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Abstract
The effect of casting design on the linear contraction of ductile iron castings produced in clay- and silicate-bonded sand moulds has been studied. The designs included free and restrained square bar castings.
Free contraction of very thin sections of ductile iron in sand moulds was found to approach 1.35%. As sections increased to 25 mm thick, the contraction decreased linearly to 1.08% in silicate-bonded sand moulds, but to 0.90% in clay-bonded sand moulds.
For test pieces with end flanges which stimulated various degrees of constraint as would be experienced in a shaped casting, the contraction was found to be sensitive to the third power of the relative cooling time of the flange and the cast section. In conditions of high constraint, contraction could fall as low as 0.55%.
The data from this study represent a first attempt to provide a designer and toolmaker with realistic contraction allowances for shaped castings.