Foundry Trade Journal : with which is incorporated the iron and steel trades journal, Vol. 72, No. 1473

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WITH WHICH IS INCORPORATED T H E IR O N A N D S T E E L T R A D E S J O U R N A L

1-17J . N O V E M B E R 9 , 1944 r S in g le C o p y 6d . B y Po s t 8d.

I A n n u al S u b s c rip tio n . Hom e Registered at the C .P 0 . as a New spaper, Offices : 49, W ellin gton Street, S tran d , London, W . C . 2 La n d O ve rs e a s , 21 /- (Prep a id .)

3ULDING ICHINE C ° LTD

PIG IRON

1„

h i

RSHAM, KENT.

• H E M A T I T E ,

• S P E C I A L H E M A T I T E t j ,

• B A S I C Mallea le Trade]

S A N D C A S T or M A C H IN E C A S T Supplied by G U E S T K E E N B A L D W I N S IRON & STEEL CO. LTD., PORT TALBOT, ENGLAND

/ f / . ¡ h

JOHN A. SMEETON LTD.

76, A u c k l a n d R d ., L o n d o n , S . E . I S

‘ C O L L I N ’ IM P R O V E D F O U N D R Y L A D L E S

‘ P E R F E C T ’ C H I L L IN G S P I R A L S M A N U FA C TU R ED IN G R E A T B R ITA IN Sm e e tolim , W e s t n o r , Lo n d on L IV 292!

:D R E A D Y FOR USE AS R E Q U I R E !

I I O N (Mansfield) Si

p. THO? W.WARD LTD..

head office:-

Albion!

Teieoiicne; SHEFFIELD 26511 (15lines) MANSFIELD I

IliDAYS & ONIONS LTD-

B IR M IN G H A M I I Brer

S, S I

^{r I} I - A I I L m n \ # n v v rfle fo r U iuscraieo a ro m u "?

■EL F O U N D P i Y P L A N T S j.p arish& co.,erith,kent.

T H E E R I T H R A N G E O F S A N D S

C o m b in e a variety of selected L-OAMS a n d S1L.1 CA S A N D S of gu aran teed q u a lity , su ita b le for ev ery a p p ro p ria te fo u n d ry re q u ire m e n t. In a ll fu n d am en tal resp e c ts th ey are th e o u tsta n d in g sa n d s fo r p resen t-d ay p rac tic e , an d are trie d a n d proved by p erfo rm a n c e a n d resu lts.

W rite fo r illu strate d Brochu re and Free Sam ples t o : fcSl A B L I5 H E D > ^ T e l e p h o n e N o , : E R I " ”

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CORE OIL COMPOUNDS I

SEND F O R . IL L U S T R A T E D B R O C H U R E '

THE FORDATH ENGINEERING C° I

T E L E P H O N E

WEST BROMWICH 0549 (z unes)

HAMBLET WORKS WEST BROMWICH

T E L E C R A M S

METALLICAL,West Bromwich M IXIN G T IM E - - 2 MIN.

DISCHARGING T IM E Vl MIN. ^{s í}'Í Í BéI Í Í

,

“ N E W - T Y P E ” F O R D A T H M I X E R S are made in F IV E sizes, from 20 lbs. to I ton per batch.

F O U N D R Y T R A D E JO U R N A L

I N O V E M B E R 9, 1944

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N O V EM B ER 9, 1944 F O U N D R Y T R A D E JO U R N A L 3

B r i t i s h M o u l d i n g M a c h i n e C ^o . L ^{t d} .

The fa ct that goods made o f raw materials in short supply owing to war conditions are advertised In this paper should not be taken as an indication that they are necessarily available for export.

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F O U N D R Y T R A D E JO U R N A L N O V EM B ER 9, 1944

O n m y f a c t o r y . . .

I f o n l y b y e a s i n g the b u r d e n s o f l a b o u r , l i g h t a l l o y s w i l l p a y t h e i r w a y . B esid es t h i s t h e y w i l l s a v e p o w e r , o v e r c o m e c o r r o s i o n . U s e d a r c h i  t e c t u r a l l y t h e y w i l l s y m b o l i s e a b e t t e r a g e w h e n l i g h t n e s s a n d c l e a n l i n e s s g o w i t h s t r e n g t h a n d b e a u t y . T h e s e , t o o , are r e a s o n s w h y ^‘1 N T A L ’ a r e so p r o u d t o b e m a k e r s o f a l u m i n i u m a l l o y s f o r every c o n c e i v a b l e p u r p o s e .

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These furnaces may be used fo r melting in vacuo or under inert atmosphere, f u ll technical information from ;

E L E C T RI C FURNACE

CO. LTD.

t „ '

N E T H E R B Y , Q U E E N 'S R O A D , W E Y B R ID G E , S U R R E Y

Telephone: W eybrldge 3891 Telegrams: Eleetrifur Weybridge

Hi 51

. . . for trial h eats and e x p e rim e n ta l w o rk . . .

F u rn ace C apacities : 4 ozs. to 40 lbs.

S p ark G ap C onverters : 3 to 35 K.V.A.

E lectronic E quipm ent : 1 to 50 K.V.A.

Motor G en e ra to r Sets : 10 to 45 K .W . L arg er sets fo r production output.

the E F C O h ig h frequency

furnace . . . ideal for m eltin g

special heats o f copper, alu

m in iu m , b ron ze, brass, iron,

steel, n ick el, silver, g o ld ,

platinum , irid iu m , palladium ,

rh od iu m , etc., etc.

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F O U N D R Y T R A D E JO U R N A L N O V EM B ER 9, 1944

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The Pneulec Jarr Squeeze Stripper is designed for pro

duction work. Only a few jarrs are required to settle the sand, and the mould is then squeezed up hard against the crosshead. The pattern is withdrawn on the return down stroke, which demands accurate, rigid pattern equip

ment. W e use long oversize pistons giving plenty of power and providing additional guide and support. The extra cost of this construction is justi

fied, both by the speed of o p e r a t i o n and t h e l ong accurate life of the machine.

Please ask for illustrated

folder. *

B u i l t i n E n g l a n d b y

P N E U L E C L I M I T E D , S M E T H W I C K , N r . B I R M I N G H A M

J R R R

S Q U E E Z E

S T R I P

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F O U N D R Y T R A D E JO U R N A L N O V E M B E R 9, 1944

The war has given high-duty iron castings an opportunity not only to play an important part in essential production but to demonstrate its poten

tialities as a factor seriously to be reckoned with in post

war re-construction plans. It has accelerated the pace of research work on pig iron carried out by BRADLEY &

FOSTER over a long period.

B R A D L E Y &

D A R L A S T O N •

^ M A K E R S O F

BRADLEY & FOSTER have developed grades of pig iron treated by the Bradley spun- refining process and subject to chemical analysis and mechanical tests at every stage of production which satisfy specifications previously con

sidered to be outside the range of cast iron. We shall be glad to discuss the application of refined pig iron to the produc

tion of high-duty castings in your foundry.

F O S T E R ^ltd I

S O U T H S T A F F S

{

Spun-refined pig irons.

Spun-refined alloy pig ¡rong B lended “ All Mine " p jg ¡ron H ig h ca rb o n steel pig iron F ire-resistin g pig iron.

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N O V E M B E R 9, 1944 F O U N D R Y T R A D E JO U R N A L 9

“ R A M O L I T H ”

(REGISTERED)

FOR LINING FURNACE DOORS

NO BRICKS TO FALL OUT

T H O M A S E . G R A Y & C O . LT D . G R A N B Y C H A M B E R S , K E T T E R IN G

ES T A B LIS H ED 1877.

