ASM Handbook, Volume 15: Casting is a comprehensive reference on the principles and practice of metalcasting, covering fundamentals, process selection and parameters, and materials performance. This reference work is designed for those who s pecify, manufacture, design or evaluate cast metal components. This broad-based collection of applied casting knowledge provides a valuable resource for students, educators, practicing engineers, and technical support staff.
The latest edition of Volume 15 updates and expands coverage on the principles and practices of casting in several ways:
- Melt processing methods and equipment are described for iron, steel, and aluminum in terms of fluxing, degassing, molten metal filtration, refinement, and modification.
- Solidification, process modeling, and filling and feeding concepts are updated to reflect the continuing improvements in casting methods and processing.
- The major methods of green-sand, no-bake, and shell molding are described further in individual articles.
- Additional articles are devoted to the foundry practice of cast iron irons, steels, aluminum, copper alloys, and zinc. Expert updates are also provided on many other significant casting methods such as high-pressure die casting, lost-foam, squeeze casting, semisolid methods, spray casting, rapid solidification, and low-pressure die casting of high-integrity product.
- Automation technology is addressed, and coverage on continuous casting of aluminum and copper are expanded.
- Updated articles are also provided on the specification, selection, and properties of gray iron, ductile irons, malleable irons, compacted graphite irons, high-alloy irons, cast steels, aluminum, copper, zinc, magnesium, cobalt, nickel, titanium, zirconium, and cast metal matrix composites.
Contents
APPLICATIONS AND SPECIFICATION GUIDELINES
History and Trends of Metal Casting
Metalcasting Technology and the Purchasing Process
Casting Design Issues and Practices
Casting Design and Processes
PRINCIPLES OF LIQUID METAL PROCESSING
Chemical Thermodynamics and Kinetics
Thermodynamic Properties of Iron-Base Alloys
Thermodynamic Properties of Aluminum-Base and Copper-Base Alloys
Gases in Metals
Inclusion-Forming Reactions
MELTING AND REMELTING
Electric Arc Furnace Melting
Cupola Furnaces
Induction Furnaces
Vacuum Induction Melting
Electroslag Remelting
Vacuum Arc Remelting
Skull Melting
Electron Beam Melting
Plasma Melting and Heating
Crucible Furnaces
Reverberatory and Stack Furnaces
MOLTEN METAL PROCESSING AND HANDLING
Transfer and Treatment of Molten Metal—An Introduction
Degassing
Molten-Metal Filtration
Steel Melt Processing
Aluminum Fluxes and Fluxing Practice
Modification of Aluminum-Silicon Alloys
Grain Refinement of Aluminum Casting Alloys
Refinement of the Primary Silicon Phase in Hypereutectic Aluminum-Silicon Alloys
PRINCIPLES OF SOLIDIFICATION
Thermodynamics and Phase Diagrams
Nucleation Kinetics and Grain Refinement
Transport Phenomena During Solidification
Plane Front Solidification
Non-Plane Front Solidification
Eutectic Solidification—An Introduction
Solidification of Eutectic Alloys: Aluminum-Silicon
Solidification of Eutectic Alloys: Cast Iron
Peritectic Solidification
Microsegregation
Macrosegregation
Interpretation and Use of Cooling Curves—Thermal Analysis
X-Ray Imaging of Solidification Processes and Microstructure Evolution
The Oxide Film Defect: The Bifilm
Shrinkage Porosity and Gas Porosity
Castability—Fluidity and Hot Tearing
Semisolid Metal Processing
Spray Casting
Rapid Solidification
Solidification During Casting of Metal-Matrix Composites
