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Process

• In a foundry operation, molten metals are shaped into a variety of forms. Iron and steel parts are typically formed by the sand casting method; aluminum and other non-ferrous metals are typically formed by the die cast method.
• Sand casting utilizes a pattern molded from a mixture of sand, clay, and binder (often called "green sands").Molten metal is poured into this pattern, and allowed to cool. During "shake out," the cooled cast part is then removed from the now-waste sand mixture and proceeds to various processes including machining and assembly.  Examples of component parts  include the engine block and cylinder head, and CV joint.
•  Die casting is often used to mold smaller metal parts such as transmission or compressor casings. The shape of the component part is forged in relief in a metal pattern. Molten metal is poured into this die and allowed to cool. The cast part is removed and to prevent sticking, a releasing agent is often sprayed before the metal is poured. Examples of die casting include the transmission case and various interior trim and component parts.

Technology

• Manufacturing techniques have been developed over several decades that allow control over the macro & microstructure of the materials to produce several important material effects. Three forming techniques dominate – ribforming, rollerforming and isopressing. Each gives different structural features in a crucible.
•  Rib and rollerforming techniques impart shearing effects on the material which orient the graphite along a designated direction.
•  Isopressing involves relatively little shearing of the materials, producing a random orientation of the structure. The orientation effect has a huge influence on crucible behaviour. High levels of orientation promote improved thermal shock and impact resistance.

Application

• The key applications for Phenol and Acetone are in the production of polycarbonate, plastics, phenolic
  resins, synthetic fibres (such as nylon) and solvents. These products are used in a diverse range of endmarkets, including the automotive, construction, electronics and fibre industries.

• The beneficial use of waste foundry sand generated by metal casting foundries using sand containing the sand binders or binder systems in their sand mold production processes.

• Market the application of fly ash as a base material substitution for foundry sands (FASAND mixture) to produce iron castings for the automotive industry. Two types of fly ashes were examined: the fly ash from the FirstEnergy Eastlake Plant (USA) and, the fly ash from the Skawina Power Plant located in, Poland from where the visiting professor working on the project is the Deputy Director.

Market

• The U.S. foundry industry is characterized by a high degree of concentration and a large proportion
  of small producers. The top 10 responding producers collectively accounted for 32 percent, by quantity, of
  the industry's total production.
• Approximately 50 percent of responding producers have 100 or fewer production workers. An average responding firm produced about 24,000 short tons of castings and employed 184 production workers

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