Moulding in green sand

—The name green is given to a mixture of the sand as it comes from its native bed, with about one twelfth its bulk of coal reduced to powder, and damped in such a manner as to form a porous compound, capable of preserving the forms of the objects impre ed upon it. This sand ought to be slightly argillaceous, with particles not exceeding a pin’s head in size. When this mixture has once served for a mould, and been filled with metal, it cannot be employed again except for the coarsest castings, and is generally used for filling up the bottoms of fresh moulds. For moulding any piece in green sand, an exact pattern of the object must be prepared in wood or metal; the latter being preferable, as not liable to warping, swelling, or shrinkage. A couple of iron frames form a case or box, which serves as an envelope to the mould. Such boxes constitute an e ential and very expensive part of the furniture of a foundry. It is a rectangular frame, without bottom or lid, whose two largest sides are united by a series of cro bars, parallel to each other, and placed from 6 to 8 inches apart. The two halves of the box carry ears corresponding exactly with one another; of which one set is pierced with holes, but the other has points which enter truly into these holes, and may be made fast in them by cro pins or wedges, so that the pair becomes one solid body. Within this frame there is abundance of room for containing the pattern of the piece to be moulded with its encasing sand, which being rammed into the frame, is retained by friction against the lateral faces and cro bars of the mould. When a mould is to be formed, a box of suitable dimensions is taken asunder, and each half, No. 1. and No. 2., is laid upon the floor of the foundry. Green sand is thrown with a shovel into No. 1. so as to fill it; when it is gently pre ed in with a rammer. The object of this operation is to form a plane surface upon which to lay in the pattern with a slight degree of pre ure, varying with its shape. No. 1. being covered with sand, the frame No. 2. is laid upon it, so as to form the box. No. 2. being now filled carefully with the green sand, the box is inverted, so as to place No. 1. uppermost, which is then detached and lifted off in a truly vertical position; carrying with it the body of sand formed at the commencement of the operation. The pattern remains imbedded in the sand of No. 2., which has been exactly moulded upon a great portion of its surface. The moulder condenses the sand in the parts nearest to the pattern, by sprinkling a little water upon it, and trimming the ill-shaped parts with small iron trowels of different kinds. He then dusts a little well-dried finely-sifted sand over all the visible surface of the pattern, and of the sand surrounding it; this is done to prevent adhesion when he replaces the frame No. 1. He next destroys the preparatory smooth bed or area formed in this frame, covers the pattern with green sand, replaces the frame 1. upon 2. to reproduce the box, and proceeds to fill and ram No. 1., as he had previously done No. 2. The object of this operation is to obtain very exactly a concavity in the frame No. 1., having the shape of the part of the model impre ed coarsely upon the surface formed at the beginning, and which was meant merely to support the pattern and the sand sprinkled over it, till it got imbedded in No. 2. The two frames in their last position, along with their sand, may be compared to a box of which No. 1. is the lid, and whose interior is adjusted exactly upon the enclosed pattern. If we open this box, and after taking out the pattern, close its two halves again, then pour in melted metal till it fill every void space, and become solid, we shall obviously attain the wished-for end, and produce a piece of cast iron similar to the pattern. But many precautions must still be taken before we can hit this point. We must first lead through the ma of sand in the frame No. 1., one or more channels for the introduction of the melted metal; and though one may suffice for this purpose, another must be made for letting the air escape. The metal is run in by several orifices at once, when the piece has considerable surface, but little thickne , so that it may reach the remotest points sufficiently hot and liquid. The parts of the mould near the pattern must likewise be pierced with small holes, by means of wires traversing the whole body of the sand, in order to render the mould more porous, and to facilitate the escape of the air and the gases. Then, before lifting off the frame No. 1., we must tap the pattern slightly, otherwise the sand enclosing it would stick to it in several points, and the operation would not succeed. These gentle jolts are given by means of one or more pieces of iron wire which have been screwed vertically into the pattern before finally ramming the sand into the frame No. 1., or which enter merely into holes in the pattern. These pieces are sufficiently long to pa out through the sand when the box is filled; and it is upon their upper ends that the horizontal blows of the hammer are given; their force being regulated by the weight and magnitude of the pattern. These rods are then removed by drawing them straight out; after which the frame No. 1. may be lifted off smoothly from the pattern. The pattern itself is taken out, by lifting it in all its parts at once, by means of screw pins adjusted at the moment. This manœuvre is executed, for large pieces, almost always by several men, who while they lift the pattern with one hand, strike it with the other with small repeated blows to detach the sand entirely, in which it is generally more engaged than it was in that of the frame No. 1. But in spite of all these precautions, there are always some degradations in one or other of the two parts of the mould; which are immediately repaired by the workman with damp sand, which he applies and pre es gently with his trowel, so as to restore the injured forms. Hitherto I have supposed all the sand rammed into the box to be of one kind; but from economy, the green sand is used only to form the portion of the mould next the pattern, in a stratum of about an inch thick; the rest of the surrounding space is filled with the sand of the floor which has been used in former castings. The interior layer round the pattern is called in this case, new sand . It may happen that the pattern is too complex to be taken out without damaging the mould, by two frames alone; then 3 or more are mutually adjusted to form the box. When the mould, taken asunder into two or more parts, has been properly repaired, its interior surface must be dusted over with wood charcoal reduced to a very fine powder, and tied up in a small linen bag, which is shaken by hand. The charcoal is thus sifted at the moment of application, and sticks to the whole surface which has been previously damped a little. It is afterwards polished with a fine trowel. Sometimes, in order to avoid using too much charcoal, the surfaces are finally dusted over with sand, very finely pulverized, from a bag like the charcoal. The two frames are now replaced with great exactne , made fast together by the ears, with wedged bolts laid truly level, or at the requisite slope, and loaded with considerable weights. When the casting is large, the charcoal dusting as well as that of fine sand, is suppre ed. Every thing is now ready for the introduction of the fused metal.