Solidification Research in Microgravity
Homogenization
Heat Treatment
Hot Isostatic Pressing of Castings
MODELING AND ANALYSIS OF CASTING PROCESSES
Numerical Methods for Casting Applications
Modeling of Transport Phenomena and Electromagnetics
Direct Modeling of Structure Formation
Modeling of Microsegregation and Macrosegregation
Modeling of Stress, Distortion, and Hot Tearing
Practical Issues in Computer Simulation of Casting Processes
Thermophysical Properties
PRINCIPLES AND PRACTICES OF SHAPE CASTING
Shape Casting Processes—An Introduction
Patterns and Patternmaking
Casting Practice: Guidelines for Effective Production of Reliable Castings
Filling and Feeding System Concepts
Processing and Finishing of Castings
EXPANDABLE-MOLD CASTING PROCESSES WITH PERMANENT PATTERNS
Introduction: Expendable Mold Processes with Permanent Patterns
Aggregates and Binders for Expendable Molds
Green Sand Molding
No-Bake Sand Molding
Coremaking
Shell Molding and Shell Coremaking
Slurry Molding
No-Bond Sand Molding
EXPANDABLE-MOLD CASTING PROCESSES WITH EXPENDABLE PATTERNS
Introduction: Expendable Mold Processes with Expendable Patterns
Lost Foam Casting
Investment Casting
Replicast Molding
CENTRIFUGAL CASTING
Centrifugal Casting
Horizontal Centrifugal Casting
Vertical Centrifugal Casting
PERMANENT MOLD AND SEMIPERMANENT MOLD PROCESSES
Permanent Mold Casting
Low-Pressure Metal Casting
Low-Pressure Countergravity Casting
HIGH-PRESSURE DIE CASTING
High-Pressure Die Casting Hot Chamber
Die Casting Cold Chamber
Die Casting Squeeze Casting
Vacuum High-Pressure Die Casting
Die Casting Tooling
Automation in High-Pressure Die Casting
SEMISOLID CASTING
Semisolid Casting—Introduction and Fundamentals
Thixocasting
Rheocasting
Thixomolding
CAST IRONS
Introduction to Cast Irons
Cast Iron Foundry Practices
Gray Iron Castings
Ductile Iron Castings
Compacted Graphite Iron Castings
Malleable Iron Castings
White Iron and High-Alloyed Iron Castings
High-Alloy Graphitic Irons
STEEL CASTINGS
Steel Ingot Casting
Steel Continuous Casting
Shape Casting of Steel
Steel Castings Properties
Selection and Evaluation of Steel Castings
CASTING OF NONFERROUS ALLOYS
Nonferrous Casting—An Introduction
Dross, Melt Loss, and Fluxing of Light Alloy Melts
Aluminum Alloy Ingot Casting and Continuous Processes
Aluminum Shape Casting
Copper Continuous Casting
Casting of Copper and Copper Alloys
Casting of Zinc Alloys
NONFERROUS ALLOY CASTINGS
Aluminum and Aluminum Alloy Castings
Copper and Copper Alloy Castings
Zinc and Zinc Alloy Castings
Magnesium and Magnesium Alloys
Cobalt and Cobalt Alloy Castings
Nickel and Nickel Alloy Castings
Titanium and Titanium Alloy Castings
Zirconium and Zirconium Alloy Castings
Synthesis and Processing of Cast Metal-Matrix Composites and Their Applications
QUALITY ASSURANCE, NONDESTRUCTIVE EVALUATION, AND FAILURE ANALYSIS
Approaches to Measurement of Metal Quality
Nondestructive Testing of Components
Casting Fracture Characteristics
Casting Failure Analysis Techniques and Case Studies
Common Defects in Various Casting Processes
Repair Welding of Castings
Quality Planning Tools and Procedures
Maintenance, Repair, Alterations, and Storage of Patterns and Tooling
PROCESS DESIGN
Riser Design
Gating Design
Design for Economical Sand Molding
Design for Economical Coring
DESIGN AND GEOMETRY
Casting Design and Geometry
Design Problems Involving Thin Sections
Design Problems Involving Uniform Sections
Design Problems Involving Unequal Sections
Design Problems Involving Junctions
Design Problems Involving Distortion
REFERENCE INFORMATION
Abbreviations and Symbols: Casting