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Foundry Practice.
Detailed illustrations
For the
Hobby Foundry Worker.
ebook
Compiled By:
The Home Foundry Publications
Australia.
Permission granted to use drawings and material
By: C.W. Ammen
Manitou Springs Colorado USA.
Copyright 1996.
C.W. Ammen is one of the great pioneers
of the backyard hobby foundry movement.
Contents Page.
Gating & risering of metal castings. .................................................................3
The general rules for gates & riser...................................................................4
Gate ratio design..............................................................................................6
Spin Casting. ...................................................................................................7
Venting Green Sand Moulds. ...........................................................................8
Multiple Branch Gates......................................................................................9
Types of top gates. ........................................................................................10
Correct heights for cope & drag. ....................................................................11
Notched gates & risers for cast iron. ..............................................................12
Good riser design guide.................................................................................13
Styrofoam Blind Riser. ...................................................................................14
Correct shrink bob design. .............................................................................15
Horn gate Design. ..........................................................................................16
Chill Designs. .................................................................................................18
Chill application on wheel rim. .......................................................................19
Herring bone ingate design............................................................................20
Gates and risers is just one of the many operations & techniques required to
carry out metal casting successfully; it is also one of the areas that will give
hobby metal casters the most problems.
Nothing will kill a casting (or your enthusiasm for that matter) as quick as insufficient
feed metal from an incorrectly placed riser, or an ingate that delivers too little
metal to the mould cavity, leaving voids and an unfilled mould cavity.
On the other hand, a feeder or ingate that allows the metal to enter the mould
cavity at a great rush and volume will also create big problems for the
inexperienced metal caster.
The placement of gates and risers can be as complex as choosing where to
place multiple ingates for large castings, or choosing the ideal place for a
single ingate or riser on a single casting such as would be found in the home
hobby shop.
The gating & riser illustrations provided in this book will be of great value to
the novice or advanced metal caster alike, study the illustrations carefully.
These are gate & riser designs from a master foundry worker, principles
that were put to good use in many foundries C.W. Ammen managed over
a long period of time, in his long career in the foundry industry.
Compare the ideas and principles shown in this ebook with those that you are
currently using. If youre having problems with your castings, such as hot
tears, shrink cavities, and very bad porosity, then there is a good chance that
you will trace it back to the way you are feeding your castings.
The basic parts of a gating system is to allow the mould to be filled as rapidly
as possible with a minimum amount of turbulence, and to provide sufficient
hot metal to feed the casting during solidification to prevent shrinkage defects.
A given casting will solidify from the thinnest towards the heavy section. The
heavy section must be supplied with a riser or reservoir of hot metal, or it
would shrink as it gives up its liquid metal to feed the solidifying thin section. It
is essential to gate into the heavy section of the casting to provide it with feed
metal.
Always gate into the heaviest section of the casting to provide it with feed
metal. The metal entering the riser must be hot (the last metal to enter during
pouring) to promote feed metal based on directional solidification.
Very often, the amount of feeder metal left attached to the casting could very
well be about half the amount that was actually used to fill the mould cavity,
Gates & Risers reprint rights granted to myhomefoundry by C.W.Ammen.
Copyright 1996.
this wont always be the case, but the point we are making is Do Not Skimp
on the feed metal for your castings.
Is the riser neck too narrow, which will freeze too early and cut of the
feed metal supply before the casting has solidified?
These questions, and dozens more will present themselves every time that
you carry out moulding and metal casting, it is only through much experience
where you will come to a point which will enable you to asses a pattern, and
decide how you will feed and place risers for successful metal casting.
The following illustrations will help the hobby metal caster make an informed
decision regarding the correct method to gate and riser your castings.
This end of the
runner bar will
also act as a dirt
& dross catcher.
This method of
gating is normal
accepted practice
It is not unusual for the runner bar and gates to consume a considerable
amount of metal, if you only have a small capacity crucible, just be aware of
the total amount of metal you will use to pour the castings and runners etc.