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10 F O U N D R Y T R A D E JO U R N A L N O V E M B E R 9, 1944

B A L L A R D CON™ 0" ,S I

G A S O R C O K E F I R E D

We also m an u factu re S h e lf T ype, D raw er T ype a n d Bogie T yp e UNIFORMITY OF BAKE ASSURED

SAYING IN FLOOR SPACE

CONTINUITY OF OPERATION

NO ESCAPE OF FUMES INTO SHOP

Illu stra tio n o f C oke-üred C ontinuous Core OveD

Consult: F. J. BALLARD & CO., LTD.

TIVIDALE • TIPTON r STAFFS.

Phone: T IP T O N 1281-3.

G A B R i E L & ^{C ° -} L td .

Telephone No. :

B IR M IN G H A M .

Telegraphic Address :

A STO N CROSS 0756/7/8 ■' G A B R IE L , BIRM IN G H A M

BEG TO ADVISE THE ENGINEERING AND ALLIED TRADES TH AT THEY ARE NOW IN A P O S IT IO N TO S U PPL Y

SMALL

A LLO Y STEEL CASTINGS

(5 to 40 Lbs.)

M A Y W E R E C E IV E Y O U R E N Q U I R I E S ?

A L L C O M M U N I C A T IO N S T O T H E R E G . O F F IC E S , 4 & S, A . B . R O W , B IR M IN G H A M

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KEITH BLACKMAN LTD., MILL MEAD ROAD, L O N D O N , N.I7. TOTTENHAM 4522. TA. : ” KEITH BLAC PH ONE LO N D O N .”

r

A new re-circulating FAN for

HEAT TREATM ENT FURNACES

N O V EM B ER 9, 1944 F O U N D R Y T R A D E J O U R N A L I I

T h is new p a te n te d u n it is a v e ry stro n g ly c o n stru cted p ropeller ty p e fan for in te rn a l circu latio n of high te m p e ra tu re gases an d a ir on v ario u s ty p es of h eat tr e a tm e n t furnaces. C o n stru cted in sh eet or cast m etals, a n d expressly designed for h an d lin g e x tre n cly h igh te m p e ra tu re gases.

FURNAC

47, W O L S E Y R O A D ,

E A S T M O L E S E Y , S U R R E Y . T E L E P H O N E S :

M O L E S E Y 3 1 1 1 -2

T e l e g r a m i i M E T A S T E I N A . P H O N E .L O N D O N

If you are in terested , we shall be pleased to send you full p articu la rs.

S T E IN & A T K I N S O N L TD-

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S C R E E N A R A T O R

F O R R A P I D S A N D C O N D I T I O N I N G

★ P ow erfu l gyro-reciprocating m otion of riddle.

★ D riving gear totally en closed .

★ Sturdy construction throughout.

★ P u sh button electric control.

★ C leans, aerates, and delivers sand clear of m ach in e.

★ A n efficient labour-saving unit.

F O U N D R Y P L A N T & M A C H IN E R Y LT D . 13

wgl

S J ST

K N O C K - O U T B A R

FO R , S M A L L M O U L D S " S A N D

D I S C H A R G E S P O Ü T (A N G L E A D J U S T A B L E )

\ P U S H B U T T O N

“I S W IT C H

F E E D IN G H O P P E R

I M P E L L E R C A S IN G D U S T P R O O F

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B R I T I S H I N S U L A T E D C A B L E S L T D .

P R E S C O T — L A N C S . T e l e p h o n e P R E S C O T 6S71.

Selected high grade raw material and careful technical control at all stages of manu

facture from the mine to the loading bank ensure the con

s iste n t high q u a l i t y of NETTLE (42/44% Alumina) Firebrick.

CREOSOTE-PITCH F IR IN G : A n u m b e r o f firm s ad o p tin g th is fuel have e n co u n te red n e w R e fra c to ry P ro b le m s caused by C o r ro s io n and V itr ific a tio n S p allin g. B u t. if a s u ita b le design o f b u r n e r is used, the tro u b le can usually be o v e rco m e by using a H ig h A lu m in a F ir e b r ic k such as N E T T L E — a p o in t phoved by the p ra ctica l e x p e rie n c e of se ve ral cu sto m e rs. A n ad d itio n al p r o te c tio n to th e b r ic k w o r k b y w ash co atin g w ith M ak siccar II o r S te in S llllm a n ite C e m e n t w ill often be found e co n o m ic. F u r th e r in fo rm a tio n w ill be gladly su p p lied on req u est.

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14 F O U N D R Y T R A D E JO U R N A L N O V E M B E R 9, I9<w

Y ou c a n h a v e It b o th w a y s !

There is something to be said for the conservative method of manufacturing pig iron with plenty of limestone in the charge— it does keep down the sulphur content of the iron. There is a lot more to be said for the modern tendency to operate the blast furnace with a leaner burden and thus increase output — maximum iron production needs no brief in these days. No, we are not overlooking the resulting additional sulphur pick-up, but you can — if you treat the iron in the ladle with Sodium

Carbonate. I n the case of most grades of cast iron, treatment in the ladle with 1% dense sodium carbonate removes 50% of the sulphur present in the metal. Simple, effective, economically increased output.

I M P E R I A L C H E M I C A L I N D U S T R I E S L I M I T t u

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Iron, Steel and Brass Foundry Melting Equip

ments are our Speciality

C U PO LA S, STEEL C O N V ER T ER S, C R U C IBLE A N D N O N - C R U C IB LE FU R N A C ES, C U PO LA C H A R G IN G M A C H IN ES, H O ISTS, M OTO R FANS, LAD LES, SA N D MILLS A N D SIFTERS, RU M B LER S, PIG IR O N B R E A K IN G M AC H IN ES,

R O T A R Y C O R E M A C H IN ES, ETC.

G E O R G E G R E E N & C O .

Foundry Equipment Engineers & Contractors

K E I G H L E Y , Y O R K S .

(E sta b lish e d 1900)

T e l e g r a m s : “ C u p o la ,” K e ig h le y . T e le p h o n e : 2518 Ke ig h le y.

1 - f l \ l ' ; Ï o J t I u p l y Established 1902

in H 1 . U . M

WITH WHICH IS INCORPORATED T H E IR O N A N D S T E E L T R A D E S JO U R N A L

49, W e llin g to n S tre e t, London, W . C J L

W A R T I M E A D D R E S S to w hich all communications should be sent I—

3, A m e ra h a m R o ad , H I G H W Y C O M B E , B u cks, 'G ram s I “ Zacatecas, High W y c o m b e ."

'P h o n e i H IG H W Y C O M B E 1792 (3 lines).

P U B L I S H E D W E E K L Y i 21s. per annum (H o m e and O v e rs e a i)

O F F IC IA L O R G A N O F i

C O U N C I L O F I R O N F O U N D R Y A S S O C I A T I O N S C h ilrm a n i F ltz H e rb e rt W r ig h t, The B u tte rle y Com pany, Rip ley, near D erby. S e cretary i V . D e lp o rt, 2, Caxton Stre e t, W e s tm in s te r.

S . W . I .

