How to make a Mould for Cast Iron

Iron is a metal present abundantly in the earth’s crust. However, it has to be extracted from its ore, processed and only then can it be converted to the required. The ore will be subjected to a process called smelting, whose immediate product obtained is called pig iron. Pig iron has high carbon content. Pig iron, on further treatments provides cast iron. Cast iron comprises of lesser carbon content compared to pig iron. Cast iron is first heated to a very high temperature, until it melts. This molten iron has to be solidified using various moulds to obtain the desired commodity. Cast iron finds wide applications in construction sites, cookware, and decorative features and in industries. Let’s take a tour on the moulding process.

The first step in the process of moulding is pattern making. A pattern of the required shape and dimensions is prepared with the help of iron or steel or even using plastics. Usually for fabrication of iron, steel patterns in sand moulds are preferred.

Moulds for casting iron can be classified as sand mould, blow mould, compression mould and extrusion mould. Technically moulds comprise two halves iron cast cookware. Each half is fabricated separately. One half of the mould is called cope and the other half, drag. When the two halves are brought together (i. e. ) placed one over the other, a hollow cavity is created between them, into which iron in the molten state in poured and allowed to solidify so as to obtain the required casting.

A typical sand mould comprises of 85% sand, 7. 5% bentonite, 3. 5% coal dust and 4% water. Bentonite is an impure form of clay mainly composed of montmorillonite. The patterns used in the mould are mostly made of wood, metal or plastic. Iron during the process of solidification, will contract. Because of uneven cooling, the pattern must be larger than the original size required. The basic processes in sand moulding are as followsThe process of casting has always been used in the iron industry to make iron products according to requirements. The introduction of automobiles in the early part of 20th century resulted in a rapid increase of iron consumption in automotive companies all over the world. Today the automobile companies remain as the single largest consumer of metal castings. Automotive Castings are a bit different from other iron castings. As the products of these casting forms important parts of a vehicle, the casting has to be perfect and flawless.

It is the most commonly found cast iron and is also one of the most widely used materials for casting. Graphite is generally present in this cast thus giving it a distinct grey color. It is mainly used in products with non critical tensile strength like pump housings, electrical boxes, decorative items and valve bodies. It facilitates high level of thermal conduction for which it is also used in making cookware and rotors for brakes. Most Grey Iron Castings have 1 to 3 percent of silicon and 2. 5 to 4 percent of carbon. Silicon, being a reliable graphite stabilizing agent, is widely used in grey iron casting.

This type of cast iron was introduced in 1943 and since then it has been widely used by different industrial sectors including the automobile sector. The main advantage of this casting is that unlike other castings, it is not brittle and is able to withstand stress for a long period of time. Several materials are mixed with iron to form ductile casting. The main materials that are used for this purpose are carbon, silicon, manganese, magnesium, phosphorus and sulfur. Carbon and silicon are, however, present in the highest concentration.

Castings are widely used in automobile sector and are used to produce a number of automotive components. These components are manufactured by placing the molten iron in moulds specifically designed according to the requirements of the automobile industry. The cast products are t hen taken out of the moulds and are fitted in the automobiles. Nowadays, almost all equipments in an automobile are made of cast metals. Cast Iron cookware has been around for hundreds of years. The proper seasoning of your cast iron is one of the most important things to remember. It has a great effect on how cooking and clean-up is made easier. Seasoning your skillet is done by heating it up on the stove top until its smoking hot, then rubbing it down with oil or bacon grease then let it cool. Each time you us your skillet you will maintain the seasoning process. Cast Iron can rust so hand wash and use a stiff scrubber if necessary and dry immediately. Reapply a thin coat of oil to prevent rust and continue the seasoning process.

Copper cookware has a good distribution of heat and heats up very quickly. Since copper isn’t food safe in its natural state of protective layer of stainless steel or nickel is usually applied. Being coated means avoid abrasive cleansers and sponges. Copper being a very good conductor of heat a good rule of thumb is to reduce heat when cooking. Preventing food from sticking will make for easier clean-up.

Stainless steel is very popular in the kitchen because it doesn’t rust. They are also very versatile because they can go right from stove top to the oven. Stainless steel is a non-stick surface preheating the cookware before adding oil can prevent your food from sticking. Cleaning your stainless steel may require a soaking in warm soapy water before scrubbing with non-abrasive cleaners.

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