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Foundry and Casting Week 1 > Week 1 > Flashcards

Week 1 Flashcards

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1
Q

What is the oldest known casting in existence?

A

A copper frog cast in Mesopotamia in 3200 B.C.

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2
Q

When was iron discovered?

A

Iron was discovered in 2000 B.C.

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3
Q

When did the first Chinese production of cast iron occur?

A

The first Chinese production of cast iron occurred between 800-700 B.C.

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4
Q

What is the significance of 645 B.C. in casting history?

A

Earliest known sand molding occurred in China.

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5
Q

What was poured in China in 233 B.C.?

A

Cast iron plowshares.

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6
Q

When was cast crucible steel first produced in India?

A

Cast crucible steel was first produced in India in 500 A.D., but the process was lost until 1750.

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7
Q

What was the first use of cast iron pipe?

A

Dillenburg Castle in Germany used cast iron pipe to transport water in 1455.

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8
Q

Who is considered the father of the foundry industry?

A

Vannoccio Biringuccio, born in 1480 in Italy, documented the foundry process in writing.

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9
Q

What is significant about Saugus Iron Works established in 1642?

A

It was America’s first iron foundry and the first American iron casting, the Saugus pot, was poured there.

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10
Q

Who created the first true foundry flask?

A

Abraham Darby created the first true foundry flask for sand and loam molding in 1709.

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11
Q

What did Rene Antoine de Reaumur develop in 1720?

A

The first malleable iron, known today as ‘European Whiteheart.’

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12
Q

What innovation did Abraham Darby introduce in 1730?

A

He was the first to use coke as fuel in his melting furnace in Coalbrookdale, England.

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13
Q

What process did Benjamin Huntsman reinvent in 1750?

A

The process of cast crucible steel in England.

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14
Q

What happened in 1776 related to foundrymen?

A

Foundrymen signed the American Declaration of Independence.

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15
Q

What was the first use of the Cupola in iron founding?

A

The first use occurred in 1794, invented by John Wilkinson of England.

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16
Q

Who developed centrifugal casting in 1809?

A

A. G. Eckhardt of Soho, England.

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17
Q

When was the cupola introduced in the United States?

A

The cupola was introduced in Baltimore, MD in 1815.

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18
Q

Where was the first cast steel produced by the crucible process in the U.S.?

A

At the Valley Forge Foundry in 1818.

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19
Q

What significant event occurred in 1825?

A

Aluminum, the most common metal in the earth’s crust, was isolated.

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20
Q

Who developed a process for blackheart malleable iron in 1826?

A

Seth Boyden of Newark, NJ.

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21
Q

What did William Garrard establish in 1831?

A

The first commercial crucible steel operation in the U.S. in Cincinnati, OH.

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22
Q

What was marketed by the S. Jarvis Adams company in 1837?

A

The first dependable molding machine.

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23
Q

What was developed in 1845?

A

The open hearth furnace.

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24
Q

What did Sir Henry Bessemer and William Kelly invent in 1851?

A

A simple converter that uses blasts of air to burn out impurities in pig iron.

