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I have seen
video scanning software for this purpose identifying surface defects on polished forging surfaces, but
even that has its limitations.
Casting is a whole other ball game. With castings you get various types of sub-surface defects including
inclusions, porosity etc which will be revealed when machined or glazed. Apparently even the world
class forging houses get between 5 and 10% defect rates in their castings (This is based on my
experience within the casting industry, I don't have hard data to back this up).
X-Ray can pick up larger internal defects, but all the commercial applications of this technology just don't
have the resolution to pick up smaller defects and would require multiple shots at all kinds of angles to
determine is a casting was "defect free" (dependent on the geometry of the component in question).
I'd be interested to hear if anyone else has seen other techologies to accurately inspect castings &
identify internal defects.
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This abstract is a brief summary of the referenced standard. It is informational only and not an official part of the
standard; the full text of the standard itself must be referred to for its use and application. ASTM does not give any
warranty express or implied or make any representation that the contents of this abstract are accurate, complete or
up to date.
Significance and Use
4.1 For ferromagnetic materials, magnetic particle examination is widely specified for the detection of surface and
near surface discontinuities such as cracks, laps, seams, and linearly oriented nonmetallic inclusions. Such
examinations are included as mandatory requirements in some forging standards such as
Specification A508/A508M.
4.2 Use of direct current or rectified alternating (full or half wave) current as the power source for magnetic particle
examination allows detection of subsurface discontinuities.
1. Scope
1.1 This practice2 covers a procedure for magnetic particle examination of steel forgings. The procedure will
produce consistent results upon which acceptance standards can be based. This practice does not contain
acceptance standards or recommended quality levels.
1.2 Only direct current or rectified alternating (full or half wave) current shall be used as the electric power source
for any of the magnetizing methods. Alternating current is not permitted because its capability to detect subsurface
discontinuities is very limited and therefore unsuitable.
1.2.1 Portable battery powered electromagnetic yokes are outside the scope of this practice.
NOTE 1Guide E709 may be utilized for magnetic particle examination in the field for machinery components
originally manufactured from steel forgings.
1.3 The minimum requirements for magnetic particle examination shall conform to practice standards of
Practice E1444/E1444M. If the requirements of this practice are in conflict with the requirements of
Practice E1444/E1444M, the requirements of this practice shall prevail.
1.4 This practice and the applicable material specifications are expressed in both inch-pound units and SI units.
However, unless the order specifies the applicable M specification designation [SI units], the material shall be
furnished to inch-pound units.
1.5 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values
stated in each system may not be exact equivalents; therefore, each system shall be used independently of the
other. Combining values from the two systems may result in non-conformance with the standard.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appropriate safety and health practices and determine the
applicability of regulatory limitations prior to use.
2. Referenced Documents (purchase separately)
ASTM Standards
A508/A508M Specification for Quenched and Tempered Vacuum-Treated Carbon and Alloy Steel Forgings for
Pressure Vessels
E709 Guide for Magnetic Particle Testing
E1444/E1444M Practice for Magnetic Particle Testing
Other Document
RecommendedPracticeN Supplement B-Magnetic Particle Method Available from American Society for
Nondestructive Testing (ASNT), P.O. Box 28518, 1711 Arlingate Ln., Columbus, OH 43228-0518,
http://www.asnt.org.
ICS Code
ICS Number Code 77.040.20 (Non-destructive testing of metals); 77.140.85 (Iron and steel forgings)
UNSPSC Code
UNSPSC Code 31132100(Steel forgings)
DOI: 10.1520/A0275_A0275M-08R13
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This group of ASTM specifications covers standard properties of steel and iron castings and forgings for
valves, flanges, fittings, and other pressure containing parts for high-temperature and low-temperature service.
This group of ASTM specifications covers standard properties of steel and iron castings and forgings for
valves, flanges, fittings, and other pressure containing parts for high-temperature and low-temperature service.
Additionally, in the table below standards for evaluating the microstructure of graphite in iron castings and
methods for mechanical testing of cast irons are presented.
