This article is relating to the foundry of Métaux.
Pour foundries of devices with Semiconductor S (electronic chips), to see with Foundry (electronic) or Manufactoring process of the devices to semiconductors
For the Mulhousian district to see with the Foundry

---- The foundry is one of the processes of forming the metals which consists in running a Métal or a Alliage liquid in a mould to reproduce, after cooling, a part given (interior and external form) while limiting as much as possible later work of completion.

The foundry includes/understands the foundry of ferrous metals, cast iron (NAF 275A), and Acier (NAF 275C). It also integrates the foundry of the non-ferrous metals, light Aluminum and other alloys (NAF 275E), and Cuivre, Zinc and alloys (NAF 275G).

The techniques employed depend on alloy melted, dimensions, the characteristics and the quantities of parts to be produced. It is an industry of subcontracting very dependant on the sectors purchasers: car, iron and steel industry, material of handling, industrial plant, electrical material, aeronautics, etc

One distinguishes mainly the foundry carried out with moulds known as not-permanent, or " moulds perdus" , generally sands some and the foundry with permanent metal moulds, which one calls also " coquilles".

Except in the cases of moulding to lost model (Lost foam or waxes lost), the mould of basic foundry consists of two half-moulds assembled on the level of the mating plane . This basic mould can be supplemented, according to the complexity of the part, by a " core (X) " out of sand, either one or pins (or " dagger (S) ") for the moulding cockles.

Not-permanent moulds

Introduction

A not-permanent mould is a mould which is useful only once, to carry out a part. For each blank of produced casting, the mould is destroyed.

The foundry starting from not-permanent moulds is divided into two categories:

• the traditional moulding for which each mould is manufactured starting from a permanent model;
• the moulding by lost model for which one carries out as many models as moulds.

For the traditional foundry, each mould is built in " sable" ; it can be a question of silico-argillaceous sand (traditionally used in foundry) or of silica bound by resins (proceeded more recent said " sand with catch chimique"). For the lost wax moulding, also called " foundry of précision" each mould is made out of a ceramic material.

The Lost foam is a process " intermédiaire" between the moulding sands and the moulding waxes lost, with which the model is lost as for wax, but using nevertheless nondependant sand for the realization of the mould.

For more details on a particular case: the moulding with sand, by gravity, of prototype parts or small series out of aluminum alloys, to see the article " Works aluminum smelting ".

Contact in France to have information on the trade, the C.T.I.F (Centre Technic of the Industries of the Fondery) is an Industrial Technical center.

Moulding sands: sand

Characteristics

A Sable of foundry must satisfy two fundamental requirements which are:

• the setting forms some in contact with a model mother by marrying all her details. The tightening of sand is carried out by a manual or mechanical effort (pressure, jolt, vibration, mechanical projection or tire),

• the conservation of this form until the Solidification supplements metal; that implies carateristic sufficient mechanics to resist the Static pressure of the molten metal like to the dynamic Pression (in order to avoid the phenomena of erosion) without making obstacle with the shrinking of metal in the course of solidification.

Other properties are also necessary:

• the Réfractarité, because sand must have a melting point higher than the temperature of run the alloy considered,

• the Permeability, which allows the evacuation of gases contained in the print of the mould or generated during casting,

• the absence of the reactions mould-metal likely to create defects of solid or gas inclusions in metal constituting the part,

• facility of Stripping, in order to be able to easily separate the part obtained from its mould.

General composition

The satisfaction of the whole of the requirements above makes that a sand of foundry is very generally composed of three categories of materials which are:

• a material Granulous or sands basic which constitutes the principal mass of it, to some extent its refractory skeleton,

• a Liant intended to agglomerate the grains between them and which must obligatorily be able to evolve/move of the liquid or plastic state in a solid state, it is the phenomenon of hardening,
• a certain number of Adjuvant S, without flexible capacity but nevertheless necessary to the success of a moulding, intended to confer secondary properties like the surface quality or the properties of release from the mould (of the model).

There exist three types of Sable:

• natural sand,
• theargillaceous one,
• sand with chemical catch.