Spin Casting.
Venting of green
sand moulds is one
of the most
important steps to
carry out as you go
through the
moulding process.
The vent holes act
as relief valves for
the steam that
builds up in the
sand mould during
the pouring of the
hot molten metal.
Green
sand
is
tempered
with
about 6% of water when working with aluminium, the drier and less water you
can use; the less steam will be generated during the pour. Unfortunately you
have to use water to condition your sand, otherwise it wont hold together
when the mould is rammed.
The only alternative to counteracting the moisture in the sand is to vent the
mould thoroughly, dont spare the vent holes! you need as many as you can
get into the sand. Take care during the venting procedure, do not press the
vent wire into the sand so hard as to damage the soft timber pattern, just ease
the vent wire down until you feel it touch the pattern, and then withdraw and
repeat the process over & over until the whole sand mould has been vented.
There are no short cuts to achieve good quality metal castings, you must
follow the guidelines and proper procedure at all times, as tedious as this may
soundthe quality of castings produced will only be as good as the total
preparation put into the moulding/casting session from start to finish.
If you follow poor procedures, then you will be rewarded with poor castings,
and this is the reason why so may people who try metal casting give up on the
hobby, the simple reason is that they dont understand why theyre not
achieving the success they desire.
The technique of green sand casting is centuries old; take a look at some of
the brilliant castings displayed in museums, produced by ancient civilisations.
Producing quality castings should not be a real problem today not even for
the dedicated hobby foundry worker.
Gates & Risers reprint rights granted to myhomefoundry by C.W.Ammen.
Copyright 1996.
Multiple branch
gates allow very
efficient feeding of
castings from a
runner and single
sprue, you may
need to refer back
to the design ratio
discussed in the
previous pages.
The
10
The height of the cope and drag is very important; the following illustrations
will give you material to study so that you can implement the correct height for
moulds being constructed.
They need to be right for the type of casting being produced, you neither need
them to be too high which means using too much sand nor too low in which
case there will be insufficient hydrostatic pressure in the sprue to maintain
enough pressure on the casting during the pour and solidification.
The illustration here
clearly shows that the
height of the cope & drag
are far too low. The
casting is too close to the
bottom mould board and
the height of the cope is
too low.
Insufficient pressure will
result from such a low
sprue height.
11
The
Study the illustrations above, they are really self-explanatory, and do not
require further explanation.
The neck core above is placed in this position which otherwise would be
impossible to notch with normal procedure, the neck core could be a dry sand
core ring, or baked sand core ring of a suitable size.
The size would need to be carefully calculated so as to not impede the flow of
feed metal back into the casting; otherwise shrinkage or hot tears may result.
12
Apply the principles of good riser design shown in the image at the top left
hand corner.
Be aware of the problems shown in the other images. The riser design, if
correctly done will ensure that sound castings will be delivered.
As a hobby caster the ideas shown on these pages should be an excellent
guide to good gate & riser design.
Gates & Risers reprint rights granted to myhomefoundry by C.W.Ammen.
Copyright 1996.
13
To make a styrofoam
riser, plain styrofoam
packing can be used to
good effect.
The shape can be
fashioned to resemble a
sphere but it is not
totally important, as long
as it is somewhere near
the shape shown here
the riser will work OK.
The Styrofoam riser method is an easy way to solve feeding problems that
would otherwise be very difficult to achieve, the secret to the whole idea is to
make sure the foam riser will stay captive in the sand and not break away
while the moulds are parted to remove the pattern.
With some practice and careful work, the process should not give many
problems, in fact this is a good intro to actually using full styrene foam
patterns instead of normal wood patterns etcbut this process is another
story, we wont be covering the use of foam patterns here.
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The
You should by now have a further understanding of the importance of gates &
risers in your casting work, hopefully you will give a little more thought to the
gating and riser arrangements required for good casting practice.