STEEL CASTINGS
A27
A27/A27M-95
A47
A47/A47M-99
A48M A48M-94e1
A48
A48-94ae1
A74
A74-98
A126 A126-95e1
Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings
A128
A128/A128M-93
Specification for Steel Castings, Austenitic Manganese
(1998)
A148
A148/A148M-93b
Specification for Steel Castings, High Strength, for Structural Purposes
(1998)
A216/A216M-93 Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for
(1998)
High- Temperature Service
A217 A217/A217M-99
Reply
Nearly all steel components begin life as a casting, metal that has been melted, poured into a
mould and solidified. In the casting process at the foundry, because the mould has the shape of
the desired component, there are finishing processes that need to be completed once a casting is
done. The first "shape" in forgings is an ingot or continuously cast billet. Ingots are large, usually
rectangular in form and weigh up to several tons. Ingots or continuously cast billets are forged
into shapes by hammers or presses. Extensive machining to final configuration usually is required,
before finishing operations can begin. Casting and Forging defects are difficult to detect as they
are not always visible on the surface. Ultrasonic flaw detection is commonly used for internal
defects and magnetic particle or liquid penetrant for surface inspection.
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Kadvani Forge Limited has it's own inspection plan for all the components and it's processes
at different stages of production.
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1.
Raw material incoming from the approved steel mills are kept in the stock yard and 100%
visual examination and spark testing is done.
Chemical, metallurgical and physical testing is also carried out as per the plan or instruction
of the customer.
After approval of the material in the laboratory, color code given to each and every bar of
the same grade.
Physical testing e.g. upset test, step turn test, tensile test, Impact test, macro etching is
also carried out.
Metallurgical testing of the material e.g. Inclusion rating, Grain Flow, Microstructure is also
carried out.
Top
2.
Process Inspection :-
Inspection is carried out at every stage of production at different stages e.g. Die Shop,
Cutting Shop, Forge Shop, Heat Treatment Shop.
Each shop or processing dept has it's own inspection plan to
satisfy the customer's needs depending upon the experience
and expertise.
reference.
Cutting Shop :- All the cut pieces are checked for the required cut weight as needed
to produce particular parts.
Heat Treatment:- Personals responsible for the process under direct supervision of
qualified metallurgies and experienced chemist and skilled workers are working as
per the work instruction and inspection plan.
Certain pieces are selected from each lot of components passing through the process
of heat treatment and are tested to confirm the hardness, microstructure, grain size
of the lot as per need of the customer.
Heat treatment furnaces are equipped with temperature indicator and controller.
We can do normalizing, annealing, hardening, tempering, solution annealing,
Isothermal annealing of the steel forged components.
All care is taken to control the hardness within a navigation of hardness from piece
to piece upto 15 BHN.
Top
3.
Final Inspection :-
All the forged parts coming this shop are shot blasted and following inspection carried out
as per plan.
1.Visual inspection for scale pit, folds, unfeeling etc.
2.Dimensional inspection :- critical dimensions like thickness and references points for 1st
operation at the customers end are checked 100%.
3.Layout :- Some of the piece/lot are fully laid out for dimension as per the drawing before
dispatch.
4.Packing :- Packing of the components and dispatches are made as per customer
requirement.
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RGING
A type of gravity drop hammer where the ram is raised for each stroke by an air cylinder. Since length
lled, ram velocity and thus energy delivered to the workpiece may be varied.
aracteristic of exhibiting different values of a property in different directions with respect to a fixed
material.
mely large, heavy block of metal which supports entire structure of conventional gravity or steam driven
the block of metal on which hand (or smith) forgings are made.
ed layer just beneath the scale produced by heating steel in an oxidizing atmosphere.
ACE. A furnace for heating materials in which the loading and unloading is done through a single door
ng a die impression, tool, or mechanical device designed to bend forging stock to conform to the
f die impressions subsequently to be used.
ed, cogged, hot-rolled, or continuous-cast metal product of uniform section, usually rectangular with
s are relatively larger than bars.
sed by gas bubbles either on the surface or beneath the surface of the metal.
NG IMPRESSION). The impression in the dies (often one of a series of impressions in a single die set)
rging an intermediate shape, preparatory to forging of the final shape.
cker dies are characterized by generous contours, large radii, draft angles of 7 or more, and liberal
RGING. A forging which approximates the general shape of the final part with relatively generous finish
ch forgings are sometimes specified to reduce die casts where only a small number of forgings are
machining each part to its final shape is not excessive.
operation often used to impart an intermediate shape in the finishing impression of the dies. Blocking
king of the material and contribute to great die life.
en released. Energy for forging is obtained by the mass and velocity of the freely falling ram and the
ecured to the bed of a press for locating and supporting the die assembly.
damaged metal caused by heating conditions producing incipient melting or intergranular oxidation.