Participating Associations I B ritish Bath M anufacturers' A ssociation B ritish Iron fou n ders’ Association ; British M alleable Tube Fittings A ssociation ; Cast Iron A x le b o x Association ; Cast Iron C h a ir Associa

tion ; Cast Iron Heating. B o ile r and Radiator M anufacturers' Association ; Cast Iron Segm ent A ssociation ; Greensand Pip e Fou n d e rs'A ssociation of S co tlan d ; Iron fou n ders’ N atio n al Confederation ; N atio n al Associa

tion of M alleable Ironfounders ; N atio n al Ingot M ould Association ; N atio n al Ironfoun ding E m p lo y e rs ’ F e d e ra tio n A s s o c ia tio n o f A u to m o b ile and A llie d H ig h D u ty Iro n fo u n d e rs ; B ritis h Cast Iron Research Association (a ffilia te d ): British G r it A ssociation (affiliated);

Flushing C is te rn M ak ers’ A ssociation (affiliated) ; In s titu te o f B ritish F ou n d rym en (affiliated ). ______

I N S T I T U T F O F B R I T I S H F O U N D R Y M E N P R E S ID E N T , 1944-45 : Jo h n W . G ard o m , R ip le y D e r b y s h ir e . G e n e ral S e cretary i T. Makemson. A ctin g S e c re ta ry , J . Bolto n Saint Jo h n S tre e t Cham bers, Deansgate, M anchester 3.

B R A N C H E S

Birm ingham , C o v e n try and W e s t Midlands i A . A . Tim m ins, F .I.C . 33. C a r t e r s Lane, Q u in to n . B ris to l and W e s t o f E n g la n d : A . Hares, 20, G r e e n b a n k Ro ad , H a n h am , B ristol. E. M idlands I S. A . H o rto n " T h r e e , ’’ M ostyn A ven ue, L lttle o v e r, D e rb y. Lancs t H . B u c k ley. Elle sm e re, N o r fo lk A v e n u e , B u rn le y . London i V . C . Fau lkn er, 3, Am ersham Road, High W yco m b e . Middlesbrough (pro tem.) i J. K . Smithson, N orth-Eastern Iron Refining Com pany, Lim ited, Stilllngton, Stockton-on-Tees. Newcastle-upon-Tyne i C . Lashly, S ir W . G . A r m strong, W h itw o r t h & C o . (Ironfounders), Ltd ., Close W o r k s , Gateshead Scottish i J. Bell, 60, St. Enoch Square, Glasgow. Sheffield : T . R. W a l k e r, M .A ., English S te e l C o rp o ra tio n , L td ., Sheffield. W a le s and M onm outh i A . S. W a ll, 14, P a la ce A v e n u e , Llandaff, C ard iff. W e s t Riding o f Y o r k s h ir e : D ouglas Jep son , M .Sc., 9, A m bleside A v en u e, Bra d fo rd . South A frica : B . P. Sko k, M utual Building, Johannesburg.

S E C T IO N S

B u r n le y ! H. Bu ckley, Ellesm ere, N o rfo lk A ven u e, B u rn le y, Lancs.

C ap e T o w n : K . Z w a n z L e r , P .O . B o x 346, C ape T o w n , S. A frica.

East Anglian i A . N . S u m n e r, 516, N o r w ic h Road, Ipswich F a lk ir k : T. R. G o o d w in . " V le w fie ld ," Falkirk Road, Bonnybridge. Lincoln i E.

R . W a lt e r , P h .D ., T h e Technical College, Lincoln.

A S S O C I A T I O N O F B R O N Z E A N D B R A S S F O U N D E R S P re s id e n t : H . BlsselJ, J. S to n e & C o ., L td ., Lo n d o n . S e c re ta rie s : H e ath co te & C o lem an , 25, B e n n e tts H ill, Birm in gh am , 2

T H E I N S T I T U T E O F V I T R E O U S E N A M E L L E R S Presid en t i W . H . W h it t le , W . H. W h it t le , Lim ited , Eccles, near M anchester. Chairm an i W . To d d , Park in so n S to v e C o .. L td ., Stech- fo rd , B irm in g h am . Hon. Sec. i W . Thom as, A .I.C ., B a n k H ouse, H igh S tr e e t, R ick m an sw o rth , H e rts.

F O U N D R Y T R A D E S ' E Q U I P M E N T A N D S U P P L I E S A S S O C I A T I O N

P r e s id e n t : D . C h e r r y Pate rs o n , M .I M e ch .E., B ed fo rd H ouse, Bed

fo rd S tr e e t, S tra n d , London, W .C . 2 . H o n o ra ry S e c r e t a r y : K. W . B rid g es. A ssistan t S e cre ta ry : Miss L. C o x , 52, Su rb ito n H ill Park , S u rb ito n , S u rrey.

W E L S H E N G I N E E R S ’ A N D F O U N D E R S ' A S S O C I A T I O N Presiden t i W . E. C le m e n t, C .B .E ., M orfa Foundry, N e w D ock, Llan elly S e cretary i J- D . D . Davis, I, St. Jam es G ardens, Swansea.

B R I T I S H C A S T I R O N R E S E A R C H A S S O C I A T I O N A lv e c h u rc h , B irm in g h a m . 'P h o n e and 'G r a m s : R e d d ltch 716.

S c o ttis h L a b o r a to r ie s !— F o u n d ry T e ch n ica l in s tit u te ,M e e k 's R o a d , F a lk ir k . (P h o n e I 3 3 Z f

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T h e n e e d f o r a ll p o s s ib le c o n s e r v a tio n o f m a n p o w e r ; th e d e m a n d f o r th e m a x im u m o u t p u t o f v ita l c a s t m e ta llic p r o d u c ts ; th e in s is te n c e u p o n t h e lo w e s t c o s t o f p r o d u c t i o n ; a n d th e n e c e s s ity o f m a in ta in in g , a n d e v e n im p r o v in g , th e q u a lity o f th o s e p r o d u c t s .

A ll th e s e c o n d itio n s c o m b in e to p o i n t to t h e o n ly s a tis f a c to r y s o l u t i o n t o a ll th e s e p r o b le m s —

b u t i t m u s t b e m e c h a n is a tio n p a r tic u la r ly c o n s id e r e d , d e s ig n e d a n d a d a p te d to th e i n d iv id u a l s ite c o n d i t i o n s ; t o th e p a r tic u la r p r o d u c t ; a n d w ith fu ll r e g a r d t o a ll t h e fa c to r s , e c o n o m ic , g e o g ra p h ic a l a n d h u m a n , w h ic h m a y h a v e a n y b e a rin g o n th e p r o b l e m .

I n o t h e r w o r d s c o n s u l t :—

“ The Specialists in F oun dry M echanisation"

M E C H A N I S A T I O N

w h o s e p r o d u c t s

"

S et th e Standard b y which F ou n dry Plant is j u d g e d

LIMITED

'Ph ones : 61247 &. 8

HALIFAX, ENG LAND

’G ram s : August, H a l i f a x Sole Licensees a n d m a n u f a c t u r e r s for B ritish E m p ir e ( e x c lu d in g C a n a d a ) o f the S i m p s o n S a n d M ixer

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F oundry Trade Journal, Sorember 9, 1944

established 1902

M l l r H E f

WITH WNKH S m c o v o u m TH E IK O N A N D STEEL TRADES JO U RN AL

Vol. 74 Thursday, November 9, 1944 No. 1473

The Future fo r Trade Associations

W e w o u ld lik e to see e v e ry f o u n d r y o w n e r in p o ss e s sio n o f “ T h e O r g a n is a tio n o f B ritish I n d u s tr y ,” w h ic h is a R e p o r t ju s t issu e d b y a C o m m itte e o f th e F e d e r a tio n o f B ritish in d u s tr ie s , b e c a u se it c le a r s u p so m a n y m is c o n c e p tio n s h e ld by th e in n a te in d iv id u a lis t. M o r e o v e r , it is th e m o st f o r w a r d - lo o k in g d o c u m e n t a s to th e d ir e c tio n s w h ic h p o s t- w a r b u s in e s s w ill ta k e t h a t w e h a v e s o f a r e n c o u n te r e d . E v e r y b o d y n o w is th in k in g a b o u t d e c o n tr o l; it is re a lis e d t h a t th e s o lu tio n o f th is d iffic u lt p r o b le m w ill h a v e , fo r g o o d o r ill, f a r - r e a c h in g effects. It se e m s to us th a t th e G o v e r n m e n t d e p a r tm e n ts w ill b e a b le to liq u id a te th e c o n tr o ls b o t h q u ic k e r a n d m o r e efficien tly i f th e y c a n d e a l w ith re a lly r e p r e s e n ta tiv e tr a d e a s s o c ia tio n s t h a n w ith n u m b e r le s s in d i

v id u a l firm s .