Natural sand

It is directly extracted from career and is composed of silica, clay in strong proportion and dust. It is the version " naturelle" sand silico-argileux.

Silico-argillaceous sand

Sands silico-argillaceous, known as so synthetic in opposition to natural sands, consist of a refractory (Silica) agglomerated by clay activated by water. Additives are added to this sand in order to improve its behavior with casting of it

The components of sand are:

• siliceous sand
• the Clay, often of the type bentonite
• carbonaceous additives
• water
• of other elements possibly

Siliceous sand

Silica (Si02) is largely widespread on Earth. Extracted from careers, rough sand is treated by washing, is classified according to its granulometry, then dried. The purity of sands thus treated borders the 99,5%. The choice of sand depends on its granulometry i.e. size of the grains which constitutes it. It is defined by the calculation of the index of smoothness of sand. (index AFS).

The index of smoothness on a scale defined such as the smallest index represents a coarse granulometry, example the 35 AFS, the strongest index represents a fine granulometry, for example 120 AFS. A high index supports the surface quality of the blank to the detriment of the permeability of the mould and vice versa. Moreover one high index brings to an earlier vitrification of sand. In the ferrous alloy foundries this index is of order 55 to 65 AFS (case of the pig iron and cast iron), higher in the case of the light alloys (where the problem of vitrication does not arise).

NB: The temperature of pure vitrication of silica is of 1700°C.

Clay

Clay, generally of bentonite, is used as binder between the silica grains by coating of these grains. This clay is activated by water (built-in water mass equal to the third of the clay mass).

• carbonaceous additives

It is mainly made up of Mineral Black. This product is a pulverized coal whose size of the particles is lower than 80μm. Its role in the sand of moulding is to avoid the drenching, the penetration of alloy between the grains of sable.

Water

Its role is to activate clay in order to confer its plasticité.
to him

Sand with chemical catch

It is composed of silica (for the pig iron and cast iron) or of chromite (for steels), of resins (approximately 1% to 2% of the mass of sand) and of a catalyst (5 to 60% of the resin mass). The polymerization of the resins, started by catalyst makes it possible to ensure cohesion between the grains of sand. The addition of the resins and catalyst is done right before the moulding, generally using fast a screw mixer, provided with proportioning pumps which delivers the quantity of prepared sand necessary to the realization of a mould. The " duration of vie" of this prepared sand (time during which it can be worked before hardening) is adjustable according to the size of the moulds to realize. Generally about 5 minutes, it can be lengthened up to 15 min for the moulding of large parts. The fitting of this time is done while exploiting the proportioning of catalyst. sand is stored “dry”, generally in a silo located at the top or near the malaxeur.
There exist several types of resins, like the “Furan one” or the “PEP-SET”, for example.

Comparison of the three types of sands

• silico-argillaceous sand has weak mechanical properties with respect to sand with chemical catch.
• silico-argillaceous sand is employed in the moulding of part of low dimension (of 10 with 800mm), of unit manufacture to the very great series, while the moulding by sand with chemical catch also makes it possible to carry out large parts (of a few grams to 80 tons), but generally in small series (1 to 2000 parts).
• natural sand is reserved for the Foundry of Art because it gives a skin of remarkable part, however it is not very permeable and harms the evacuation of gases during casting, which is not génant in Foundry of Art because the parts are entirely worked over again, but is not acceptable for certain technical parts (porosity of gazage). Thus, this type of sand requires the drilling of vents (" Stack for evacuation of the gaz") in the mould in order to evacuate gases imprisoned in the print during casting. The natural sand mould requires a stoving to make it possible to dry them because it contains much water.

• These sands are which can be recycled, the first by de-dusting, clay addition, new sand addition (seldom) and water addition. The second by calcination, crushing dépoussiérage.
  Après these operations they are reintroduced in storage bins or hoppers to be again used. However, it is often necessary, in the case of sand with chemical catch, to use new sand in contact with the part, recycled sand being used to fill the zones of the moulds without contact with metal; or to incorporate a certain proportion of new sand in the mixture. This is why one generally uses:

• either two distinct silos,
• or of the silos provided with a separation.

