DEFSTAN 02-824(PT2)/2(2005) : 2005

SCOPE
FOREWORD
Sponsorship
Conditions of Release
Related Documents
Health and Safety
SECTION 1 - PERFORMANCE SPECIFICATION
SECTION 2 - NATIONAL/INTERNATIONAL REGULATIONS
SECTION 3 - MILITARY STANDARDS/REQUIREMENTS
SECTION 4 - DESIGN REQUIREMENTS/GUIDANCE
  4.1 The Casting Process
      4.1.1 Preface
      4.1.2 Recommended Design Procedures
      4.1.3 Casting Design
      4.1.4 The Design Sequence
      4.1.5 The Casting Drawing
      4.1.6 Use of Casting Simulation software
  4.2 Solidification and Casting Moduli
      4.2.1 Introduction
      4.2.2 Solidification of Cupronickel
      4.2.3 The Mechanism of Solidification
      4.2.4 Directional Solidification
      4.2.5 Casting Moduli
      4.2.6 Geometric Moduli
      4.2.7 Estimation of Moduli
      4.2.8 Modulus Correction Factors: Effect of Shape
      4.2.9 Modulus Correction Factors: Effect of Junctions
      4.2.10 Modulus Shape Correction Factors for 'L' and
             'T' Junctions
      4.2.11 Estimation of Modulus Shape Correction Factors
             for Junctions
      4.2.12 Remedial Measures to Alleviate Problems at
             Junctions
      4.2.13 Influence of Chills on the Modulus of Castings
      4.2.14 Influence of Core and Sand Thickness on Casting
             Moduli
      4.2.15 Effect of Sand Thickness Between Parts of Castings
      4.2.16 Minimum Allowable Sand Thicknesses between
             Moulding Boxes and Castings
      4.2.17 Summary of Solidification and Casting Moduli
  4.3 Designing for Soundness: Positioning and Sizing of
      Feeders
      4.3.1 Introduction
      4.3.2 Designing for Directional Solidification
      4.3.3 Positioning of Feeders: Feeding Distances of
             Parts of Castings of Uniform Thickness
      4.3.4 Example of the use of Feeding Distance
             Information
      4.3.5 Use of taper
      4.3.6 Example of the use of the Taper Calculator
      4.3.7 Circumferential Feeding of Tubes Using Taper
      4.3.8 Feeding of Thin Sections by Thick Sections
      4.3.9 Example of a Thick Section Feeding a Thin Section
      4.3.10 Feeding of Junctions
      4.3.11 Example of Feeder Zone Calculation
      4.3.12 The Size and Design of Feeders
      4.3.13 Examples of Minimum Feeder Size Calculation
      4.3.14 Summary of Rules for Designing a Feeding System
  4.4 Filling the Mould: Design of the Running and Gating System
      4.4.1 Introduction
      4.4.2 Design and Calculation of the Dimensions of Bottom
             Gating Systems
      4.4.3 Summary of Rules for Designing Filling Systems
  4.5 Preparation of the Mould
      4.5.1 Introduction
      4.5.2 Patterns
      4.5.3 Machining Allowances
      4.5.4 Dimensional Tolerances
      4.5.5 Summary of Mould Preparation
  4.6 Melt Quality Control
      4.6.1 Introduction
      4.6.2 Selection of Furnaces
      4.6.3 Crucible and Furnace Linings
      4.6.4 Selection of Charge Materials
      4.6.5 Melting Practice
      4.6.6 Summary of Metal Quality Control
ANNEX A - RELATED DOCUMENTS
ANNEX B - DEFINITIONS
ANNEX C - PROCUREMENT CHECK LIST
ANNEX D - EXAMPLES OF RUNNING, GATING AND FEEDING METHODS FOR
          PRODUCTION CASTINGS
ANNEX E - NON-ESSENTIAL DOCUMENTS PROVIDING BACKGROUND
          INFORMATION
ANNEX F - THERMOPHYSICAL PROPERTIES OF CuNiCr FOR USE WITH
          SIMULATION SYSTEMS
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.