T h e R e p o r t c o n firm s w h a t w e h a v e a lr e a d y fo u n d in p r a c tic e , a n d t h a t is th e E x p o r t G r o u p s c a n n o t u s e fu lly c o n tin u e t o b e d iv o r c e d f r o m th e a c tiv itie s o f th e c o r r e s p o n d in g tr a d e a s s o c ia tio n Y e t u n d e r e x is tin g c o n d itio n s th e r e r e m a in s th e d ifficu lty t h a t w h ils t th e l a t t e r is o b v io u s ly s e le c tive a s to m e m b e rs h ip , th e f o r m e r a r e b y la w o p e n to a n y f irm p r e p a r e d to p a y th e fe es in v o g u e . T h e a d v ic e o f th e R e p o r t is “ T h e c o u r s e to be p u r s u e d s h o u ld b e t h a t w h e re tr a d e a s s o c ia tio n s ex ist th e ir f u n c tio n s s h o u ld b e e x te n d e d to c o v e r th o se o f th é c o r r e s p o n d in g e x p o r t g ro u p s , a s th e la tte r a r e n o t f itte d to d e a l w ith th e w o r k o f tr a d e a s s o c ia tio n s .”

A n e x c e lle n t p ie c e o f a d v ic e is g iv en a s to th e m ain o b je c tiv e f o r tr a d e a s s o c ia tio n s , w h ic h in s h o r t is— g iv e s e rv ic e to th e c o n s u m e r o f y o u r p ro d u c ts , p lu s a n e q u a l se rv ice to th e n a tio n at larg e. T h e s e c o n d f u n c tio n is n o w a d a y s m a d e p o ss ib le as so m a n y G o v e r n m e n t d e p a r tm e n ts — th o u g h n o t a ll— p r e f e r to d e a l w ith tr a d e a s so c ia - tionsT T h e e n th u s ia s m f o r th e c o n tin u a tio n o f th e c o n ta c ts e s ta b lis h e d w ill o b v io u s ly d e p e n d o n th e in te g r ity a n d c a p a b ility s h o w n b y th e o fficers o f th e tr a d e a s s o c ia tio n s . W e w o u ld e sp e c ia lly d ir e c t th e a tte n tio n o f f o u n d r y p r o p r ie to r s to c la u s e 10 o f th e R e p o r t, w h ic h d e ta ils th e f u n c

tio n s o f tr a d e a s s o c ia tio n s . T h e y a r e so c o m p le te t h a t th e y s h o u ld b e th e b a sis o f th e ir A rtic le s o f A s s o c ia tio n . T h e y n u m b e r 12, a n d e a c h o n e c o u ld v e ry w ell c a r r y a s u b -c o m m itte e to see th a t e a c h f u n c tio n is p r o p e rly p e rfo rm e d . W h e re an a s s o c ia tio n is to o s m a ll to c a r r y o u t a p re s c rib e d f u n c tio n , th e n it s h o u ld a ss o c ia te its e lf w ith a g r o u p o f o th e r s sim ila rly p la c e d f o r jo in t a c tio n .

T h e 12 C o m m itte e s m ig h t c a r r y th e fo llo w in g t i t l e s : — P o lic y ( f o r tr e a tin g w ith G o v e r n m e n t c o m m itte e s ); C o - o r d in a tio n ( f o r n e g o tia tio n s w it!

o th e r o r g a n is e d a c tiv itie s); P r o d u c tio n (to alig n p r o d u c tio n w ith c o n s u m p tio n ) ; F a i r T r a d in g ; I n t e r n a tio n a l R e la tio n s (to tr e a t w ith o p p o s ite n u m b e r s a b r o a d ) ; S ta tis tic a l; C o s tin g ; E x p o r t; P r o p a g a n d a ; R e s e a rc h ; E d u c a tio n ; a n d C o m m e rc ia l D e v e lo p m e n t ( s ta n d a r d is a tio n , d e sig n , etc.). T h e o r g a n is a tio n o f su c h C o m m itte e s w o u ld h e lp to m a in ta in in te r e s t in th e A s s o c ia tio n s b y s p re a d in g th e w o rk o v e r a la r g e r n u m b e r o f m e m b e rs , o r if th e A s s o c ia tio n b e to o sm a ll, a r e q u e s t t h a t a r e p re s e n ta tiv e b e a p p o in te d to th e c o m m itte e o f an a llie d a s s o c ia tio n ; a c o -o p e ra tiv e re s e a rc h o r g a n is a tio n o r a te c h n ic a l in s titu te w o u ld r a re ly b e re fu s e d . T h e m a in f a c to r is th a t n o t o n e o f th ese f u n c tio n s s h o u ld b e n e g le c te d .

W e w a n t e v e ry s m a ll fo u n d ry ' o w n e r to a ss o c ia te h im s e lf w ith th e tr a d e a s s o c ia tio n s a n d to m a k e h im s e lf h e a rd . H e h a s h is sp e c ia l p ro b le m s w h ic h a n y w e ll o rg a n is e d a s s o c ia tio n is c a p a b le o f so lv in g . If, a s w e b e lie v e, tr a d e a s s o c ia tio n s w ill b e a c c o rd e d G o v e r n m e n t re c o g n itio n , th e r e w ill b e an o n u s im p o s e d u p o n th e m to m a k e th e in d u s try c o n c e rn e d tru ly efficient, a n d th is c a n o n ly b e a tta in e d b y g iv in g a d d e d a tte n tio n to th e s m a lle r u n its . Contents

T h e F u t u r e o f T r a d e A ss o c ia tio n s, 191.—N o te s fro m th e B ra n c h e s , 192.—I n s t i t u t e C a le n d a r , 192.—T h e M e c h a n is e d P r o d u c tio n o f A lu m in iu m G r a v it y D ie -C a s tin g s fo r th e M e rlin E n g i n e , 193.—R e i n s t a te m e n t in C iv il E m p lo y m e n t, 199.—I r o n - f o u n d r y F u e l N e w s —X X V I I I . 200.—T y r e U p k e e p , 200.—B r it is h S ta n d a r d s I n s t i t u t i o n . 200.—Z in c D e v e lo p m e n t A ss o e ia tic n . 200.—T h e S id e F e e d in g o f S te e l C a s tin g s , 201.—B o o k R ev iew . 204.—U s i n g W a r E x p e r ie n c e fo r P e a c e P r o d u c tio n , 206.—F ro m W a r to P e a c e P r o d u c tio n , 206.—P e r s o n a l, 208.—O b itu a r y , 208.—

F ir th - B r o w n A p p o in tm e n ts , 210.—I r o n a n d S tee l I n s t i t u t e , 210.—C o n tr a c ts O p en . 210.—N e w s in B r ie f , 210.—P a r li a m e n ta r y N o te s , 210.—R a w M a te r ia l M a r k e ts . 212.—C o m p a n y R e s u lts.

212.