Moulding sands: the model

General information

So " of imprimer" in sand the shape of the required part (and thus to make the mould), one manufactures a model. The traditional model out of wooden is less and less used, with the profit of models out of resin or metal which, more and more often, are cut on machines with Numerical control.

The model with the shape of the part and makes it possible to manufacture the desired mould. It is often cut into two following the " plan of joint" and can be supplemented by one or more " boxes with cores ".

The core boxes are intended to carry out negative out of sand of the hollow parts of the part, or zones not démoulables directly (undercut). The cores (out of sand with chemical catch) carried out in these boxes will be laid out in the mould before its closing.

The various parts composing the model must have " dépouille" , i.e. no surface of the model must be perpendicular within the meaning of release from the mould. The release from the mould in question is that which consists in removing the model of the mould, because the release from the mould of the part is carried out by breaking the mould (Décochage).

The model will have dimensions slightly larger than the part to be obtained, in order to take account of the shrinking of alloy with cooling. This withdrawal depends mainly on alloy to mould, but also other parameters like the average thicknesses of the part to be realized. The founder always indicates to the modeller the withdrawal to be taken into account for the realization of his models. For example, in the case of a withdrawal of 15 per thousand, a finished part of 1000mm length will have a model of 1015mm length.

Various types of models

• a natural model is a model out of wooden or resin whose form is that of the part. It can be crossed into two or delivered on mating plane, if this " plan" of joint is not plane with the geometrical direction of the term; in this case, the modeller delivers with his model a support materializing the mating plane, in which the model will be placed.

• a model of wood, resin, or metal alloys assembled on die is cut into two and each part is fixed on a plate comprising of the devices of positioning. This type of model is used with frames, comprising the same devices of positioning, intended to contain sand and to maintain it during handling of the mould and cast (black sand). The distances between centres of the frames and the die are not standardized, each foundry having its own standards.

• a model out of boxes (one speaks sometimes about snap-moulding) is similar to the model on die, but the plate is surrounded by four interdependent wood panels, assembled with the suitable skin. Sand took chemical is formatted in these boxes and unmoulded after catch (a few minutes). One thus does not use a frame. The devices of positioning can be holes of pins or centring devices made out of sand.

• One uses sometimes also a model of single use, in expanded polystyrene known as " model poly ". The model is obtained by machining and/or assembly of polystyrene plates. It is very economic and makes it possible to carry out large parts, but it is destroyed at the time of run mould. It is used for the realization of unit parts. The model poly is used as a model nature.
  Ce carried out reserved prototyping should not be confused with the process " Lost foam" applied to the mass production.

• the stereo model , realized in Stéréolithographie is another type of natural model, of which the use currently develops, only for prototyping. The model " nature" is realized by resin polymerization using a laser, according to a numerical definition. It is about a light and economic model, only adapted to the realization of some parts.

• In the case of the restoration of castings, for example, one can use the part to be restored like model, this method known as of against moulding , makes it possible to obtain a part " neuve" , but of size slightly lower than those of the original (approximately 12 per thousand in the case of aluminum) because of the withdrawal. In addition, the part intended to be used as model must be " habillée" , i.e. one will give of thickness (resin, stuck paperboard, etc) on the zones intended to be machined.

Process Lost Foam

This type of moulding says PMP (Proceeded by Lost Model) appeared in the years 1980, it consists in using an expanded polystyrene model which will remain in the mould and will vaporize with casting.

The model

For mass production, the model is obtained by moulding of a " maquette" in tools of the " type; injection moulding machines plasturgie ".

Stages of the process

• Manufacture of the expanded polystyrene model.
• Assembly of the models in bunch.
• Steeping in a barbotine bath for coating of refractory.
• the unit is plunged in a vibrating vat which one fills little by little with sand.
• the alloy is cast in the mould, the model vaporizes.
• sand is withdrawn, the part is ready to be finished.

Characteristics

Its advantages compared to gravitating casting in metal shell are a better profitability, a better quality, less pollution while making it possible to carry out parts with the complex forms.

