Procedure

1. The mould box, pattern, tools and the table/floor are cleaned.

2. The drag is filled with green sand after positioning the lower part of the pattern
on the table.

3. The green sand is rammed carefully and the excess sand is struck off.

4. Tilt the drag upside down and sprinkle river sand on top of it.

5. The cope is positioned on top of the drag and upper part of the pattern is
positioned carefully.

Position the sprue pin and riser pin, then fill the cope with sand and ramming is
done and the excess sand is struck off.

6. Remove the sprue pin and the riser pin carefully.

7. Apply water on the edges of the pattern and remove them carefully using the
draw spike, then finish the cavity.

8. Vent holes are made using vent wire.

10. A funnel-shaped opening and gate is made to pour the molten metal.

Result

Thus the mould cavity of the given split pattern is obtained.

 Procedure

9. The mould box, pattern, tools and the table/floor are cleaned.

10. The drag is filled with green sand after positioning the flange pattern on the table.

11. The green sand is rammed carefully and the excess sand is struck off.

12. Tilt the drag upside down and sprinkle river sand on top of it.

13. The cope is positioned on top of the drag.

14. Position the sprue pin and riser pin, then fill the cope with sand and ramming is
done and the excess sand is struck off.

15. Remove the sprue pin and the riser pin carefully.

16. Apply water on the edges of the pattern and remove it carefully using the draw
spike, then finish the cavity.

17. Vent holes are made using vent wire.

10. A funnel-shaped opening and gate is made to pour the molten metal.

Result

Thus the mould cavity of the given flange pattern is obtained.

Chipping Hammer

A chipping hammer is used to remove slags which form during welding.

Ground Clamp

It is connected to the end of the ground cable. It is normally clamped to the welding
table or the job itself to complete the electric circuit.

Wire Brush

The wire brush is used to clean the surface to be welded. Arc

Welding

Electric arc welding is widely used to join metal plates using a filler rod. The filler
rod (welding rod) melts on the electric arc produced and welds the metal plates.

Arc Welding Procedure

18. The surface to be welded is cleaned and the edges of the plates may be filed for
perfect joint and more strength.

19. The welding rod is held in the electrode holder and the ground clamp is clamped
to the plate to be welded.

20. The electric arc produced melts the welding rod and joins the two metal plates.
Maintain a gap of 3 mm between the plate and the welding rod.

4. Complete the welding process by removing slag using chipping hammer.

Gas Welding

Gas welding is also widely used to join metal plates. The filler rod and parent metal
plates are melted by the heat of the flame produced using oxygen and acetylene gas
mixture.

The components used in gas welding are

(a) Oxygen and acetylene gas cylinders with pressure regulators and pressure
21. Welding torch where flame is obtained by mixing oxygen and acetylene.

22. Hosses in black (oxygen) and maroon (acetylene) colours to connect the gas
cylinders and the welding torch.

Types of Gas Flames

Depending on the ratio of oxygen and acetylene three types of flames are obtained

Neutral flame It has equal quantity of oxygen and acetylene and is used for
welding steel, stainless steel, cast iron, copper, etc. This flame is also used for cutting
metal plates.

Oxidizing flame It has more quantity of oxygen. The acetylene to oxygen ratio is
1 :1.2 to 1.5. This flame is used for welding copper, brass, and bronze.

Carburising flame It has more quantity of acetylene. The acetylene to oxygen

ratio is 1:0.9. This flame is used for welding alloy steel and aluminium.

Gas Welding Procedure

23. The surface to be welded is cleaned.

24. Open the acetylene and oxygen cylinder valve slowly, then open the acetylene
valve in the torch. Keep the tip of the torch away from body and light it using
lighter. Open oxygen and acetylene valves in torch slowly to get the required
flame for welding.

25. Maintain a gap of 3 mm between the plate to be welded and the inner cone of the
flame. The torch and filler rod are moved backwards along the line to be welded.