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192 F O U N D R Y T R A D E JO U R N A L N O V E M B E R 9. 1944

NOTES FROM THE BRAN C H ES

S cottish B ranch.— T h e b ran ch opened th e session on O cto b er 14 with a reco rd a tte n d an ce o f a b o u t 160, including m em bers a n d friends. M r. Y oung, the retiring P resident, w as in the chair, a n d th an k e d the m em bers fo r the su p p o rt given him last y ear, a su p p o rt which, he said, according to the a tte n d an c e a t this m eeting, was likely to be im proved u p o n in the session on w hich they h a d ju st entered. H e c o n g ratu la ted the m em bers on their choice of P resid e n t fo r 1944-45, an d assured th em th a t by training, experience, an d tem p eram en t, M r. T y rie is well fitted fo r his duties.

He h a d p leasure in asking M r. T y rie t® ta k e th e chair.

Mr. Ty r i e, whose Presidential A ddress will ap p e a r in a fu tu re issue, th a n k e d the m em bers fo r th e m ag n i

ficent atten d an ce a t th e opening m eeting, a n d expressed the h o p e th at this sta n d ard w ou ld b e m ain tain ed d u r

ing th e session. H e also th an k e d M r. Y o u n g f o r the fine m an n er in w hich he h a d conducted the affairs of the b ra n ch last session, a n d fo r having b ro u g h t it up to its p resent high stan d ard . A fte r the P residential A ddress, M r. Jo h n Vickers intro d u ced the so u n d film,

“ W artim e C alls o n W om en to m ak e A lu m in iu m A ir- cooled C y lin d er H e ad s.” H e gave a resum e o f the film, an d referred to the p rin cip al p o in ts to be noted, and, at the conclusion, he rep lied to one o r tw o p oints w hich w ere raised by m em bers. T h e o p p o rtu n ity w as tak en also to show an o th e r so u n d film —a new s reel—

a n d fo r this an d the use o f the so u n d p ro jec to r the branch is indebted to M r. D avid M u rray , th e Scottish Regional W orks R elatio n s Officer, M inistry o f Supply, an d his staff.

L o n d o n Branch.—T h ere was a reco rd a tte n d ance of m em bers w hen M r. M alcolm Brown, w orks m an a g er o f H adfields, L im ited, o f Sheffield, addressed th em on th e subject o f “ Steel C astings ” at the C h arin g C ross H o te l recently. M r. A. J.

M urphy, M .Sc., acting president, was in the chair. T h e lecturer, by m eans o f sam ples an d lantern slides, d etailed the successful m an u fa ctu re o f a co m plicated a irc raft casting. H e outlined the difficulties both persistent and tran sien t w hich h ad been overcom e.

A fter a prolo n g ed an d interesting discussion, he was cordially th an k e d on b e h alf o f the m em bers by M r.

F ra n k R ow e an d M r. P. F assotte. It w as anno u n ced that in place o f the sym posium on “ M o u ld ing B oxes,” scheduled to take place a t 2.30 p.m . on N o v em b er 18 a t th e C h arin g C ross H o tel, D r. Skerl h a d kin d ly consented to present a P a p e r on “ R ecent D evelopm ents in C orem aking M aterials.”

B risto l an d W est o f E n g la n d Branch.— T h e new session opened on O cto b er 7 at th e G ra n d H o te l, Bristol, M r. E. Griffin presiding. M r. J. W . G a rd o m , the P resident o f the Institute, w as also present, a n d in a sh o rt address expressed his p leasu re a t th e progress m ade b y the b ran ch an d the en th u siasm show n by th e m em bers. M r. F . A. A llen p resented a P a p e r on

“ Statistical Q uality C o n tro l o f L ig h t A llo y C astin g s,”

w hich was follow ed by h igh tea an d a concert.

S A V E P A P E R W H E N Y O U C A N

IN ST IT U T E C A LEN D A R

M EET IN G S FOR N O V E M B E R

M id d lesb ro u g h B ranch.— “ M ech an ical A ids to C o re P ro d u ctio n ,” by J. B lak isto n , A .M .I.M ec h .E . A t the C leveland T ech n ical In stitu te , M id d lesb ro u g h , N o v e m ber 10, a t 7.30 p.m .

B ristol B ranch.— “ W artim e C alls on W o m e n to M ake A lu m in iu m A ir-co o led C y lin d e r H ead s ” (sound film). A lso a film on “ P ig -iro n P ro d u c tio n .” A t the G ra n d H otel, B road S treet, B ristol, N o v e m b e r 11, at 3.0 p.m.

Lancashire Branch.— ' G ra v ity D ie-castin g s,” by A. R. P alm er. A t the E n g in eers’ C lu b , A lb e rt S quare, M anchester, N o v e m b er 11, a t 3.0 p.m .

L in co ln Section.— “ F o u n d ry L o ad in g an d P la n n in g ,”

by A. T ipper. A t the T ech n ical C o lleg e, L incoln, N o v e m b er 11, a t 3.0 p.m.

Scottish B ranch.— 1944 “ Jo h n S u r te e s ” G o ld M edal Papers will be read by the w in n e rs: R. D. C h e y n e and J. G. N isbet. S u b ject: “ T h e B asic P rin c ip le s Involved in the F eeding of C astings a n d the M a n n e r in which T hey M ay Be A pplied in P ractice. P a rtic u la rly in the C ase of M etals an d A lloys w hich S h o w a H ig h S h rin k age.” P resen tatio n o f In stitu te D ip lo m a s. A t the R oyal T echnical C ollege, G eo rg e S treet, G lasgow , N o v em b er 11, a t 3.0 p.m .

W est R id in g o f Y o rksh ire B ra n ch .— “ W h a t the E n g i

neer E xpects fro m the F o u n d ry ,” by W . P. E astw o o d , M .I.P.E. R eplied to by A. S. W o rcester, rep rese n tin g the fo u n d ry trad e A t the T ech n ica l C ollege. B radford.

N o v em b er 11, a t 6.30 p.m .

E ast M id la n d s Branch.— “ C u p o la C o n tro l,” by C . A.

Payne, B.Sc. A t the T ech n ical C ollege, D erb y , N o v e m ber 18, a t 6.0 p.m .

F a lkirk Sectio n .— “ T h e D esign an d T estin g o f Space H e ate rs,” by J. S. H ales, B.Sc. A t th e S m oke R oom . T em p eran ce C afé, L in t Riggs, F a lk irk , N o v e m b e r 24.

at 7.0 p.m.

B irm in g h a m B ranch.— “ T h e P rin cip les o f M e c h an i

cal H a n d lin g ,” by J. V. Sm ith. A t the Ja m es W att In stitu te, G re a t C h a rle s S treet. B irm in g h a m , N o v e m

b e r 25, a t 2.30 p.m . *

S heffield B ranch.— Jo in t m eetin g w ith th e Iro n and Steel In stitu te. D iscu ssio n o f P a p e r on “ T h e Side F eed in g o f Steel C a stin g s— A N o te on th e Influence of the M ech an ism of F re e zin g ,” b y B. G ra y . A t the R o y al V icto ria H o te l, Sheffield, N o v e m b e r 27, at 7.0 p.m .

T h e M inistry o f Labour and N ational Service has issued a n “ In d u strial R e la tio n s H a n d b o o k ,” p re p are d orig in ally fo r the use o f officers of the M in istry of L a b o u r an d N a tio n a l Service. It h a s now b een issued fo r general p u b licatio n in the belief th a t the in fo rm a tion co n ta in ed in it will be o f w id er interest p a rtic u lari y to e m p lo y ers’ o rg an isatio n s an d trad ^ u n io n s C opies m ay be o rd ered direct fro m H .M . Station«™

Office. L o n d o n (price 3s. 6d. net). a tio n ery

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THE MECHANISED PRODUCTION OF ALUMINIUM GRAVITY DIE-CASTINGS

FOR THE MERLIN ENGINE

By JO H N VICKERS

This paper, which was presented to the 4 1 st annual m eeting o f the Institute o f British Fouttdrymen held in M anchester, was also sent to the Am erican Foundry m en 's Association as an official E xchange Paper. Properly to appreciate this Paper, reference should be made to M r. V ickers' earlier Paper covering the m anufacture o f the

sand-cast components. It appeared in the Proceedings o f the I.B.F. fo r 1942-43.

