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the Technology Interface/Spring 2008 Klein Once cured the plaster pattern was removed from the model. (Figure 16) Using basic woodworking hand tools such as a coping saw and file, the large pattern is reduced in size to create the proper pattern for the foundry. (Figure 17) V. CASTING THE ALUMINUM MOLD Sand casting of metals goes back to 4000 BC. [6] The dry sand casting process uses a pattern, in this case our plaster pattern, to create a void or cavity in the sand which was then filled with molten aluminum. When the aluminum cools, the sand was removed leaving a detailed aluminum replication of the pattern. [7] The dry sand mixture, casting sand with a petroleum based binder, was packed around the pattern to create the cavity. This was done in a metal framework called a flask. (Figure 18 & 19) A sprue was cut in the sand which was the location that the molten aluminum will be poured into the sand mold. A riser is also cut into the sand which will allow gasses to flow out of the mold cavity as well as supply a reservoir of aluminum for the part to draw from during cooling; this will reduce some common molding defects. (Figure 20) Page 6PDF Image | 12 mil Reinforced Polyethylene
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