As we have mentioned previously, it is only when you have had some trial and
error experience with metal casting, that you realize just how important this
department of moulding is. It is just not good enough to scratch a channel in
the sand from the sprue to the casting cavity and hope for the best.
It is possible to make an effort and set out a carefully designed gating and
riser system for your castingsno matter how simple they are.
The more practice you have with this work the better you will become at
judging what kind of gating, eg size, quantity and areas needed for a
particular single or multiple casting set up. The many examples shown in this
ebook will be of great benefit to you.
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Foundry workers of days gone by always used the horn gate to feed a large
number of castings in green sand moulds. There is no reason why the hobby
foundry worker of today cannot apply the same techniques.
The horn gate allows infinite control over the speed at which the metal enters
the mould cavity, By looking at the horn gate design shown here, it is clear
that it is tapered from one end to the other, therefore the horn can be reversed
to allow a very calm non turbulent entry of molten metal to the mould cavity,
this is particularly useful when delicate parts of the sand mould are prone to
metal wash, such as during the casting of name plates & plaques with fine
letters and details etc.
The following illustrations will detail the design features of the horn gate, to
make one from wood will require a lot of patience and carving skill, an ideal
way would be to turn a taper on some flexible material, finish it very smoothly
and bend it and sand mould it, then pour an aluminium casting from it.
The casting would also require much hand finishing before you could use it.
This is the shape or design of the simple
horn-gate; the size will need to be chosen to
suit the casting jobs you have at hand.
There are no hard and fast rules as to how
you apply the design.
A horn gate could also be made by making a
core box designed to give a horn gate in the
shape of a U, the U would be a wide
shallow shape made up of two halves glued
together to form the horn gate, it would most
likely give as good a result as the traditional
horn gate.
The illustration above shows the drag upside down, it has been rammed with
the pattern and horn gate in place, and the next illustration will show the
mould has been turned right side up, ready to carry out the rest of the
operations.
16
17
An excellent material for the hobby worker is craft wood, this can be easily cut
& sanded to prepare and make permanent gates on pattern boards. This
technique is explained in the metal casting made easy foundry ebook.
Chill Designs.
Chills are placed in certain positions in sand moulds to act as denseners i.e.
to make the metal cool much quicker than the metal which is surrounded by
the cool moulding sand. This chilling effect has the effect of tightening the
molecular structure of the metal. Chills can be used to control the rate of
solidification towards a particular area of the casting. Chills are also used to
create dense metal in castings to be used as pressure castings, eg hydraulic
slave cylinders etc.
The small selection of chills shown here will give you some idea of the
many different shapes & sizes that can be applied to metal casting there is no
one set of chill design, it depends entirely on what you want to achieve.
I know of one case where a small foundry was casting small aluminium
clutch slave cylinders, the first batch ever made were so porous that fluid
sprayed out through the walls of the Al cylinder when under pressure, this
problem was not discovered until the cylinders were fully machined and
tested.
Many problems had to be solved, the first was insufficient feed metal
(risers) the second was solved by using steel chills on the ends and along the
Gates & Risers reprint rights granted to myhomefoundry by C.W.Ammen.
Copyright 1996.
18
barrel of the cylinder, chills made the metal as tight as a drum, & that was the
end of all the problems.
19
analyse where you went wrongif there are no notes how are you going to do
this?
20
Carry out some trial and error casting work to see what works best for you,
hobby casting as all about experimenting and learning the simple processes
that work well for you.
This ebook is not the last word on setting up gates and risers, there are many
other complex methods, which could be used, but the hobby caster would find
them too complex to implement.
Read over the material as many times as you need, to learn the methods
which will give you good results with your foundry, sand and working
methods.
We hope you have enjoyed reading and learning from this ebook.
If you need to contact us please use this email address
col@myhomefoundry.com
The web site URL is:
http://www.myhomefoundry.com
The home foundry publications
4058 Usshers Drive
Wangaratta
Victoria
Australia.
Other publications available.
The 3 - volume hobby metal casting ebook.
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