Lost wax moulding

Case of the Foundries of precision

The models are out of wax or synthetic matter cast in metal forms (one thus moulds the models). These models can be made up of several assembled parts.

To manufacture the moulds of foundry, one assembles the models in bunches then one soaks them in a liquid ceramics then one powders with stuccos ceramic. These operations are repeated several times until obtaining a layer of seven millimetres thickness at least.

The wax is then liquefied by heating and is evacuated, then one runs metal aluminum, steel or bronzes in the still hot forms.

The main advantage of this process consists of the realization of parts with acute angles, a very smooth surface and tight dimensional tolerances. It is besides the only process of foundry of precision to mould steel. After cooling it is enough to eliminate ceramics by vibration or with the jet from water or sand blast.

Case of the Foundries of Art

The Foundry of Art is the specialist in the moulding of works to the very complicated forms. Indeed, the sculptor takes a free choice of the shapes of his statues and the Foundry of Art must reproduce with identical the work of the artist.

The model is obtained starting from the sculpture brought by the artist.

Stages of the process:

• Analysis of the sculpture by the moulist
• Cutting (possible) of the sculpture to facilitate obtaining the model
• Mould of the parts of the sculpture with an elastomer (we obtain an elastomer mould of two parts)
• Démoulage of the elastomer
• Assemblage of the two parts of the mould obtained
• Coulée wax in the mould
• Attente of solidification of wax either in mass (whole part) or in thickness (several millimetres of solidified then re-emptying)
• Assemblage of the various parts out of wax of the model
• Ajout of the system of filling and food, addition of the vents
• Enrobage of the model ofa refractory layer, obtaining the mould
• Stoving of the mould, the wax melts and is recovered
• Coulée mould
• Nettoyage of the part
• Ebarbage
• Ciselage of the part
• Polissage

Characteristics of elastomer

The elastomer offers possibilities of realization of forms in complex undercuts. The elastomer by its elasticity and its high lengthening is unmoulded simply by withdrawing undercuts without effort. Thus it is possible to obtain human faces reproduced in depth.

Characteristics of the works of art out of bronze

Work once polished, reveals the yellow/red color bronze, however it is noted that the majority of the bronze statues are green, brown, etc It is the application of a patina, (liquid made up of water and several secret ingredients) on the parts of work heated by the blowtorch, which while oxidizing gives this color to the statues.
The Foundries of Art are ancestral by their existances, artisanal by their achievements, and modern by their means of implementations (vacuum casting for example).

Case of use

The moulding sand is mainly employed in the foundries of pig iron and cast iron and steels, but also in the works aluminum smelting, for the realization of prototypes and small series (aeronautics and armament, in particular). As soon as the size of the series justifies it, one prefers the use of permanent moulds for the moulding of aluminum alloy part (cost of the tools much higher, but important rates from where overall costs of the weaker part).

The lost wax moulding is more expensive than the moulding sands, but it makes it possible to obtain fine parts and a great dimensional accuracy. Multiple veins or throats all are realizable the same standard of details complexes.
Inter alia applications are manufactured parts of structure for aerospace industry, but the process waxes lost can also apply to the foundry of Article.

The Lost foam is a recent process which is in particular used for the series production of certain parts of cars. This process should not be confused with the prototype moulding of parts starting from model " poly" , which remains moulding sands traditional on the level of the realization of the mould.

Permanent moulds

Introduction

For the foundry with permanent mould, this one is made out of metal (steel or cast iron). One often calls this mould “cockles”.

Contrary to the moulding sands, it does not have there stripping of the part, but a release from the mould. It is thus always the same mould which is used to carry out all the parts of a series.

The mould is in:

• steel (chromium 5%) or out of foundry pig iron cockles revolved (or low pressure)
• steel (chromium 5%) of type X38 CrMoV5 (standardized designation). Steel, after machining, undergoes a heat treatment made up of a hardening and two (or three) returned. Final hardness concerned is from 45 to approximately 55 HRC.

The mould is designed by the founder, carried out by the moulist (who can sub-contract the realization of the carcass and the heat treatments).

