On The Subject Of Foundry Work. Part I

1. Why is facing used on a mold?

2. What is the practical way to test the temper of molding sand?

3. What are chaplets?

4. What three forms of gases must be carried off by venting?

5. What is a skimming gate?

6. What are the properties of a good molding sand?

7. When making a large core, what provision is made for handling it after baking?

8. How should a deep mold of heavy section be gated?

9. How are molds for pulleys usually gated?

10. What are feeders?

11. What is the effect on the casting of ramming the mold too hard?

12. Name two means used to support the sand in the cope of a mold.

13. What are the common forms of chaplets?

14. How are the sides of deep molds vented when a flask is used?

15. What is the upward pressure on a cope where the exposed surface is 2 feet square and the depth 19 inches?

16. Why is blacking used on a core?

17. How are molds secured before pouring?

18. What are gaggers?

19. What precautions are taken in venting the sides and bottom of work which is bedded in the floor?

20. Name three important objects sought in venting a mold.

21. What size of runner is good on bench work?

22. What is the object in using a sand match?

23. Where are gaggers most commonly used?

24. What precaution is taken with sand coming next the pattern?

25. What is the danger resulting from too soft ramming?

26. How are bench molds vented?

27. How does a skimming gate act in keeping impurities out of a mold?

28. How should thin work be gated?

29. What is the object in feeding castings?

30. Why is hay rope used on loam or barrel cores?

31. How are small patterns arranged when quantities of the same piece must be put up by hand?

32. What operations are done on the three ordinary classes of molding machines?

33. How are molding machine patterns drawn?

34. How is the vent taken from the ends of long cores?

35. How are the cores for pockets or deep recesses in a casting supported in a mold?

36. Give two methods of coring holes through a casting at a level below the joint line.

37. How are cores hung in the cope?

38. How may a warped core plate be used for baking a flat core?

39. What are the advantages of using a machine to make stock cores?

40. How are irregular shaped cores, like port cores, baked?

On The Subject Of Foundry Work. Part II

1. What is meant by the sand bottom of a cupola? How is it formed?

2. How many thicknesses of fire brick is usually placed inside of the shell of a cupola?

3. In the design of a cupola, what bearing should the class of work to be poured have on the height at which the tuyeres should be placed above the bed?

4. What are some of the precautions necessary in pouring a mold in order to obtain the best results?

5. Describe the operations in making a simple loam mold.

6. Having 65 per cent of a mixture settled upon, with a silicon content of 1.66 per cent, in what proportions could No. 1 and No. 3 irons be added, with silicon 2.65-1.75 per cent, respectively, so that the castings should contain 2.25 per cent silicon? Deduct 20 per cent silicon for loss in cupola.

7. State the successive steps necessary in operating a cupola furnace.

8. How should the bed charge for a new cupola be determined?

9. What regulates the amount of fuel to be put between the charges of iron in a cupola?

10. What is the difference between the shrinkage of steel castings and that of iron?

11. What are some of the methods used to produce sound steel castings?

12. How is steel poured? What precautions are taken to prevent a mold for steel being "cut" by the rush of the metal?

13. What precautions are taken to prevent fracture at interior corners on steel castings?

14. How does the riser on a steel casting differ from one for iron?

15. What kinds of flasks are generally used for steel molds? Why?

16. What process are the larger steel castings put through to relieve internal shrinkage strains?

17. What are some of the properties of brass molding sand?

18. In what order are the metals for bronze melted?

19. What care must be used in melting and mixing brass?

20. What is the highest percentage of tin that may be mixed with copper and form a serviceable alloy?

21. What are the usual proportions of copper and zinc in yellow brass?

22. How is a common brass furnace constructed?

23. Why must copper alloys be melted without access of oxygen?

24. What is the best modern method of heating and ventilating a foundry?

25. What is the basis of Keeps tests, and what size bar is used for them?

26. What is the size of the test bar or "arbitration bar" so called, recommended by the American Foundrymens' Association; and how is it poured?

27. What is the advantage of overhead traveling cranes over jib cranes?

28. Where should the blower be placed in relation to the cupola?

29. What is the advantage of having the coke and iron stor-age on a level with the charging platform of the cupola?