PART 1 Introduction to Casting
Section 1: Overview of the Casting
1.
The development of casting
2.
Casting process
Section 2 Classification of Castings
1.
Classification by material
2.
Classification by mold
3.
Classification by casting method
4.
Classification by purpose
5.
Classification of other castings
Section 3 Castability of Castings
1.
Castability of castings
2.
Casting stress and cracking
3.
segregation
4.
Absorption of gases and inclusions

PART 2 MOLD MATERIALS AND MANAGEMENT
Section 1 Casting
1.
Conditions and properties of foundry sand
2.
Types of foundry sand
Section 2: Gyu-sa
1.
Types of silica
2.
Special silica
Section 3: Binders and Additives
1.
Weapon adhesive
2.
Organic binder
3.
Special binder
4.
additives
5.
Brother Do
6.
Lee Hyung-je
Section 4: Adjustment and management of foundry workers
1.
Foundry sand adjustment
2.
Regeneration treatment of foundry sand
Section 5: Mixing of foundry sand by material
1.
Foundry sand for cast iron
2.
Foundry sand for steel casting
3.
Copper alloy foundry sand
4.
Aluminum alloy foundry sand
Section 6 Casting Sand Testing Method
1.
Moisture measurement test method
2.
Clay content test method
3.
Particle size test method
4.
Air permeability test method
5.
Strength test method
6.
Surface hardness test method
7.
High temperature properties and heat resistance tests

PART 3: Circular and Mold 69
1st verse circle
1.
Circular material
2.
Types of circles
3.
Things to consider when making a prototype
Section 2 mold
1.
Role and conditions of the mold
2.
Classification of molds
3.
Mold making method
4.
Finishing work of the mold
Section 3 Mechanical Sculpture
1.
The antithesis
2.
Mechanization of molding operations
4-section core production
1.
Core characteristics
2.
Structural features of the core…
3.
Core manufacturing
PART 4 ​​Casting Method
Section 1 General casting method
1.
Casting method
2.
Tanggu injection method
3.
Tanggu system design
Section 2: Pressure cooker method
1.
The necessity of pressure
2.
Types and shapes of pressure cookers
3.
Directional coagulation and effects of pressure
4.
Location and effects of pressure points
5.
Pressure calculation
3-section casting design
1.
Design for casting stress
2.
Design for directional coagulation
3.
Establishment of a casting plan
4.
Basic shapes of castings and their casting methods
5.
3D solidification analysis and design of the spout system
Section 4 Casting methods for various castings
1.
Cast iron castings and steel castings
2.
copper alloy castings
3.
aluminum alloy castings

PART 5 SPECIAL MOLDS AND SPECIAL CASTINGS 155
Section 1 Special Casting Law
1. CO2 mold
2.
Self-healing mold
2-1.
Huran mold
2-2.
Pep set mold
3.
Casting of lost models
4.
cold box mold
5.
Die-cut mold manufacturing
6.
magnetic mold
Section 2 Special Casting Method
1.
vacuum casting
2.
low pressure casting
3.
High pressure solidification casting
4.
centrifugal casting
5.
Mold casting
Section 3 Other casting methods
1.
Show Process Casting
2.
plaster casting
3.
Chilled casting
4.
continuous casting process

PART 6 Precision Casting
Section 1 Die casting
1.
Die casting method
2.
Classification of die casting machines
3.
Structure of a die-casting casting machine
4.
Diecasting machine accessories
5.
Die casting mold
6.
Main processes of die casting
7.
Key management items by process
8.
Defects and countermeasures in die-casting products
9.
Causes and countermeasures for dimensional defects
10.
Causes and countermeasures for material defects
Section 2 Investment Casting
1.
outline
2.
Characteristics of wax models
3.
Making a wax model
4.
Assembling a wax model
5.
Mold making
6.
dewaxing
7.
Mold firing and molten metal pouring
8.
Defects in investment castings
3-section shell mold casting
1.
outline
2.
Characteristics of shell molding method
3.
Coated sand manufacturing
4.
How to make a shell mold
5.
Shell core manufacturing method
6.
Defective shell parts

