The Founding Process

The founding process: Metal objects can be produced in the form of castings after molten metal is spread on a mold.

Founding, or sometimes called casting, involves having a molten metal poured in a hollow mold to produce metal objects. The pattern which is to be enclosed in molds could be in the form of wood if only a few castings are to be produced. If they are in large numbers, the pattern could be in the form of metals, plastics, aluminum, etc. These patterns are then in an enlarged shape to give an exact size on the casting as it shrinks while being cooled. It also has to have 2 parts being connected by means of holes and sticks to make sure that they are properly aligned.

A mold consists of two separate wooden boxes having holes and other materials on it to make them fit properly together once they are connected. These boxes are also called flasks. They also don't have a top or bottom part. The upper box is called cape while the lower one is called drag. To start, a pattern is put on a flat plane while a drag is enclosed around it. The flask is then poured completely with molding sand. The other half of the pattern is placed on top of it. It is then sprinkled again with a dry,specialized type of sand called a parting sand. The cope is connected and placed on top of the drag and sand is poured on it. The patterns are then removed from the flasks and additional holes are drilled into the sand within the cope. Other pre-made patterns which are supposed to be the replicas of the metals that are gonna form in the mold are heated. It is then placed on the part of the sand where the other half of the pattern was removed.

Finally, molten metal is placed into a large container and poured in the mold. The casting is then left for a certain time until it cools down enough. Once it is, the casting is removed from the mold. The remaining mold is then discarded including the cores that keep on sticking around its edges.

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