DEFSTAN 02-747(PT5)/1(2000) : 2000

TITLE PAGE
SCOPE
FOREWORD
Sponsorship
Conditions of Release
General
MOD Tender or Contract Process
Related Documents
Health and Safety
Warning
CONTENTS
SECTION 1 - THE CASTING PROCESS
            1.1 Preface
            1.2 Solidification of Liquid Nickel-Aluminium-Bronze
            1.3 The Relationship between Casting Dimensions
                and Solidification Time
            1.4 The Formation of Sound Metal and the Reasons
                why Shrinkage Occurs
            1.5 Tapers
            1.6 Chills
            1.7 Feeders
            1.8 The Formation of Oxides
SECTION 2 - THE MOULDING PROCESS
            2.1 Applicability
            2.2 Patterns
            2.3 Determination of Moulding Direction
            2.4 Dimensional Tolerances
            2.5 Wall Thickness
            2.6 Machining Allowances
SECTION 3 - THE DESIGN PROCESS
            3.1 Introduction
            3.2 Casting Design
            3.3 The Design Sequence
            3.4 The Casting Drawing
            3.5 Records of Feeding and Mould Filling System
            3.6 Calculators and their Use
SECTION 4 - DESIGNING FOR DIRECTIONAL SOLIDIFICATION AND
            ADEQUATE FEEDING
            4.1 Applicability
            4.2 Designing for Directional Solidification
            4.3 Modulus
            4.4 Geometric Moduli
            4.5 Simplified Modulus Calculations
            4.6 Modulus Correction Factors: Effect of Shape
            4.7 Modulus Correction Factors: Effect of Junctions
            4.8 Effective Moduli of 'L' and 'T' Junctions
            4.9 Effective Moduli of Other Junctions
            4.10 Method to Determine the Solidification
                 Pattern of a Complex Junction
            4.11 Influence of Cores and Sand Thicknesses
                 on Modulus
            4.12 Minimum Allowable Sand Thicknesses Between
                 Moulding Box and Casting
            4.13 Effect of Sand Thickness Between Parts of
                 Castings
            4.14 Influence of Chills on the Moduli of Castings
            4.15 Influence of Insulating Mould Inserts on the
                 Moduli of Castings
            4.16 Feeder Position-Feeding Distances of Parts
                 of Castings of Uniform Thickness
                 4.16.1 Parts of Castings 12 mm to 75 mm Thick
                 4.16.2 Parts of Castings less than 12 mm thick
            4.17 Use of Taper to Induce Directional
                 Solidification
                 4.17.1 Minimum Taper Required to Ensure
                        Soundness of Plate Castings
                 4.17.2 Minimum 'Straight' Taper Required to
                        Ensure Soundness in Plate Castings
                 4.17.3 Minimum Taper Required to Ensure Feeding
                        around the Circumference of Tubes
                 4.17.4 Feeding Distances along Tubes Tapered
                        around their Circumference
            4.18 Progressive Feeding of Parts of Castings by
                 other Parts of Higher Modulus
                 4.18.1 When the Ratio of Moduli is Equal to,
                        or Greater than 1.5
                 4.18.2 When the Ratio of Moduli is Less Than 1.5
            4.19 Feeding Distances and Junctions
                 4.19.1 Chilled Junctions
                 4.19.2 Fed Junctions
            4.20 Insulating Mould Inserts
                 4.20.1 Materials
            4.21 Limitations of Ceramic Fibre Insulating Mould
                 Inserts
                 4.21.1 Dross Formation
                 4.21.2 Dimensional Stability
                 4.21.3 Optimum Thickness
                 4.21.4 Feeding Distance and Insulating Mould
                        Inserts
                 4.21.5 Insulating Mould Inserts and Isolated
                        Thick Sections
            4.22 Feeder Zones
            4.23 Minimum Feeder Size
            4.24 Simplified Method of Determining Whether
                 Feeder Zones are Volume-Dependent Using
            4.25 Additional Feeding Volume Requirements when
                 Blind Feeders are Used
            4.26 Feeder Height, Shape and Connection to Casting
            4.27 Summary of Rules for designing a Feeding
                 System
SECTION 5 - FILLING THE MOULD DESIGN OF THE RUNNING AND
            GATING SYSTEM
            5.1 Introduction
            5.2 Filling Rate
            5.3 Mould Rotation Techniques
                 5.3.1 Design Principles
            5.4 Temperature Variations in Durville Filled
                 Moulds
            5.5 Static Bottom-Gating Systems
                 5.5.1 Design Principles
            5.6 Temperature Variations in Bottom-gated Moulds
            5.7 Filling Rates
            5.8 Simplified Calculation of Initial Filling Rate
                 from Cast Weight
            5.9 Choosing the Ingate Sites-Horizontal or Vertical?
            5.10 Positioning of Ingates
            5.11 Calculation of the Dimensions of a Bottom-Gating
                 System
                 5.11.1 Design Principles
            5.12 The Ingates
                 5.12.1 Ingate Shape
            5.13 Runners
            5.14 Multi-running System Castings
            5.15 The Sprue
            5.16 The Pouring Basin
            5.17 The Well-base
            5.18 The Dross Traps
            5.19 Calculation and Recording of Running and
                 Gating Designs in Everyday Practice
            5.20 Summary of Rules for Designing Running and
                 Gating Systems
ANNEX A - RELATED DOCUMENTS
ANNEX B - DEFINITIONS AND ABBREVIATIONS
ANNEX C - CASTING DESIGN EXAMPLES
ANNEX D - EXAMPLES OF RUNNING, GATING AND FEEDING METHODS FOR
          PRODUCTION CASTINGS
ANNEX E - MATERIAL PROPERTIES OF SAND CAST NICKEL-ALUMINIUM-BRONZE
          TO NES 747 PART 2
ANNEX F - SUMMARY OF CALCULATORS AND TABLES USED IN NES 747
          PART 5, ALSO SUMMARY OF RULES FOR DESIGNING FEEDING
          AND MOULD FILLING SYSTEMS
ANNEX G - NON-ESSENTIAL DOCUMENTS PROVIDING BACKGROUND INFORMATION
ALPHABETICAL INDEX

Gives casting designers and founders advice on the use of procedures to be followed for the production of high integrity sand castings in complex nickel aluminium bronzes to Class 1 standards.