PART 7 METAL MELTING MATERIALS 241
Section 1 Iron Now Material
1.
pig iron
2.
Recycled iron…
3.
steel
4.
ferroalloys
Section 2 Non-ferrous metals
1.
Pure metal now
Section 3 Other Materials
1.
Gatanje
2.
desulfurizer
3.
Inoculant
4.
Conceptualization
5.
Jo Jae-je
Section 4 Refractory
1.
Overview of refractories
2.
Classification and types of refractories
3.
Properties of refractories
4.
acid refractories
5.
Basic refractories
6.
Refractory insulation
7.
Irregular refractories

PART 8 METAL MELTING 269
Section 1 Melting furnace
1.
Into the crucible
2.
electric melting furnace
3.
Flat surface
4.
reflector
Section 2 Dissolution Operation
1.
Melting of steel by arc furnace
2.
Melting of aluminum alloys
3.
Melting of copper alloys
4.
Melting of cast iron by induction furnace
5.
Melt temperature measurement
Section 3 molten metal treatment
1.
Degassing treatment
2.
Desulfurization work
3.
inoculation
4.
Graphite spheroidization treatment
Section 4: Old-age test method
1.
Shape of the molten metal surface
2.
Cold test
3.
Carbon equivalence analyzer
4.
Fracture examination of graphite
Section 5: Pouring molten metal
1.
ladle
2.
Setting the injection temperature

PART 9 Post-processing, Maintenance, and Inspection 313
Section 1 Post-processing of castings
1.
Mold separation and desanding
2.
Casting cleaning work
Section 2 Repair of the casting
1.
Repair by welding
2.
Repair by filler
3.
Repair by impregnation treatment
4.
Repair by metal rising
5.
Repair by soldering
6.
Repair by over-pouring
Section 3 Inspection of Castings
1.
Appearance inspection
2.
Chemical composition test
3.
non-destructive testing
4.
Dimensional inspection

PART 10 Casting Defects and Prevention Measures
Section 1 Defects in Castings
1.
pore
2.
shrinkage cavity
3.
crack
4.
Interventions
5.
surface defects
6.
Miss Run
7.
Tanghui defect
8.
Dimensional defects

PART 11 ENVIRONMENTAL MANAGEMENT AND SAFETY 349
Section 1 Environmental Facilities
1.
Dust equipment
Section 2: Workplace Environment Inspection
1.
Daily inspection of the foundry
2.
Workplace Environment Equipment Checklist
Section 3 Safety Management
1.
Disaster Prevention Basics
2.
Safety management by task
3.
Preemptive prevention and inspection of risk factors in the casting process

Appendix and References

As industrial society developed, the demands for shapes and materials required for products diversified, and casting technology for producing them also developed.
These various casting technologies are broadly divided into general casting, precision casting, and special casting.
General casting refers to the most commonly used sand casting, and all casting technologies other than general casting, such as die casting, investment casting, shell mold, centrifugal casting, metal mold casting, low-pressure casting, vacuum casting, high-pressure solidification casting, and self-hardening casting, are collectively called special casting or precision casting.
These special casting technologies will continue to be developed as new technologies are developed in the future.
This textbook, Metal Casting Engineering, covers the overall process required to produce castings.
We have put a lot of effort into writing this book by inserting as much on-site casting technology content as possible, using technical data collected through numerous on-site casting technology training sessions and the author's research materials.
I believe this will be very helpful to the general public, working professionals, and college students who are just starting to learn casting techniques, and especially to those who wish to obtain a casting technique certificate.
As we enter the Fourth Industrial Revolution, casting technology capable of developing, manufacturing, and distributing suitable metal materials will also develop alongside the Fourth Industrial Revolution.
I sincerely hope that this textbook will be of some help in the development of the foundry industry, and that it will also serve as a resource for foundries to live in a good environment and receive good treatment.