Aggregate Moulding Materials
  • 15.3. Binders
  • 15.4. Other Aggregate Mould Processes
  • 15.5. Rubber Moulds
  • 15.6. Reclamation and Re-cycling of Aggregates

Chapter 16. Casting

  • 16.1. Gravity Casting
  • 16.2. Horizontal Transfer Casting
  • 16.3. Counter-gravity
  • 16.4. Centrifugal Casting
  • 16.5. Pressure-Assisted Casting
  • 16.6. Lost Wax and Other Ceramic Mould Casting Processes
  • 16.7. Lost Foam Casting
  • 16.8. Vacuum Moulding (V Process)
  • 16.9. Vacuum-Assisted Casting
  • 16.10. Vacuum Melting and Casting

Chapter 17. Controlled Solidification Techniques

  • 17.1. Conventional Shaped Castings
  • 17.2. Directional Solidification
  • 17.3. Single Crystal Solidification
  • 17.4. Rapid Solidification Casting

Chapter 18. Dimensional Accuracy

  • 18.1. The Concept of Net Shape
  • 18.2. Mould Design
  • 18.3. Mould Accuracy
  • 18.4. Tooling Accuracy
  • 18.5. Casting Accuracy
  • 18.6. Metrology

Chapter 19. Post-casting Processing

  • 19.1. Surface Cleaning
  • 19.2. Heat Treatment
  • 19.3. Hot Isostatic Pressing
  • 19.4. Machining
  • 19.5. Painting
  • 19.6. Plastic Working (Forging, Rolling, Extrusion)
  • 19.7. Impregnation
  • 19.8. Non-Destructive Testing

Product details

About the author

JC

John Campbell

John Campbell OBE is a leading international figure in the castings industry, with over four decades of experience. He is the originator of the Cosworth Casting Process, the pre-eminent production process for automobile cylinder heads and blocks. He is also co-inventor of both the Baxi Casting Process (now owned by Alcoa) developed in the UK, and the newly emerging Alotech Casting Process in the USA. He is Professor Emeritus of Casting Technology at the University of Birmingham, UK.
Affiliations and expertise
Professor Emeritus of Casting Technology, University of Birmingham, UK

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