KING IMPRESSION). A type of die impression sometimes used to combine preliminary forging
ng and fullering with the blocking operation to eliminate blows.
rom edge straitness, usually referring to the greatest deviation of side edge from a straight line.
cate crown on flat rolls.
impression, generally due to forging pressure and/or excessive die temperature. Die blocks too hard for
pression have a tendency to check or develop cracks in impression corners.
DESIGN. A forging designed with commercially recommended draft radii and finish allowances, but
nces of less than one-half the commercial tolerances recommended for otherwise similar parts. Often
s required after forging.
of applying necessary pressure to all or some portion of a forgings surface in order to obtain closer
rfaces, or to eliminate draft. Coining may be done while forgings are hot or cold and is usually
parallel to the parting line of the forging.
rking metal at room temperature in such a manner that the cross-sectional area of a portion or all of the
A visual (usually final) inspection of the forgings for visible defects, dimensions, weight, and surface
erature. The term may also be used to describe certain nondestructive tests such as a magnetic particle,
c inspection.
used when a workpiece fails to fill the die cavity during first forging. A seam is formed as subsequent
is gap to leave a seam on the workpiece surface.
emoving flash or excess metal from the forging in a trimming press when the forging is at room
rmanent plastic deformation of a metal at a temperature below its recrystallization point low enough
ning.
ENGTH. The maximum stress that a material subjected to compression can withstand when loaded
fracture.
process of displacing metal with a punch to fill a die cavity.
RGING EQUIPMENT. A category of forging equipment wherein two opposed rams are activated
g repeated blows on the workpiece of a midway point. Action may be vertical, as in the case of
mmers, or horizontal as with the Impacter.
og in mating surfaces of dies to prevent lateral die shifting from side thrust developed in forging
nt strain occurring under stress. The resistance to creep, or creep strength, decreases with increasing
minary working of forging stock in flat dies so that the principal increase in dimension is in the
h respect to the original axis of the ingot.
usually) of heat-treated steel into which desired impressions are machined or sunk and from which
produced on hammers or presses. Die blocks are usually used in pairs with part of the impression in one
alance of the impression in the other.
ompound sprayed, swabbed or otherwise applied on die surfaces of forgings during forging to reduce
ging and the dies. Lubricants may also ease release of forgings from the dies and provide thermal
dition where dies, after having been set up in the forging equipment, are in proper alignment relative to
The metal blocks into which forging impressions are machined and from which forgings are produced.
n requiring correction where, after dies have been set up in the forging equipment, displacement of a
e corresponding point in the opposite die occurs in a direction parallel to the fundamental parting line
ERTIES. Anisotropic values. Physical or mechanical properties varying with the relation to a specific
m structural fibering and preferred orientation.
t placed between mating surfaces of the die shank and die holder in the forging equipment to assure
f taper on the sides of the forging necessary for removal of the workpiece from the dies. Also the
the side walls of the die impressions.
angle of taper, expressed in degrees, given to the sides of the forging and the side walls of the die
operation in which the cross section of forging stock is reduced and the stock lengthened between flat or
ee FULLER.)
orging produced by hammering metal in a drop hammer between dies containing impressions designed
hape. (See IMPRESSION DIE FORGING.)
rm generally applied to forging hammers wherein energy for forging is provided by gravity, steam, or
R-LIFT HAMMER, BOARD HAMMER, STEAM HAMMER.)
PRESSION). The portion of the die impression which distributes metal during forging into areas where
litate filling the cavities of subsequent impressions to be used in the forging sequence. (See FULLER.)
cess of forcing metal to flow through a die orifice in the same direction in which energy is being applied
in the reverse direction (backward extrusion) in which case the metal usually follows the contour of the
ng tool. The extrusion principle is used in many impression die forging applications.
NG. (l) Forcing metal into or through a die opening by restricting flow in other directions. (2) A part
ntersection of two surfaces. In forging, the desired radius at the concave intersection of two surfaces is
E. The amount of excess metal surrounding the intended final shape. Sometimes called clean-up
elope, or machining allowance.
ntinuous, internal fissures in ferrous metals attributed to stresses caused by localized transformation and
hydrogen during cooling after hot working.
tal in excess of that required to completely fill the finishing impression of the dies. Flash extends out
rging as a thin plate at the line where the dies meet and is subsequently removed by trimming. Cooling
the component during forging, flash can serve to restrict metal flow at the line where dies meet, thus
g of the finishing impression.
additional cavity machined along the parting line of the die cavity to receive the excess metal as it flows
ough the flash gap.
uration in the finishing impression of the dies designed either to restrict or to encourage growth of flash
hever may be required in a particular instance to ensure complete filling of the finishing impression.
