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A technical manual for metal casters with emphasis on local non-ferrous materials rather than imported products. This introduction to small-scale non-ferrous casting includes step-by-step instructions on how to make equipment using local materials, and provides information on moulding techniques, design and pattern making, core and core mixtures, the use of wax, repairs and welding, cleaning, metal preparation and melting. There is also a chapter on fault finding and remedies. The book looks at green sand moulding, a technique common in developing countries; and investment casting based on traditional Indian and Italian methods, which is appropriate to engineers and entrepreneurs working in developing countries. A final section contains a guide to kilns and furnaces. This text should be of interest to metalworkers, engineers and manufacturing entrepreneurs working in rural workshops, or medium-sized engineering businesses in a small town.
Section One: Setting up the workshop and foundry; Making the form; Patternmaking; Flexible moulding for waxes. Section Two: Sand moulding; Material; The nature of moulding sand. Section Three: Investment casting; Introduction to lost-wax casting, including lost polystyrene and mercury process; Waxes and wax patterns; The Italian (Roman) and Shaw processes; The clay slurry process; The ceramic shell process. Section Four: Die casting. Section Five: Basic metallurgy; Alloying and recycling scrap; Metal flow and solidification; Designing the sprue system. Section Six: Kilns and furnaces; Crucibles. Section Seven: Common faults in castings; Fettling and finishing.