Advantages o f g ravity die-casting over sand castings

P A R T 1.

Speaking b ro ad ly o f the alu m in iu m alloy castings on the liquid co o led aero-engines o f R olls-R oyce, Lim ited, experience h as show n th at invariab ly w here a p a rt co u ld be p ro d u ced as a gravity die-casting, m any ad v an tag es w ere possible over sand cast

ings. T h e p rin cip al o f these c a n be sum m arised as follow :— (a) S m o o th er finish a n d closer dim ensional accuracy; (6) greater possible speed of p ro d u c tio n ; (c) con serv atio n o f raw m ate ria l; (d) red u ctio n o f p ro d u c  tion scrap ; an d (e) im proved m ech an ical p ro p erties in the casting.

■ F o r this reason R olls-R oyce, L im ited, have ad o p ted the policy o f pro d u cin g as m an y o f the castings on the M erlin engine as possible by die-castlng, an d the extent to w hich this has been carried o u t m ay be gauged fro m th e fa c t th at, o f th e 130 castings on the engine, 103, o r nearly 80 per cent, o f the to tal, are p roduced as g rav ity die-castings.

T he cost o f m an u fa ctu re o f the die, o r p erm an en t m ould as it is kn o w n in A m erica, is, how ever, fre qu en tly m o re th an th a t involved in th e m an u fa ctu re of the necessary p a tte rn e q u ip m e n t fo r the p ro d u ctio n of castings by th e “ sand-cast ” m eth o d , but, if the q u a n tities re q u ire d off a p a rticu la r casting w ould w a rra n t the e x p en d itu re on a die, the red u ced cost p e r casting w ould soon “ w rite-off ” the difference in c o st o f the two types o f tooling, a n d the p a rt co u ld then be looked upon as a p o ten tial die-casting.

D ie D evelopm ent

W hen a draw ing is presented to the fo u n d ry fo r the production o f castings, it is the responsibility o f the fo u n d ry ch ief insp ecto r, being fully c o nversant with engine dev elo p m en t, to en su re th a t the draw ing is o f the latest, issue. W h eth er o r n ot fu rth e r inquiries into the p ro sp ect o f p ro d u cin g castings by the gravity die- cast m eth o d are justified depends u p o n m achine-shop req u irem en ts, an d this p o sition m u st also be ascer

tain ed by h im b efo re the draw ings can be released fo r fu rth e r investigations.

H a vin g_ p assed satisfacto rily these inquiries, the d raw ing is accepted by the die d e velopm ent d e p art

m en t, w here the resp o n sib ility rests fo r the d eterm in a

tio n a s to w h eth er o r n ot, m echanically and m eta llu r

gically, it is possible to produce the castings required as die-castings. W here the p a rt does n o t lend itself to die-casting, due to the presence o f aw kw ardly placed undercuts, etc., end eav o u rs are m ade to have the d e sign m odified, w ith o u t m aterially im pairing the tech nical value o f the casting, to m ake possible its m a n u factu re by gravity die-cast m ethods.

D ie Design

T he essential an d a ll im p o rta n t org an isatio n al feature o f the R olls-R oyce C o m p an y ’s staff set-up is the fact th a t the c h ief die designer is also responsible fo r the c o n tro l o f the experim ental die fo u n d ry , w hich will be described later, b u t o f w hich it sh o u ld be w orthy of n o te a t this stage th a t every die m u st be passed o ut with an a p p ro v ed technique a n d producing perfect castings, dim ensionally, radiologically and m echanic

ally, w ith n o t m ore th an 5 p e r cent, scrap over a run o f 100 castings m inim um .

T h e p racticability o f the proposed die-casting having b een ascertained, the ch ief die designer th en d eter

m ines th e gating system , together w ith the position o f the “ d ie-parting,” the lo catio n and d irectio n o f e x tra c tion o f cores, the m eth o d o f release o f the casting fro m the die, general die shape an d thickness, etc., passing this in fo rm a tio n o n to th e fo u n d ry die d raw ing office, w ho proceed w ith the com pletion o f the d etail draw ings fo r the die.

W here it has n o t been fo u n d possible o r necessary to hav e m odifications m ade to th e general design of the casting to sim plify p roduction, th e decision is also m ade at this stage, toy th e ch ief designer, as to w hether the die will in c o rp o ra te m ultipiece cores o r result in a sem i-die-casting, i.e., m ak in g use o f sand cores. T he use o f sand cores is discouraged fo r various reasons, p rincip ally because b y ad o p tin g this m eth o d a cer

tain degree o f accu racy is lo st th ro u g h co re location and. secondly, th e presence o f a n o il-sand co re results in the g en eratio n o f core gases p resen t during casting

— a fe atu re w hich is avoided as fa r as possible.

T h e ex ten t to w h ich this policy o f elim inating th e use o f san d cores h as been applied can be seen from the fa ct th at, o f th e 103 die-castings on the M erlin X X engine, o n ly nine, o r 8.7 p e r cent., have th eir internal passages fo rm ed by the use o f sand cores.

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Aluminium G ra v ity Dfe-C astings

GRAVITY D IE CASTINGS.

St a n d a r d Pr o d u c t i o n Te c h n i q u e.

P art No. D .14864. Mat. R .R .50

Description : Cover P late and Guide Die Preparation

F.S.14 die-coat to be used. Norm al applications to die cavity and cores. H eavy coating to be given to risers.

All bearing surfaces to be lubricated w ith colloidal graphite.

A fter each cast, all cores and pick-off pieces to be plunged into colloidal graphite, to facilitate their easy removal from the casting.

Asbestos insulation on outside of die blocks to be renewed periodically.

Casting Technique.

Die tem perature 300 to 350 deg. C.

Pouring tem perature 710 to 720 deg. C.

Pouring tim e . . 5 seconds.

M etal to be poured smoothly down sloping runner.

To avoid wrenching, pick-off pieces to be tapped with small m allet when removing from casting.

Clearance of vent plug to sand core to be verified prior to casting to ensure th a t core gases do n o t enter th e casting.

Production Statistics.

No. of casters 2 Cooling time 60 to 90

seconds.

Casting cycle

tim e 5 minutes R ate per hour 12

Bonus tim e allowance . . 24 m inutes. ! Inspection Report on Trial Batch of 100.

Inspection. Quan.

Scrap. R eason for rejection.

Chalk test 5 Surface cracks under top

flange caused through wrenching loose pieces on removal.

Pressure test Nil —

Final dimensional Nil —

T otal percentage scrap—5.

Issued by M. R . Hincheliffe. D ate 20.8.42.

Fi g. 1.— Ex a m p l e o f S t a n d a r d La y o u t o f Pr o d u c t i o n Te c h n i q u e.