The mould is made up:

• of the carcass (out of less noble steel) which has as a role to maintain the prints and to ensure fastening on the plate of the moulding equipment.
• of the prints in contact with the molten metal. These prints are treated thermically and can be the subject of surface treatments (carbonitriding and standard surface treatment DEVELOPING COUNTRY TiAlN for the pins and cores).
• of a system of ejection (to leave the parts) made up of ejectors and of a battery of ejection (plate, laminates,…)

The moulds in foundry under pressure can be very complex, to cost between 30  000 € and 500  000 €, and to represent between 10 and 15% of the final price of the parts carried out (except machining).

The prints have one lifespan of:

• 150  000 injections (for aluminum alloys)
• 500  000 to 1 million injections for zinc alloys ( Zamak )
• 20  000 with 40  000 injections for copper alloys (brass 60/40)

The prints “die” by progressive crackings resulting from the thermal shocks (brutal heating during the injection of alloy and cooling caused by the refractory wash).

Various types of foundry with permanent mould

One distinguishes several processes according to the pressure to which one runs metal.

For aluminum alloys, for example, the standard IN 1706 distinguishes three types of foundries using of the permanent moulds:

• the casting chill by gravity , for which metal (Al Si7Mg, Al If 12, Al Si 7Cu 3, Al Mg 10,…) with the Atmospheric pressure (as for the moulding sands) in a metal mould is cast,

One distinguishes:

1. the moulding cockles conventional (statics)
2. the casting chill rocking (in which the machine and the mould swivel, thus guaranteeing a calmer filling eet a health improved part)
3. the process Cobapress (St Jean Industries) which combines 2 phases, the first of moulding of an outline and a second of forging mill, allowing to give a fiber drawing to alloy (Al Si7Mg) and to improve the mechanical characteristics (in fatigue it in particular)

• the moulding low pressure cockles of it, for which metal (Al Si7Mg) is injected into the mould by bottom with one pressure slightly higher than the atmospheric pressure (about 0,7 bar) and
• die casting , for which the pressure of injection of the molten metal (Al Si9Cu3Fe) can go up to 700 bar and the speed of injection in the mould up to 50 m/s. To note that the foundry under pressure also makes it possible to transform zinc alloys, brasses and alloys of magnesium.

The foundry under pressure is reserved for large productions series for markets of the automobile type, electric household appliances or electric because of the important price of the tools (mould and tool of cutting). The mould accounts for approximately 10% of the price of the parts.

A traditional cycle in foundry under pressure aluminum breaks up as follows: - proportioning of metal in an automatic ladle (furnace of maintenance near the machine) - payment of metal in the container - slow phase of injection - fast phase of injection - phase of compaction of alloy - solidification of the bunch - opening of the mould (part moving) - retreat of the drawers (so present) - ejection of the bunch (battery of ejection advances) - catch of the bunch automatically (arm robot) and evacuation towards a water vat (cooling) and a tool of cutting (press to be cut out in the cell) - descent of an arm of refractory wash and refractory wash (water and unmoulding agent) - phase of blowing (to eliminate free water on the surface) and left the arm of refractory wash - closing of the drawers and the moving mussel part

The duration of the cycle varies 40 seconds (machine of 400 tons) at approximately 2 minutes (machines 2000 tons) for alloys of aluminum and 10 S with 50 S for zinc alloys (smaller parts). Very many parts of size reduced or average are carried out in mussel multi-prints (2, 4 or 8 parts), which makes it possible to reduce the manufacturing costs.

Other processes of foundry (not standardized) and drifting of the foundry under pressure were developed. They remain exotic and little used at present:

• the squeeze casting (indirect) in which metal (Al Si7Mg) is injected at slow speed and is solidified under very strong pressure (1500 bars). This process is developed a little more in Asia.
• thixocoulée (and Rhéocoulée) the , for which the aluminum alloy is injected in a pasty state (and either in the liquid state).

