Complete Casting Handbook Metal Casting Processes Techniques and Design 3rd Edition Edition by John Campbell ISBN 1856178099 9781856178099

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ISBN 10: 1856178099 
ISBN 13: 9781856178099
Author: John Campbell

Complete Casting Handbook is the result of a long-awaited update, consolidation and expansion of expert John Campbell’s market-leading casting books into one essential resource for metallurgists and foundry professionals who design, specify or manufacture metal castings.

The first single-volume guide to cover modern principles and processes in such breadth and depth whilst retaining a clear, practical focus, it includes:

• A logical, two-part structure, breaking the contents down into casting metallurgy and casting manufacture
• Established, must-have information, such as Campbell’s ‘10 Rules’ for successful casting manufacture
• New chapters on filling system design, melting, molding, and controlled solidification techniques, plus extended coverage of a new approach to casting metallurgy

Providing in-depth casting knowledge and process know-how, from the noteworthy career of an industry-leading authority, Complete Casting Handbook delivers the expert advice needed to help you make successful and profitable castings.

Complete Casting Handbook Metal Casting Processes Techniques and Design 3rd Table of contents:

Volume 1 – Casting Metallurgy

Chapter 1: The Melt
1.1 Reactions of the Melt with Its Environment
1.2 Transport of Gases in Melts
1.3 Surface Film Formation
1.4 Vaporization

Chapter 2: Entrainment
2.1 Entrainment Defects
2.2 Entrainment Processes
2.3 Furling and Unfurling
2.4 Deactivation of Entrained Films
2.5 Soluble, Transient Films
2.6 Detrainment
2.7 Evidence for Bifilms
2.8 The Importance of Bifilms

Chapter 3: Flow
3.1 Effect of Surface Films on Filling
3.2 Maximum Fluidity (The Science of Unrestricted Flow)
3.3 Extended Fluidity
3.4 Continuous Fluidity

Chapter 4: Molds and Cores
4.1 Molds: Inert or Reactive
4.2 Transformation Zones
4.3 Evaporation and Condensation Zones
4.4 Mold Atmosphere
4.5 Mold Surface Reactions
4.6 Metal Surface Reactions
4.7 Mold Coatings

Chapter 5: Solidification Structure
5.1 Heat Transfer
5.2 Development of Matrix Structure
5.3 Segregation

Chapter 6: Casting Alloys
6.1 Zinc Alloys
6.2 Magnesium
6.3 Aluminum
6.4 Copper
6.5 Cast Iron
6.6 Steels
6.7 Nickel-Base Alloys
6.8 Titanium

Chapter 7: Porosity
7.1 Shrinkage Porosity
7.2 Gas Porosity
7.3 Porosity Diagnosis

Chapter 8: Cracks and Tears
8.1 Hot Tearing
8.2 Cold Cracking

Chapter 9: Properties of Castings
9.1 Test Bars
9.2 The Statistics of Failure
9.3 Effect of Defects
9.4 Tensile Properties
9.5 Fracture Toughness
9.6 Fatigue
9.7 Elastic (Young’s) Modulus and Damping Capacity
9.8 Residual Stress
9.9 High-Temperature Tensile Properties
9.10 Oxidation and Corrosion Resistance
9.11 Leak-Tightness
9.12 Surface Finish
9.13 Quality Indices

References – Volume I

---

Volume 2 – Casting Manufacture

Introduction to the Casting Manufacturing Industry

Section 1: The 10 Rules for Good Castings
10.1 Rule 1: “Use a Good-Quality Melt”
10.2 Rule 2: “Avoid Turbulent Entrainment” (The Critical Velocity Requirement)
10.3 Rule 3: “Avoid Laminar Entrainment of the Surface Film”
10.4 Rule 4: “Avoid Bubble Damage”
10.5 Rule 5: “Avoid Core Blows”
10.6 Rule 6: “Avoid Shrinkage Damage”
10.7 Rule 7: “Avoid Convection Damage”
10.8 Rule 8: “Reduce Segregation Damage”
10.9 Rule 9: “Reduce Residual Stress”
10.10 Rule 10: “Provide Location Points”

Section 2: Filling System Design
Chapter 11: Filling System Design Fundamentals
11.1 The Maximum Velocity Requirement
11.2 Gravity Pouring – The ‘No-Fall’ Conflict
11.3 Reduction or Elimination of Gravity Problems
11.4 Surface-Tension-Controlled Filling

Chapter 12: Filling System Components
12.1 Pouring Basin
12.2 Sprue (Down-Runner)
12.3 Runner
12.4 Gates
12.5 Surge Control Systems
12.6 Vortex Systems
12.7 Inclusion Control: Filters and Traps
12.8 Filters

Chapter 13: Filling System Design Practice
13.1 Background to the Methoding Approach
13.2 Selection of a Layout
13.3 Weight and Volume Estimate
13.4 Pressurized Versus Unpressurized
13.5 Selection of a Pouring Time
13.6 Thin Sections and Slow Filling
13.7 Fill Rate
13.8 Pouring Basin Design
13.9 Sprue Design
13.10 Runner Design
13.11 Gate Design

Section 3: Processing (Melting, Molding, Casting, Solidifying)
Chapter 14: Melting
14.1 Batch Melting
14.2 Continuous Melting
14.3 Holding, Transfer, and Distribution
14.4 Melt Treatments
14.5 Cast Material
14.6 Remelting Processes

Chapter 15: Molding
15.1 Inert Molds and Cores
15.2 Aggregate Molding Materials
15.3 Binders
15.4 Other Aggregate Mold Processes
15.5 Rubber Molds
15.6 Reclamation and Recycling of Aggregates

Chapter 16: Casting
16.1 Gravity Casting
16.2 Horizontal Transfer Casting
16.3 Counter-Gravity
16.4 Centrifugal Casting
16.5 Pressure-Assisted Casting
16.6 Lost Wax and Other Ceramic Mold Casting Processes
16.7 Lost Foam Casting
16.8 Vacuum Molding (V Process)
16.9 Vacuum-Assisted Casting
16.10 Vacuum Melting and Casting

Chapter 17: Controlled Solidification Techniques
17.1 Conventional-Shaped Castings
17.2 Directional Solidification (DS)
17.3 Single Crystal Solidification
17.4 Rapid Solidification Casting

Chapter 18: Dimensional Accuracy
18.1 The Concept of Net Shape
18.2 Mold Design
18.3 Mold Accuracy
18.4 Tooling Accuracy
18.5 Casting Accuracy
18.6 Metrology

Chapter 19: Post-Casting Processing
19.1 Surface Cleaning
19.2 Heat Treatment
19.3 Hot Isostatic Pressing
19.4 Machining
19.5 Painting
19.6 Plastic Working (Forging, Rolling, Extrusion)
19.7 Impregnation
19.8 Non-Destructive Testing

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