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PRODUCTION OF MOULDS AND CORES

Castings can be produced either in permanent metal moulds or in expendable refractory ones. Major part of the foundry industry output represents the castings made in refractory expendable moulds.

Moulding methods range from the manual moulding techniques up to the machine moulding ones. Owing to the low productivity and strenuous labour, manual moulding is currently used only to a limited extent. On the contrary, enabling the moulds to be produced at high rates, machine moulding is characterized by high productivity, higher accuracy and no need of a highly qualified labour force. The most modern foundries for mass production use the automatic moulding lines in which a high degree of mechanized operations and automation is achieved. The entire casting process there is mechanized and automated; not just the moulding operation itself, as is the case of individual moulding machines.

According to the class of the binder and the way of achieving the final strength of the moulding aggregate, individual methods of the mould and cores production can be divided into four generations.

Moulding Methods ofThe Way of Achieving Final StrengthBasic Composition of the Moulding Aggregate
1st GenerationMechanical compactionBase aggregate, clay binder and water
2nd GenerationHardening by chemical change of the binderBase aggregate, chemical binders
3rd GenerationPhysical binding between the aggregate grainsBase aggregate, no binder (sometimes water)
4th GenerationAggregate grains are bonded with biological substancesBase aggregate, binder of living organisms (e.g. bacteria)