This process, expensive is still not very widespread, but is in permanent evolution. Thixocoulée, initiated with M.I.T. (Flemming/1970) consists starting from bars having a thixotropic structure. These bars are cut in billets by the founder and are heated by induction on multipost carousel or single-user system in parallel. The overcost matter is of approximately 20% on the matter. Recently, several suppliers (SEED of Alcan, NRC of UBE, IDRA --> Ishinuma, Cooling slope,…) systems developed (said Rhéocoulée ) making it possible to the founder to directly manufacture thixotropic matter starting from liquid alloy Al conventional Si7Mg. Rhéocoulée replaces thixocoulée.

• the thixomolding . For magnesium alloys, the thixomolding (Thixomat company) developed a technology of injection of magnesium (by a screw) at the pasty state. These machines are marketed by suppliers Husky (USA/Europe) and JSW (Japan). The sale is conditioned by the payment of royalties (by machine). Nearly 300 machines would be in activity in Asia (Jap).
• aluminum foams which are porous aluminum materials. They have for principal innovating functions the noise or energy absorption (crash landing box), the heat transfer…

Several types of foams exist, with open or closed structure… These aluminum foams can be obtained by way of foundry in particular. This technology is implemented by the Technical center of Industries of Foundry (C.T.I.F.).

• recycling in foundry . Industries of the foundry (ferrous ore and nonferrous) make it possible to recycle a great number of raw materials resulting from other industries or other technological dies. The foundry can thus use old scrap, swarf (in bulk or compacted), matters crushed (of more or less large size) and even of the whole parts of intermediate size. In this direction, one can say that the foundry takes part in the industrial ecosystem and the valorization of the materials, whose one avoids storage in discharge thus, expensive and pollutant. The C.T.I.F works on these problems of recycling. Thus, recently, this organization developed the recycling of the PNUR (worn tires of vehicle) with the cupola furnace. The tires bring a certain quantity of iron and a combustible material, the gum, which replaces the foundry coke. The aluminum alloys can also be remelted almost indéfiniment.
  Dans the near future, the motor vehicles at the end of the lifetime will be déconstruits item by item. These parts will be sorted and the metal parts will turn over in the die foundry. The déconstruction hardly starts. At present, crushing already makes it possible to recover a strong percentage of matters, however not perfectly sorted.
• chilled casting . On a world level, approximately 5% of the cast iron are moulded in moulding cockles (in a metal mould). This specific technology is especially used in the Eastern European countries (Russia) or a knowledge to make important was developed for parts until a few hundreds of kilo approximately. In France, New Die Casting (Rochefort) is the only chilled casting founder. Let us note that this technology makes it possible to avoid the use of sand of foundry.

The mould

Contrary to the foundry sands for which the founder has a model which is, while simplifying, a model of the part life size, into positive and which will enable him to carry out as many not-permanent moulds than it has parts to manufacture, the tools used here are a mould , therefore tools in which the part appears into negative.

This mould is typically made up of a cap (or base plate) and of two sliding half moulds on this cap, which one calls the shells .

In the case of the moulding cockles by gravity, for small series, the shells are provided with handles studied to dissipate heat (what empèche not to handle them with gloves) and are operated manually.

In the case of greater series, they are operated on machines, using pneumatic or hydraulic jacks.

The interior shapes of the parts, if they are démoulables, are carried out using pins or removable daggers . The forms not démoulables are carried out with cores out of sand, like in the case of the not-permanent moulds. In this case, it is necessary beforehand to manufacture as many cores as of parts to be produced, and these cores, once the cast and unmoulded part, are stripped as in the case of the moulding sable.
(stripping consists in removing sand which is inside a part whereas stripping relates to the sand which is outside.)

Implementation

This technique seems simpler than the moulding sands in measurement or the mould is " prèt" to run the parts whereas the technique sand requires the manufacture of a new mould for each part.

However, the permanent mould requires a preparation before the casting which consists with:

• Possibly, to assemble the tools on the suitable machine (mainly in great series) provided with its jacks,
• to preheat the shells,
• To check, see remaking the refractory wash.