G (OPEN-DIE FORGING). Forging worked between flat or simple contour dies by repeated strokes and
s in a forging resulting from the elongation of nonhomogeneous constituents and the grain structure of
tion of working during forging; usually revealed by macroetching. (See GRAIN FLOW.)
e shear stress required to cause plastic deformation of solid metals. (2) The uniaxial true stress required
cular value of strain.
t of work on metal formed to a desired shape by impact or pressure in hammers, forging machines
s, and related forming equipment Forging hammers, counterblow equipment, and high-energy-rate
rt impact to the workpiece, while most other types of forging equipment impart squeeze, but the
made more plastic for forging by heating.
(UPSETTER OR HEADER). A type of forging equipment, related to the mechanical press, in which
y is applied horizontally to the work-piece which is gripped and held by prior action of the dies.
olling mills that forge comparatively uniform shapes by using variable radii around the circumference of
pposite direction from those ordinarily used for rolling.
Differential strains that result from forging or from cooling from the forging temperature, and that are
al stresses.
. Elastic stresses induced by forging or cooling from the forging temperature; sometimes erroneously
rains.
MPRESSION). Portion of the dies which is used in hammer forging primarily to reduce the cross section
of the forging stock. The fullering impression is often used in conjunction with an edger (or edging
tion of the die which has been removed by machining to permit a connection between multiple
an impression and the bar of stock.
ation which increases the cross section of part of the stock above its original size.
Any operation whereby the cross section of a portion of the forging stock is increased above its
ike lines appearing on polished and etched sections of forgings which are caused by orientation of the
al in the direction of working during forging. Grain flow produced by proper die design can improve
operties of forgings.
rage size of the crystals or grains in a metal as measured against an accepted standard.
A class of forging hammer wherein energy for forging is obtained by the mass and velocity of a freely
ression machined around the periphery of an impression in the die which allows space for the excess
ging).
Shaping of metal by impact between dies in one of several types of equipment known as forging
FT HAMMER, BOARD HAMMER, COUNTERBLOW FORGING EQUIPMENT, STEAM
e quantity of material manufactured from one melt at the metal producers facility. Metal from a single
rm in chemical analysis.
E FORGING (HIGH VELOCITY OR HIGH SPEED FORGING). The process of producing forgings on
xtremely high ram velocities resulting from the sudden release of a compressed gas against a free
mechanical working of metal at a temperature above its recrystallization point a temperature high
n hardening.
ER. A gravity drop forging hammer which uses hydraulic pressure to lift the hammer between strokes.
y machined into a forging die to produce a desired configuration in the workpiece during forging.
RGING. A forging that is formed to the required shape and size by machined impressions in specially
ert 3-dimensional control on the workpiece.
which is removable from a die. An insert can be used to fill a cavity or to replace a portion of the die
ives better service.
operation used to obtain a more exact alignment of the various parts of a forging, or to obtain a better
An operation to increase the length of a tube by reduction of wall thickness and outside diameter. (See
G.)
ING. A forging operation performed on a workpiece during which the temperature remains constant and
d when aluminum, nickel, or titanium is being forged.
rity appearing as a seam, caused by the folding over of hot metal, fins, or sharp comers and by
orging (but not welding) of these into the surface.
e plane of the mating faces of the dies. Locks aid in holding die alignment during forging by
n which a point in one die-half is aligned properly with the corresponding point in the opposite die-half
ce.
MATCH LINES). Two edges of the die face which are machined exactly at 90 to each other, and from
re taken in laying out the die impress and aligning the dies in the forging equipment.
When unsymmetrical ribs and side walls meet at the parting line it is standard practice to provide greater
ie to make the forgings surface meet at the parting line. This is called matching draft.
