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A single piece pattern, or loose pattern, is the simplest. It is a replica of the desired casting—usually in a slightly larger size to offset the contraction of the intended metal. Gated patterns connect a number of loose patterns together with a series of runners that will be detached after shake-out.
In flaskless molding, the same terms are used, cope for the top or upper piece and drag for the bottom or lower piece. In the simplest sand casting procedure, the drag is placed upside down on a board, around a pattern of the part to be cast. The pattern is a model of the desired casting.
In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag.
Full-mold casting is an evaporative-pattern casting process which is a combination of sand casting and lost-foam casting. It uses an expanded polystyrene foam pattern which is then surrounded by sand, much like sand casting. The metal is then poured directly into the mold, which vaporizes the foam upon contact.
Lost wax casting can be dated back to 4000 BC or the Chalcolithic period. [4] One of the oldest studied examples of this technique is a 6,000-year-old amulet from the Indus Valley Civilisation. [9] India is attributed as one of the first civilizations to use casting methods to mass-produce coins.
The core is normally a disposable item that is destroyed to get it out of the piece. [1] They are most commonly used in sand casting, but are also used in die casting and injection moulding. For example, cores define multiple passages inside cast engine blocks. One model of GM V-8 engine requires 5 dry-sand cores for every casting. [1]
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The shell mold casting process consists of the following steps: Pattern creation - A two-piece metal pattern is created in the shape of the desired part, typically from iron or steel. Other materials are sometimes used, such as aluminium for low volume production or graphite for casting reactive materials.