It is impossible to describe just how hard a mold should be rammed, but by observing the results the beginner can tell when a mold is too hard or too soft, and thus judge for himself. If the sand falls out of the flask when lifting the cope, or if it opens up or spreads after it is poured, it shows that the mold has been rammed too little, and if the surface of the sand next to the pattern is cracked it shows that the mold has been rammed too hard. It will be found that the edges of the mold can stand a little more ramming than the middle. In finishing the ramming, pound evenly all over the surface with the blunt end of the rammer.
After ramming, scrape off the surplus sand with a straight-edged stick, as shown at C, and scatter about 1/16 in. of loose sand over the surface for a good bearing. Place another cover board on top, as shown at D, and by grasping with both hands, as shown, turn the drag other side up. Remove the upper cover board and place the upper half of the flask, or "cope," in position, as shown at E.
In order to prevent the two layers of sand sticking together, the surface of the sand at E should be covered with coal-dust. This is done by shaking the coal-dust bag over the flask, after which the dust on the pattern may be removed by blowing. The cope is then filled with sand and rammed in exactly the same manner as in the case of the drag.
After the ramming is done a number of vent holes are made, as shown at F, from the surface of the mold to the pattern, in order to allow the escape of air and steam when the mold is being poured. These vent holes may be made by pushing a wire about the size of a knitting-needle down through the sand until it touches the pattern. The "sprue," or pouring-hole, is next cut, by means of the sprue-cutter shown at the right, which consists of a piece of thin brass or steel tubing about 3/4 in. in diameter.
Now comes the critical part of the molding operation—that of lifting the cope from the drag. It is here that the amateur often becomes discouraged, as the sand is liable to fall out of the cope and spoil the mold; but with a little practice and patience the molder can lift the cope every time without breaking it, as shown at G.
The next operation is that of cutting the gate, which carries the molten metal from the sprue to the opening left by the pattern. This is done with a spoon, a channel being cut about 3/4 in. wide and about 1/4 in. deep. The pattern is then drawn from the mold, as shown at H, by driving a sharp pointed steel rod into the pattern and lifting it from the sand. When a metal pattern is used a thread rod is used, which is screwed into a tapped hole in the pattern. Before drawing it is well to tap the drawing-rod lightly with another and larger rod, striking it in all directions and thus loosening the sand slightly from the pattern. Some molders tap the pattern gently when withdrawing, as shown at H, in order to loosen any sand which has a tendency to stick.
After drawing the pattern, place the cope back on the drag, as shown at J. Place a brick or other flat, heavy object on top of the mold above the pattern, to prevent the pressure of the melted metal separating the two halves of the mold, and then pour.
III—Melting and Pouring
Having prepared one or more molds, the next operation is that of melting and pouring. An ordinary cast-iron glue-pot makes a good crucible and can be easily handled by a pair of tongs, made out of steel rod, as shown in the sketch. In order to hold the tongs together a small link can be slipped on over the handle, thus holding the crucible securely.