KING. Subjecting metal to pressure, exerted by rolls, hammers, or presses, in order to change the
al properties.
fter the parting line has been established and a machining allowance is provided, a shape may have what
G. A forging with extremely close tolerances and little or no draft, requiring a minimum of machining to
Mechanical properties can be enhanced by closer control of grain flow and retention of surface material
. Hot mechanical forming of metals between flat or shaped dies where metal flow is not completely
as hand or smith forging.
ine along the surface of a forging where the dies meet, or the line along the corresponding edge of the
e plane which includes the fundamental parting line of the dies; the dividing plane between dies.
workpiece upon which the forging equipment performs work, including the flash, sprue, tonghold, and
made at one time.
e shaping of metal between dies by mechanical or hydraulic pressure. Usually this is accomplished with
he press for each die station.
ble die in a trimming press or forging machine. (2) A tool used in punching holes in metal.
A continuous type furnace where stock to be heated is charged at one end, carried through one or more
harged at the opposite end.
NCE. Allowable variation of quantity to be shipped on a purchase order. This tolerance is properly
g a trimmed forging in order to align or size its several components or sections. The operation can be
process of shaping weldless rings from pierced discs or thick-walled, ring-shaped blanks, between rolls
kness, ring diameter, height, and contour.
MPRESSION). The portion of a forging die where cross sections are altered by hammering or pressing
being rotated.
process of shaping stock between power driven rolls bearing contoured dies. The workpiece is
ivery side of the rolls, and is reinserted for each succeeding pass. Usually used for pre-forming, roll
ed to reduce thickness and increase length of stock.
A circular furnace constructed so that the hearth and workpieces rotate around the furnaces axis during
EL FORGING). The process of rolling and forging a pierced disc of stock over a mandrel in order to
.
m that is formed on forgings, or other heated metal, by chemical action of the surface metal with the
usion on the surface of forging stock which may carry through forging and appear on the finished
MI-FINISHING IMPRESSION). An impression in the forging die which only approximates the finish
ng. Semi-finishers are often used to extend die life of the finishing impression, to assure proper control
ging, and to assist in obtaining desired tolerances.
s a support for the stationary portions of trimming and forming dies; sometimes termed sow block.
traction of metal during cooling after forging. Die impressions are made oversize according to precise
w forgings to shrink to design dimensions and tolerances.
easuring scale or rule, used in die layout, on which graduations are expanded to compensate for thermal
of the forging during cooling.
ed when punching a hole in a forging. Also termed punch out. (2) Forging stock for one workpiece
NK.)
NAGGING). The process of removing portions of forgings not desired in the finished product, by
ie holder employed in a forging hammer to protect the hammer anvil from shock and wear. Also called
type of drop hammer where the ram is raised for each stroke by a double-action steam cylinder and the
workpiece is supplied by the velocity and weight of the ram and attached upper die driven downward
rgy delivered during each stroke may be varied.
Operation of reducing or changing the cross sectional area by revolving the stock under rapid impact
ion of the stock by which the operator grips the stock with tongs during forging.
a punch or die which permits the passage of air or gas. Venting prevents trapping air that interferes with
which interferes with stripping.
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BATCH-TYPE FURNACE. A
ce for heating materials in which the loading and
ading is done through a single door or slot.
BENDER. Term denoting a die
ession, tool, or mechanical device designed to bend
ng stock to conform to the general configuration of
mpressions subsequently to be used.
BILLET. A semi-finished,
ed, hot-rolled, or continuous-cast metal product of
rm section, usually rectangular with radiused
ers. Billets are relatively larger than bars.
BLANK. A piece of stock (also
d a slug or multiple) from which a forging is to be
BLOCKER (BLOCKING
ESSION). The impression in the dies (often one of a
s of impressions in a single die set) which imparts to
intermediate shape, preparatory to forging of the final shape.
BLOCKER DIES. Blocker dies are characterized by
generous contours, large radii, draft angles of 7 or
more, and liberal finish allowances.
BLOCKER-TYPE FORGING. A forging which approximates
the general shape of the final part with relatively
generous finish allowance and radii. Such forgings are
sometimes specified to reduce die casts where only a
small number of forgings are desired and the cost of
machining each part to its final shape is not excessive.
BLOCKING. A forging operation often used to impart an
intermediate shape in the finishing impression of the
dies. Blocking can ensure proper working of the
material and contribute to great die life.
BLOW. The impact or force delivered by one workstroke
of the forging equipment.
BLOWHOLE. A cavity produced by gas evolved during
solidification of metal.
BOARD HAMMER. A type of gravity drop hammer where
wood boards attached to the ram are raised vertically
by action of contra-rotating rolls, then released. Energy
for forging is obtained by the mass and velocity of the
freely falling ram and the attached upper die.