To wash a shell consists in coating the parts in contact with fused metal of various intended products, in particular, to control solidification, in the same manner as the provision of runners and of coolers in a mould sands; like avoiding an adherence of fused metal on the metal mould (Case of the alloys of aluminum, the alloy adheres easily to the steel of the shell).

Case of use

The moulding shell is a process for which the tools (mould) are much more expensive and difficult to modify that of the moulding sands. On the other hand, times production of the parts, once the tools prepared, are much weaker.

This technique is not practically never used for the prototypes but is appropriate for the series, in particular with regard to die casting.

The casting chill by gravity applies mainly to the small series (aeronautics for example) but costs much (because of the expenses of startup) if the quantities to be produced are weak.

Terminology

Trades

• the Mouleur is that which manufactures a sand mould, starting from a model.
• the Noyauteur is that which prepares the cores which will be incorporated in the mould to carry out the parts in hollow or undercut of the part.
• the Modeleur is that which manufactures the model out of wooden or resin.
• the Mouliste is that which manufactures tools permanent (moulding cockles and die casting).
• the Fondeur is that which deals with the smelters, which prepare metal before casting; and also, by extension, that which provides foundries to its customers.
• the Décocheur is that which breaks the moulds to leave the blank casting.
• the Ebarbeur is that which finishes the part by separating it from its system of filling and food and while grinding the possible burs.
• the Grenailleur or the Sableur is that which deals with granulating or to sand the parts (bombardment of solid particles such as balls of steel or corundum to pickle adherent sand with the blank of cast).

Techniques

• Emballer a model consists in building the mould around this model.
• Noyauter consists in carrying out the cores who will be incorporated in the mould.
• To unmould , in the case of the moulding sands, consists in removing the model of the mould.
• To core up (to pronounce ren-to mould and not remould), always with sand, consists in assembling with precision, right before casting, all the parts of the mould which were prepared separately: below, above, covers, cores, pouring basins, etc
• Décocher consists in removing the part cast from the sand which surrounds it or which it contains.
• To strip , consists in extracting from a part, after run and solidification, the sand which constituted the cores.
• To eject , consists in leaving the part out of permanent mould (revolved, low pressure and under pressure) using metal ejectors connected to a battery ejection
• Poteyage in revolved moulding shell and low pressure consists in covering the mould (out of steel) of a refractory deposit (which will be renewed once by team approximately) of 50 µm with 400 µm (according to the zones) being used for protecting the mould and modulating heat exchange.
• Poteyage in die casting consists in pulverizing with each cycle on the mould a mixture of water (98%) and unmoulding product (2%). This operation is used to cool the mould, to protect the mould and finally to unmould the part correctly.

External bonds

• the C.T.I.F (Centre Technic of the Industries of the Fondery) is an Industrial Technical center following the law of July 22nd, 1948. Today its vocation is double.

to *Servir the profession of the French Foundry like had defined it the “founding fathers” through three types of missions:

· the Research & Development collectives (process, produced,…)

· technological diffusion

· standardization (CTIF is office of standardization for the foundry)

*Proposer with industries of working of materials a pallet of performances of service (and simulation structural analysis of filling of casting, diagnosis of foundry, analyzes part, measurements on site, specific training, R & D to measure, councils various, solution to problem of nonquality) corresponding to the competences developed within the framework of its mission founder.

• the Founders of France is the French professional organization who represents the companies of industries of the foundry. It gathers nearly 300 companies.

• the B.N.I.F is the French office of standardization in the field of the foundry
• the E.T.I.F are the Technical Editions of Industries of the Foundry. They produce and market technical works and CD-ROMs on all the fields of the foundry (aluminum, cast iron, steel,….). Online shopping
• the FRA is an association of people which gathers primarily founders and suppliers. The FRA organizes jointly with the CTIF of the training courses (Cyclatef/Actifor) on catalog of which some teach the bases of the foundry (public: ing. and techn. B.E or purchasing of parts).
• the E.S.F.F is the university of foundry and forging mill which trains the engineers and frameworks of the industry of the foundry and the forging mill since 1923. It should be noted that it is the only school of this type in Europe.

Simple: Foundry

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