D ie Drawing Office

In o rd er to utilise, to th e fu llest e x ten t, sem i-skilled an d train ee la b o u r in the fo u n d ry to o l ro o m in the m an u factu re of the die, the policy o f the fo u n d ry draw ing office, w hen p re p arin g the detail draw ings, is to m ake fully detailed d raw ings o f a ll the die c o m ponents, hav in g th em cro ss-re fere n ced w ith th e indexed g en eral a rran g em en t draw ing. O rig in ally th is p lan was o p e rated as a n e x p erim e n t w ith th e m a in o b jec t o f conserving skilled to o l-m a k in g la b o u r, b u t the re sults proved th at, in a d d itio n to easin g c o n sid era b ly this p a rticu la r problem , o th e r eq u ally im p o rta n t a d v a n tages becam e ap p are n t, v iz., in creased speed o f die- m aking, w ith the m an u fa ctu rin g co st g re atly reduced.

T h e p ro ced u re fro m th a t date was a u to m a tic a lly in c o rp o ra ted in the die d raw ing office ro u tin e .

A n o th e r p o in t d em anding special a tte n tio n is the fact th at all run n ers, gates a n d risers a re a c c u ra te ly d im e n sioned, to w hich sizes the tool ro o m m u st w ork instead of, as is n o rm a l practice, leaving this, to a c e rta in e x tent, to the d iscretion o f the die-m akers. B efore a draw ing m ay be released to th e to o l ro o m fo r c o m m encing m an u fa ctu re, it is m eticu lo u sly c h ec k ed , first by the ch ief d rau g h tsm a n , w ho w ill satisfy h im self upon the d im ensional accu racy , th en th e ch ie f designer will check the design and initial his a p p ro v a l th a t the draw ings are in acco rd an ce w ith his instru ctio n s.

Final a p p ro v al m u st be received fro m the fo u n d ry m anager before th e to o l-ro o m su p e rin te n d e n t will accept the design as official a n d p ro c ee d w ith m a n u facture.

D uring the process of m a n u fa c tu re o f th e die in the tool ro o m , any a lte ra tio n o r m o d ificatio n fo u n d to be necessary o r ad v an tag eo u s m u st first receive a p p ro v al fro m the die designer b e fo re in c o rp o ra tio n in the die.

T h e details of these a d ju stm e n ts a re th e n passed to the draw ing office so th a t th e o rig in a l d raw in g s m ay be b ro u g h t up to date.

Experim ental D ie Foundry

O n com p letio n , the die, fu lly assem b led , is passed by the tool ro o m to th e ex p erim e n tal die fo u n d ry , w here it is fully tested. A s a re su lt o f this testing, the m ost suitable tech n iq u e is d ev elo p ed fo r p ro d u c tio n a n d all the m ost im p o rta n t fa cto rs, su c h as:— (a) Die- coating an d its a p p lic atio n ; (b) p o u rin g te m p e ra tu re of m etal; (c) die tem p e ra tu re; (d) m e th o d o f pouring;

an d (e) p ro d u c tio n tim e cycle, a re firm ly e stab lish ed and reco rd ed f o r th e use o f the p ro d u c tio n fo u n d ry .

T h en , in o rd e r to p ro v e the die, o n e sam ple casting is passed to the in sp ectio n d e p a rtm e n t fo r m a rk in g up to the casting d raw ing an d th ereb y checking th e d im e n sional accu racy o f the die, w hilst q ra d io lo g ica l e x am i

n a tio n is c arried o u t on a fu rth e r sam ple, or sam ples (d ep en d en t u p o n the size of the jo b ) to ascertain th a t fau lts, n o t visible to the n ak ed eye, such as in te rn al porosity, sh rin k ag e, blo w h o les, etc., are n o t p resen t th ereb y confirm ing th a t the gating system and general p ro d u c tio n tech n iq u e fo r the die is satisfactory.

U p o n re ceip t o f a sa tisfac to ry re p o rt fro m b oth dim en sio n al an d ra d io lo g ica l e x am in atio n s, the fin a i p ro d u ctio n con d itio n s u n d e r w h ich the castings h a j

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N O V EM B ER 9, 1944 F O U N D R Y T R A D E JO U R N A L 195 been p ro d u ced are tab u la te d as a fo rm o f sta n d ard

lay o u t (Fig. 1), to w hich a tria l b atch , o f a t least 100 castings, is pro d u ced , w ith, as stated previously, n o t m o re th a n 5 p er cent, rejects.

T h e resp o n sib ility of the ch ief designer a n d the die dev elo p m en t d ep artm e n t on this p a rticu la r die n o rm ally term in ates w ith this verification, and the die, to g eth er w ith the relativ e ta b u la te d d ata, can th en be officially released to the p ro d u c tio n fo u n d ry .

In o rd e r th a t the w o rk involved up to this stage can be m ore fully ap p reciated , it is proposed to

p o rtan t featu res in die design an d c o n stru ctio n w hich are w orthy o f note. I t is essential to realise th at, w hen considering a jo b o f this description as a p o te n tial die-casting, the greatest technical an d econom ical advantages are to be gained ultim ately by close co o p eratio n betw een the die designer an d the p ro d u ctio n engineer, w ith a view to elim inating as fa r as possible undesirable features such as undercuts a n d ab ru p t changes in section. In the case of the gear-case cover, a very aw kw ard in tern al flange, w hich w ould have m eant a collapsible internal core, w ith the consequent increase in initial die cost w ith decreased ra te o f p ro duction, was rem oved to the outside, w here it was easily m oulded; this w ithout affecting the technical value o f the castings.

A sub sta n tial base constructed in box fo rm fo r p u r

poses o f rigidity an d as a m eans fo r housing the ejecto r m echanism m entioned later, constitutes the m ajo r p o rtio n o f the die. O n this base are located two m ain die blocks form ing the o u ter profile o f the casting and lo catio n fo r the top core. M eans are also provided fo r op eratin g these blocks m echanically in the form o f a rack and pinion m ovem ent. A n insert secured in the die base form s the b ottom o f the cast

ing.

T h e ejectio n o f the casting is affected by m eans of a n u m b er o f ejection pins spaced u niform ly round the casting and connected to a steel p late in the base

Fi g. 2 .— Ge n e r a l Co n s t r u c t i o n o f Die f o r Fr o n t Ge a r Ca s e Co v e r.

illustrate briefly the p ro d u ctio n technique of ganeral po in ts o f in te res t in co nnection w ith different types of rep resen tativ e dies fo r M erlin engine p arts. W ith each item is given p h o to g rap h s an d a description of the special featu res o f th at p ro d u c tio n part.

Front Gear-case Cover

T h e die show n in Fig. 2 fo r pro d u cin g fro n t gear- case cover castings illu strates to a larg e ex ten t the ad v an tag es t o b e gained b y die-casting an d the possi

bilities of the process. T h is die em bodies m any im-

Ti g. 3.— Co n s t r u c t i o n o f To p Co r e o f Fr o n t Ge a r Ca s e Co v e r.

of the die, the m echanism being operated th ro u g h the actio n o f two rack s secured to the plate m eshing with pinions on a sh a ft pro jectin g o u t o f the side of the die w ith a lever attach ed . Sufficient pressure is cap ab le of being ex erted o n th is le v e r by one m an , thereby ejecting the casting w ith o u t an y disto rtio n o r cracking.

T h e o b ject in m echanising th e die in this w ay is so th a t the in tro d u c tio n o f b ru te force in the o p eratio n s is avoided, th ereb y resu ltin g in reduced fatigue on the w orkers, w ith co n seq u en t increased rate o f p roduction.

T h e intricacy o f co n to u r o f the inside of the casting

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Aluminium G r a v ity D ie-C a sting s

by th e existence o f th e stren g th en in g w ebs n o tice ab le in the illu stra tio n m ak e it essential to p rovide th e best possible venting con d itio n s in the die cavity. In this respect a study o f the c o n stru ctio n o f the to p core is interesting, as it is split up in to fo u r m ain sections, the jo in t lines co rresp o n d in g to the cen tre lines o f the strengthening webs. T h u s, th e p ro v isio n o f vent grooves along the jo in t faces is facilitated , thereb y allow ing the a ir in the die cavity to be easily displaced by the incom ing m etal w ith o u t having to re so rt to th e m ethod o f forcing o r flushing the m etal into the m ould, a practice w hich is distinctly bad.

