DEFSTAN 02-824(PT2)/1(2000) : 2000

TITLE PAGE
SCOPE
FOREWORD
Sponsorship
Conditions of Release
General
MOD Tender or Contract Process
Health and Safety
Warning
CONTENTS
SECTION 1 - THE CASTING PROCESS
            1.1 Preface
            1.2 Recommended Design Procedures
            1.3 Casting Design
            1.4 The Design Sequence
            1.5 The Casting Drawing
SECTION 2 - SOLIDIFICATION AND CASTING MODULI
            2.1 Introduction
            2.2 Solidification of Cupronickel
            2.3 The Mechanism of Solidification
            2.4 Directional Solidification
            2.5 Casting Moduli
            2.6 Geometric Moduli
            2.7 Estimation of Moduli
            2.8 Modulus Correction Factors: Effect of Shape
            2.9 Modulus Correction Factors: Effect of Junctions
SECTION 3 - DESIGNING FOR SOUNDNESS: POSITIONING
            AND SIZING OF FEEDERS
            3.1 Introduction
            3.2 Designing for Directional Solidification
            3.3 Positioning of Feeders: Feeding Distances of
                 parts of Castings of Uniform Thickness
            3.4 EXAMPLE OF THE USE OF FEEDING DISTANCE
                 INFORMATION
            3.5 Use of taper
            3.6 EXAMPLE OF THE USE OF THE TAPER CALCULATOR
            3.7 Circumferential Feeding of Tubes Using Taper
            3.8 Feeding of Thin Sections by Thick Sections
            3.9 EXAMPLE OF A THICK SECTION FEEDING A
                 THIN SECTION
            3.10 Feeding of Junctions
            3.11 EXAMPLE OF FEEDER ZONE CALCULATION
            3.12 The Size and Design of Feeders
            3.13 EXAMPLES OF MINIMUM FEEDER SIZE
                 CALCULATION
            3.14 Summary of Rules for Designing a Feeding System
SECTION 4 - FILLING THE MOULD: DESIGN OF THE RUNNING AND
            GATING SYSTEM
            4.1 Introduction
            4.2 Design and Calculation of the Dimensions of
                Bottom Gating Systems
            4.3 Summary of Rules for Designing Filling Systems
SECTION 5 - PREPARATION OF THE MOULD
            5.1 Introduction
            5.2 Patterns
            5.3 Machining Allowances
            5.4 Dimensional Tolerances
            5.5 Summary of Mould Preparation
SECTION 6 - MELT QUALITY CONTROL
            6.1 Introduction
            6.2 Selection of Furnaces
            6.3 Crucible and Furnace Linings
            6.4 Selection of Charge Materials
            6.5 Melting Practice
            6.6 Summary of Metal Quality Control
ANNEX A - RELATED DOCUMENTS
ANNEX B - DEFINITIONS AND ABBREVIATIONS
ANNEX C - EXAMPLES OF RUNNING, GATING AND FEEDING METHODS FOR
          PRODUCTION CASTINGS
ANNEX D - NON-ESSENTIAL DOCUMENTS PROVIDING
          BACKGROUND INFORMATION
ALPHABETICAL INDEX

Provide casting designers and founders with advice on the use of procedures to be followed for the production of high integrity sand castings in Copper Nickel Chromium alloy to Class I standards as detailed in DG Ships/PS/9010 although the advice is relevant to all castings in this alloy.