BOLSTER. The plate secured to the bed of a press for
locating and supporting the die assembly.
BOSS. A relatively short protrusion or projection on the
surface of a forging often cylindrical in shape.
BURNT. Permanently damaged metal caused by heating
conditions producing incipient melting or intergranular
oxidation.
BURST. An internal discontinuity caused by improper
forging.
BUSTER (PRE-BLOCKING IMPRESSION). A type of die
impression sometimes used to combine preliminary
forging operations such as edging and fullering with the
blocking operation to eliminate blows.
CAMBER. Deviation from edge straitness, usually
metal.
PUSHER FURNACE. A continuous type furnace where
stock to be heated is charged at one end, carried
through one or more heating zones, and discharged at
the opposite end.
QUANTITY TOLERANCE. Allowable variation of quantity
to be shipped on a purchase order. This tolerance is
properly agreed to by forging producer and purchaser
when order is placed.
RAM. The moving part of a forging hammer, forging
machine, or press, to which one of the tools is
fastened.
RESTRIKING. Striking a trimmed forging in order to align
or size its several components or sections. The
operation can be performed hot or cold.
RING ROLLING. The process of shaping weldless rings
from pierced discs or thick-walled, ring-shaped blanks,
between rolls which control wall thickness, ring
diameter, height, and contour.
ROLLER (ROLLING IMPRESSION). The portion of a forging
die where cross sections are altered by hammering or
pressing while the workpiece is being rotated.
ROLL FORGING. The process of shaping stock between
power driven rolls bearing contoured dies. The
workpiece is introduced from the delivery side of the
rolls, and is reinserted for each succeeding pass. Usually
used for pre-forming, roll forging is often employed to
reduce thickness and increase length of stock.
ROTARY FURNACE. A circular furnace constructed so
that the hearth and workpieces rotate around the
furnaces axis during heating.
SADDLING (MANDREL FORGING). The process of rolling
and forging a pierced disc of stock over a mandrel in
order to produce a weldless ring.
SCALE. The oxide film that is formed on forgings, or
other heated metal, by chemical action of the surface
metal with the oxygen in the air.
SCALE PIT. A surface depression formed on the forging
operation.
SEAM. A crack or inclusion on the surface of forging
stock which may carry through forging and appear on
the finished product.
SEMI-FINISHER (SEMI-FINISHING IMPRESSION). An
impression in the forging die which only approximates
the finish dimensions of the forging. Semi-finishers are
often used to extend die life of the finishing impression,
to assure proper control of grain flow during forging, and
collector cone.
DECARBURIZATION. Loss of carbon from the surface of a
ferrous alloy as a result of heating in a medium, usually
including oxygen, which reacts with carbon.
DEFORMATION TEST. An AFS sand property test which is
determined on an instrument such as the Dietest
Universal Sand Strength Testing Machine. The test
determines the amount of deformation in thousandths
of an inch that occurs before a sand specimen ruptures.
DEGASSER. A material for removing gases from molten
metals and alloys (usually nonferrous metals).
DEGREE OF RAMMING. A measure of the amount of
compaction which has occurred in a molding operation.
(See RAMMING.)
DELAVAUD PROCESS. A centrifugal process employed
chiefly for making cast iron pipe.
DEOXIDATION. Removal of dissolved oxygen from
molten ferrous alloys, usually accomplished by adding
materials with a high affinity for oxygen, the oxides of
which are either gaseous or which readily form slags.
DEWAXING. The process of melting out the expendable
wax pattern from an investment mold by heating,
usually at temperatures less than 121C (250F).
DIATOMACEOUS EARTH. A hydrous form of silica which is
soft, light in weight and consists mainly of microscopic
shells of diatoms or other marine organisms. Widely
used for furnace insulation.
DIE CASTING. A high production casting process in
which the molten metal (usually a nonferrous alloy) is
forced under greater than atmospheric pressure into a
water cooled metal mold cavity.
DIELECTRIC OVEN. A rapid curing high frequency
electric oven used to cure cores which are bonded with
non-conducting materials.
DIP COAT. In solid and shell mold investment casting, a
fine ceramic coating applied as a slurry to the pattern to
produce maximum surface smoothness, followed by a
cheaper investment material.
DIRECT-ARC FURNACE. An electric arc furnace in which
the metal being melted is one of the poles.