Fig. 3 show s th e co n stru c tio n o f the co re an d the m ethod o f venting. It will be observed th a t the fo u r separate pieces are located relativ e to each o th e r by m eans o f d ovetail pieces, thus elim inating the neces

sity fo r screw s an d dow els to h o ld the pieces together.

T he assem bled co re is th en secu red to a c ast-iro n top p late, w hich also serves as a lever p late f o r rem oving the core fro m the casting. T h is m eth o d o f c o n stru c tio n enables the core to be d ism antled easily an d rapidly fo r purposes o f cleaning and coating.

ditions, w hich m ust be very rigidly ad h ered to, in the m an u fa ctu re o f high-class castings, is th a t th e m e ta l m u st en te r th e m o u ld cav ity in the fo rm o f a n u n b ro k e n stream w ith the a b so lu te m in im u m o f tu rb u - T h e ideal w ay to acco m p lish this is to d irect the m etal th ro u g h a ru n n in g system to th e b o tto m o f the

Fi g. 4 .— Me t h o d o f Po u r in g Fr o n t Ge a r Ca s e Co v e r.

T h e n a tu re of the allo y being cast dem an d s th a t ad eq u ate head m etal be pro v id ed o v e r all h e av y sec

tions to replace shrinkage d uring solidification, an d fo r this reaso n a heavy riser has been placed ro u n d the circum ference o f the casting to feed th e thick flange and the heavy bosses thereon. T h e th ree heavy b e a r

ing bosses an d ad jacen t oil passage bosses in the bottom o f the casting a re fed fro m th e th ree co n ical risers show n. A ll h eav y bosses w hich a re isolated from the feed an d w h ich c an n o t be fed directly by o rd in ary m ethods are chilled by rem oving lo cally the insulating die co atin g a t th a t section o f th e die.

In o rd er to o b tain sound castings, the fo rem o st con-

Fi g. 5 .— Co n s t r u c t i o n o f Co o l a n t Pu m p Ca s in g Di e.

m o u ld an d allo w the die to fill by d isp lacem en t. C e r

tain designs o f castings len d them selves to this m eth o d , but in the instance o f the g ear-case co v er this m eth o d is im p racticab le, so th a t a lte rn a tiv e m ethods h av e to be used to achieve the sam e end. F u rth e rm o re , the plate-like fo rm o f the casting a ccen tu ates the difficul

ties, due to the fact th a t u n d e r n o rm al c o n d itio n s, w ith the m o u ld flat, it is im possible to m ain tain a u n ifo rm flow o f m etal across the m o u ld cavity; instead the m etal stream b reak s u p into a n u m b e r o f sm aller stream s w hich, u p o n un itin g , ten d to fo rm co ld shuts and a ir inclusions. T o avoid this tendency the die has been pivoted on tru n n io n s w hich perm it it to be tilted

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N o v e m b e r 9 , 1944 F O U N D R Y T R A D E JO U R N A L 197 ,,a n 8*e a t co m m en cem en t o f p o u rin g an d

g rad u ally low ered to a h o rizo n ta l positio n as pouring Proceeds. T h e o p e ra tio n o f p o u rin g is show n in T o illu strate the ex te n t o f the advantages gained by p ro d u cin g this p a rt as a die casting in preference to a sand casting, the follow ing d a ta a re given to e n ab le a c o m p a ris o n to b e m ad e :—

D etail. Sand-casting. Die-casting.

Bonus tim e allowance to

produce 165 mins. 40 mins.

Finished casting w eight . . 14 lbs. 12f lbs.

Standard cost per casting (S.) 4.042 1.104

Fi g. 6 .— Co n s t r u c t i o n o f “ Bo o s t Co n t r o l” Ca s i n g Di e.

C oolant Pum p Casing

A g ravity die o f a n e n tirely different n a tu re fo r p ro ducing c o o la n t p u m p casings is illu stra te d w ith a cast

ing co m p lete w ith ru n n e rs an d risers in Fig. 5. In this in stan ce th e use o f sa n d c o res is n ecessary, w hich con seq u en tly presents the sam e p ro b lem s as a re ex perienced in the sand-casting process, viz.:— (1) T he provision o f a su itab le design o f core p rin t w hich will give accu racy a n d consistency of c o re lo catio n ; an d (2) a d eq u a te venting a rra n g e m e n ts fo r draw ing off the core gases g en erated d u rin g casting.

T w o san d cores a re used in this die, o n e form ing the in v o lu te passage o f th e pum p, the o th e r fo rm in g an u n d e rc u t p o c k et in the b o tto m o f the casting, b u t b o th rep resen tin g cases w here the use o f steel cores w ould be im possible, nev erth eless still resu ltin g in a c o n sid erab le saving in tim e a n d expense over the n o r

m al san d -cast m ethods.

A c c u r a t e lo ca tio n o f the v o lu te co re is provided by m e a n s o f a c o re p rin t a t each e n d o f the core as s h o w n , e ach core having the p rin ts checked, in a s p e c ia l jig , fo r size in relatio n to th e profile o f the core b e fo r e b e in g released as su itab le fo r the die. V enting is im p o r ta n t o n this core, as the n o rm al tendency o f

core gases is to follow the co u rse o f least resistance and e n ter the m etal, th u s form ing oxide inclusions and p o ro u s regions w hich w ould be revealed on pressure testing the castings. A good artificial vent, th erefo re, is necessary an d is fo u n d in the centre o f the core.

T h e sm all c ircu lar co re, visible in th e base o f the die, presents sim ilar pro b lem s o f lo catio n an d ven t

ing, b u t in this case the difficulties o f venting are acc en tu ated by the fact th a t the co re is e n tirely su b m erged u n d er a thick lay er of m etal, resulting in there being only one exit fo r the gases, nam ely, th ro u g h the core print. T o influence easy co re gas exit the core is located on fo u r tu b u la r pins penetrating to its in

terio r and extending th ro u g h the base o f the die into the atm osphere.

Fi g. 7 .— Me t h o d o f Po u r in g “ Bo o s t Co n t r o l ” Ca s i n g.

T h e die consists p rim arily o f a base, w hich form s h a lf the cavity an d also co ntains u n d ern ea th it an ejector gear, and two m ain die halves. T h e base is constructed in shallow box fo rm an d the w hole assem bly m ounted on legs, thus co n stitu tin g an independent unit.

T h e c irc u la r core, besides fo rm in g th e inside o f the casting, also em bodies a cen tral conical riser w hich is necessary to feed a h eav y b o ss in th e b o tto m o f the die. T h e shape of th e casting a n d the disposition of the thick an d th in sections is such th at it lends itself to top p o u rin g th ro u g h the ring rise r on the top flange.

A sm o o th en try o f m etal is attain ed by p ouring sim ul

taneously dow n tw o risers, each inclined a t 45 deg., whilst the heavy sections a t each en d o f the volute are ren d ered so u n d by m eans o f risers. Below are given co m p arativ e details o f producing c o o lan t pum p casings by b o th “ sa n d ” a n d “ d ie-castin g ” m ethods:—

Details. Sand-cast. Die-cast.

Bonus tim e allowance (mins.) 171.000 81.750

Finished casting weight (lbs.) 5.015 4.630

Standard cost per casting (S.) .2.417 0.729