W.C.I.F. PRACTICAL PRESENTATION AUGUST Ahmed Abrahams

DaimlerChrysler Truck Group 2  W.C.I.F. Presentation Courses completed: - Metallurgy - Modern Supervision - Fettling and Fettling Teqniques - Mould and Moulding Sand - Quality Control - Planning and Productivity - Core and Coremaking

DaimlerChrysler Truck Group 3  1,6 CBS5 Core Sand Mix Contents: Silica Sand = 35kg Chromite Sand = 15kg Red Oxide = 0.25kg Resin Part 1 = 0.4kg Resin Part 2 = 0.4kg Amine acts as a catalyst

DaimlerChrysler Truck Group 4  Tools to produce cores

DaimlerChrysler Truck Group 5  Core making procedure

DaimlerChrysler Truck Group 6 Ramming of the sand

DaimlerChrysler Truck Group 7 Core venting

DaimlerChrysler Truck Group 8 Gassing of the Core using Amine

DaimlerChrysler Truck Group 9 Stripping of the Core from the Core Box

DaimlerChrysler Truck Group 10 Ramming of the sand

DaimlerChrysler Truck Group 11 The Core

DaimlerChrysler Truck Group 12  1.6 CBS14 Core sand Mix Contents: Silica Sand = 100kg SLC = 3kg Coaldust = 1kg Resin part 1 = 0.8kg Resin part 2 = 0.8kg Amine acting as a catalyst

DaimlerChrysler Truck Group 13  Moulding Process Cope Pattern

DaimlerChrysler Truck Group 14 Drag pattern

DaimlerChrysler Truck Group 15 Filling the Cope pattern with sand

DaimlerChrysler Truck Group 16 Ramming sand

DaimlerChrysler Truck Group 17 Compacting The Sand

DaimlerChrysler Truck Group 18 Levelling the Cope Pattern

DaimlerChrysler Truck Group 19 Venting of sand

DaimlerChrysler Truck Group 20 Gassing the sand with Amine

DaimlerChrysler Truck Group 21 Runner system

DaimlerChrysler Truck Group 22 Cope and Drag Mould completed

DaimlerChrysler Truck Group 23 Physical Properties Charge Charge mix: 2 tons returns 2 tons blocks 2 tons steel 2 tons snippers 1 ton pig iron 1 ton coils Metal specifications Chemical Analysis: Carbon = 3.35 – 3.40% Silicon = 2.10 – 2.25% Chrome = 0.15 – 0.18% Copper = 0.55 – 0.65% Sulphur = 0.85 – 0.90% Phosphorous = 0.50% max Manganese = 0.60 – 0.68% Titanium = 0.012% max Physical Properties Brinell Hardness No = Tensile Strength = N/cm²

DaimlerChrysler Truck Group 24 Pig Iron used for weights

DaimlerChrysler Truck Group 25  Casting Process

DaimlerChrysler Truck Group 26 Metal being poured into the mould

DaimlerChrysler Truck Group 27 Stripping of the mould

DaimlerChrysler Truck Group 28  Cooling Process

DaimlerChrysler Truck Group 29 The Final Product

DaimlerChrysler Truck Group 30 Quality The quality of the product depends on the customer demands. Common problems: Pinholes Blows Casting damage Metal penetration

DaimlerChrysler Truck Group 31