The arrangement of patterns with reference to having certain parts of castings solid and clean is an important matter, yet one that is comparatively easy to understand. Supposing the iron in a mould to be in a melted state, and to contain, as it always must, loose sand and 'scruff,' and that the weight of the dirt is to melted iron as the weight of cork is to water, it is easy to see where this dirt would lodge, and where it would be found in the castings. The top of a mould or cope, as it is called, contains the dirt, while the bottom or drag side is generally clean and sound: the rule is to arrange patterns so that the surfaces to be finished will come on the bottom or drag side.
Expedients to avoid dirt in such castings as are to be finished all over or on two sides are various. Careful moulding to avoid loose sand and washing is the first requisite; sinking heads, that rise above the moulds, are commonly employed when castings are of a form which allows the dirt to collect at one point. Moulds for sinking heads are formed by moulders as a rule, but are sometimes provided for by the patterns.
The quality of castings is governed by a great many things besides what have been named, such as the manner of gating or flowing the metal into the moulds, the temperature and quality of the iron, the temperature and character of the mould—things which any skilled foundryman will take pleasure in explaining in answer to courteous and proper questions.
Cores are employed mainly for what may be termed the displacement of metal in moulds. There is no clear line of distinction between cores and moulds, as founding is now conducted; cores may be of green sand, and made to surround the exterior of a piece, as well as to make perforations or to form recesses within it. The term 'core,' in its technical sense, means dried moulds, as distinguished from green sand. Wheels or other castings are said to be cast in cores when the moulds are made in pieces and dried. Supporting and venting cores, and their expansion, are conditions to which especial attention is called. When a core is surrounded with hot metal, it gives off, because of moisture and the burning of the 'wash,' a large amount of gas which must have free means of escape. In the arrangement of cores, therefore, attention must be had to some means of venting, which is generally attained by allowing them to project through the sides of the mould and communicate with the air outside.
An apprentice may get a clear idea of this venting process by inspecting tubular core barrels, such as are employed in moulding pipes or hollow columns, or by examining ordinary cores about a foundry. Provision of some kind to 'carry off the vent,' as it is termed by moulders, will be found in every case. The venting of moulds is even more important than venting cores, because core vents only carry off gas generated within the core itself, while the gas from its exterior surface, and from the whole mould, has to find means of escaping rapidly from the flasks when the hot metal enters.
A learner will no doubt wonder why sand is used for moulding, instead of some more adhesive material like clay. If he is not too fastidious for the experiment, and will apply a lump of damp moulding sand to his mouth and blow his breath through the mass, the query will be solved. If it were not for the porous nature of sand-moulds they would be blown to pieces as soon as the hot metal entered them; not only because of the mechanical expansion of the gas, but often from explosion by combustion. Gas jets from moulds, as may be seen at any time when castings are poured, will take fire and burn the same as illuminating gas.
If it were not for securing vent for gas, moulds could be made from plastic material so as to produce fine castings with clear sharp outlines.
The means of supporting cores must be devised, or at least understood, by pattern-makers; these supports consist of 'prints' and 'anchors.' Prints are extensions of the cores, which project through the casting and extend into the sides of the mould, to be held by the sand or by the flask. The prints of cores have duplicates on the patterns, called core prints, which are, or should be, of a different colour from the patterns, so as to distinguish one from the other. The amount of surface required to support cores is dependent upon their weight, or rather upon their cubic contents, because the weight of a core is but a trifling matter compared to its floating force when surrounded by melted metal. An apprentice in studying devices for supporting cores must remember that the main force required is to hold them down, and not to bear their weight. The floating force of a core is as the difference between its weight and that of a solid of metal of the same size—a matter moulders often forget to consider. It is often impossible, from the nature of castings, to have prints large enough to support the cores, and it is then effected by anchors, pieces of iron that stand like braces between the cores and the flasks or pieces of iron imbedded in the sand to receive the strain of the anchors.
In constructing patterns where it is optional whether to employ cores or not, and in preparing drawings for castings which may have either a ribbed or a cored section, it is nearly always best to employ cores. The usual estimate of the difference between the cost of moulding rib and cored sections, as well as of skeleton and cored patterns, is wrong. The expense of cores is often balanced by the advantage of having an 'open mould,' that is accessible for repairs or facing, and by the greater durability and convenience of the solid patterns. Taking, for example, a column, or box frame for machinery, that might be made either with a rib or a cored section, it would at first thought seem that patterns for a cored casting would cost much more by reason of the core-boxes; but it must be remembered that in most patterns labour is the principal expense, and what is lost in the extra lumber required for a core-box or in making a solid pattern is in many cases more than represented in the greater amount of labour required to construct a rib pattern.
Cores expand when heated, and require an allowance in their dimensions the reverse from patterns; this is especially the case when the cores are made upon iron frames. For cylindrical cores less than six inches diameter, or less than two feet long, expansion need not be taken into account by pattern-makers, but for large cores careful calculation is required. The expansion of cores is as the amount of heat imparted to them, and the amount of heat taken up is dependent upon the quantity of metal that may surround the core and its conducting power.