DIRECTIONAL SOLIDIFICATION. The solidification of
molten metal in a casting in such a manner that feed
metal is always available for that portion that is just
solidifying.
DISPERSED SHRINKAGE. Small shrinkage cavities
dispersed through a casting, which are not necessarily a
cause for rejection.
mixing reservoir.
LEAKERS. Foundry term for castings which fail to meet
liquid or gas pressure tests.
LIFTERS. Metal tool for removing loose sand from cope
or drag before closing mold. Also, a device which is
attached to the cope, to hold the sand together when
the cope is lifted.
LINING. Inside refractory layer or firebrick, clay, sand, or
other material in a furnace or ladle.
LINING, MONOLITHIC. A lining made without the
customary layers and joints of a brick wall. Usually
made by tamping or casting refractory material into
place, drying and then burning in places on the job.
LINSEED OIL. The most common of all drying oils and
used in the foundry principally as a base for core oil.
Produced by applying pressure to the seeds of flax, the
liquid constituent being linseed oil.
LOAM. A mixture of sand, silt, and clay particles in about
equal portions; i.e. roughly 50% sand and 50% silt and
sand.
LOST WAX PROCESS. A pattern casting process in which
a wax or thermoplastic pattern is used. The pattern is
invested in a refractory slurry; after the mold is dry, the
pattern is melted or burned out of the mold cavity.
MALLEABLE IRON. (See IRON, MALLEABLE.)
MASTER PATTERN. A pattern embodying a contraction
allowance in its construction, used for making castings
to be employed as patterns in production work.
METALLOID. An element intermediate between metals
and nonmetals possessing both metallic and nonmetallic properties, as arsenic.
METALLOSTATIC PRESSURE. The pressure developed
within a molten metal while it is still liquid. The metal
head can exert considerable lifting force on a cope
particularly if the cope is deep and the metal is poured
rapidly.
MELTING LOSS. Loss of metal in charge during the
operation of melting, usually due to oxidation or
volatilization.
MELTING POINT. The temperature at which a metal
begins to liquify. Pure metals, eutectics and some
intermediate phases, melt at a constant temperature.
Alloys generally melt over a range of temperature.
MELTING RATIO. The proportion of the weight of metal to
the weight of fuel used in melting.
METAL PENETRATION. A casting surface defect which
appears as if the metal had filled the voids between the
varied.
ANISOTROPY. The characteristic of exhibiting different
values of a property in different directions with respect
to a fixed reference system in the material.
ANVIL (BASE). Extremely large, heavy block of metal
which supports entire structure of conventional gravity
or steam driven forging hammers. Also, the block of
metal on which hand (or smith) forgings are made.
BARK. The decarburized layer just beneath the scale
produced by heating steel in an oxidizing atmosphere.
BATCH-TYPE FURNACE. A furnace for heating materials
in which the loading and unloading is done through a
single door or slot.
BENDER. Term denoting a die impression, tool, or
mechanical device designed to bend forging stock to
conform to the general configuration of die impressions
subsequently to be used.
BILLET. A semi-finished, cogged, hot-rolled, or
continuous-cast metal product of uniform section,
usually rectangular with radiused comers. Billets are
relatively larger than bars.
BLANK. A piece of stock (also called a slug or
multiple) from which a forging is to be made.
BLISTER. A defect caused by gas bubbles either on the
surface or beneath the surface of the metal.
BLOCKER (BLOCKING IMPRESSION). The impression in
the dies (often one of a series of impressions in a single
die set) which imparts to the forging an intermediate
shape, preparatory to forging of the final shape.
BLOCKER DIES. Blocker dies are characterized by
generous contours, large radii, draft angles of 7 or
more, and liberal finish allowances.
BLOCKER-TYPE FORGING. A forging which approximates
the general shape of the final part with relatively
generous finish allowance and radii. Such forgings are
sometimes specified to reduce die casts where only a
small number of forgings are desired and the cost of
machining each part to its final shape is not excessive.
BLOCKING. A forging operation often used to impart an
intermediate shape in the finishing impression of the
dies. Blocking can ensure proper working of the
material and contribute to great die life.
BLOW. The impact or force delivered by one workstroke
of the forging equipment.
BLOWHOLE. A cavity produced by gas evolved during
solidification of metal.
BOARD HAMMER. A type of gravity drop hammer where
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