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25
What was developed by Henry C. Sarby in 1863?
Metallography, the first process to physically examine the surface of castings for quality analysis.
26
What innovation did James Nasmythe develop in 1867?
A gear-tilted foundry ladle, increasing worker safety and operational economy.
27
What was first used to clean large castings in 1870?
Sandblasting by R. E. Tilghman of Philadelphia.
28
What was developed between 1880-1887?
The Sly tumbling mill, the first cleaning machine for small castings.
29
What organization was formed in 1896?
The American Foundrymen's Association.
30
What did B.F. Philbrook rediscover in 1897?
Investment casting for dental inlays.
31
What was the first electric arc furnace used in the U.S.?
It was used at Holcomb Steel Co. in Syracuse, NY in 1906.
32
What significant steel was melted by Harry Brearley in 1913?
The first true stainless steel.
33
What was installed by Crucible Steel Casting Co. in 1913?
The first low frequency electric furnace for special melting.
34
What was formed in 1923?
The International Committee of Foundry Technical Associations in Zurich, Switzerland.
35
Who invented 18/8 stainless steel in 1924?
Dr. W.H. Hatfield.
36
What was pioneered by University of Michigan professors in the 1930s?
Spectrography for metal analysis.
37
What was installed in the Lebanon Steel Foundry in 1930?
The first high-frequency coreless electric induction furnace in the U.S.
38
What was introduced as a sand additive in 1940?
Wood flour.
39
What was discovered by U.S. officials in 1947?
The Shell Process, invented by J. Croning of Germany during WWII.
40
What was developed in 1948?
Ductile iron, a cast iron with a fully spheroidal graphite structure.
41
What patent was granted in 1949?
A U.S. patent for developing ductile iron was granted to K.D. Millis, A.P. Gagnebin, and N.B. Pilling.
42
What system was developed in 1953?
The Hotbox system for making and curing cores in one operation.
43
What patent was granted to H.F. Shroyer in 1958?
The full mold process, the forerunner of the expendable pattern casting process.
44
What tests were developed in the 1960s?
Compatibility and methylene blue clay tests for green sand control.
45
What molding machine was introduced in 1964?
The first Disamatic molding machine.
46
What was invented in 1965?
The Scanning Electron Microscope.
47
What was first poured at International Nickel Company in 1965?
Cast metal matrix composites.
48
What process was introduced in 1968?
The Cold Box Process for high production core making.
49
What was conceived at MIT in the early 1970s?
The Semi-Solid Metalworking (SSM) process.
50
What molding method was developed by the Japanese in 1971?
V-Process molding using unbonded sand and a vacuum.
51
What was developed at MIT in 1971?
Rheocasting.
52
What legislation was passed by U.S. Congress in 1971?
The Clean Air Act and OSHA.
53
What component was produced by Wagner Castings Company in 1972?
The first production Austempered Ductile Iron (ADI) component.
54
What process did Fiat introduce in 1974?
The in-mold process for ductile iron treatment.
55
What was developed in the U.K. in 1976?
Compacted graphite iron (CGI).
56
What binder system was introduced in 1982?
The Warm Box binder system.
57
What was the first foundry application of a plasma ladle refiner?
It occurred at Maynard Steel Casting Company in 1993.
58
What process did Babcock and Wilcox patent in 1995?
A lost foam vacuum casting process for stainless steel castings.
59
What was first used in a production model automobile in 1996?
Cast metal matrix composites in the brake rotors for the Lotus Elise.
60
What processes were developed in 1997?
Electromagnetic casting processes by Argonne and Inland Steel Corporation.
61
What is blackheart malleable iron?
An American type of malleable iron with a medium gray outer rim and a very black interior.
62
What is coke?
A coal derivative used as a fuel in cupola melting.
63
What is the Cold Box Process?
A rapid core making process that hardens cores through chemical reaction rather than heat.
64
What is a crucible?
A ceramic pot used for melting metal for casting.
65
What is a cupola?
A vertically oriented melting furnace.
66
What is ductile iron?
A type of iron with spherical graphite content, providing greater tensile strengths.
67
What is green sand?
Natural sands combined with water and organic additives for mold creation.
68
What is investment casting?
A method using an expendable pattern surrounded by a molding medium.
69
What is malleable iron?
Iron that can be shaped without fracture, with carbon in the form of graphite nodules.
70
What is rheocasting?
A metal forming process using semi-solid metal for casting.
71
What is the Shell Process?
A process using resin-coated sand to form a hardened shell for casting.
72
What is the Warm Box Process?
A core making method where the corebox is warm to initiate curing.
73
What is a captive foundry?
A foundry integral to a manufacturing organization.
74
What is a jobbing foundry?
A foundry producing small numbers of castings for different customers.
75
What is a production foundry?
A highly mechanized foundry producing castings economically on a mass scale.
76
What is a semi-production foundry?
A combination of jobbing and production foundry.
77
What does a steel foundry produce?
Plain carbon steel, low and high alloy steels.
78
What does a grey cast iron foundry produce?
Castings of grey color.
79
What does a malleable iron foundry produce?
Castings that can be hammered or pressed into shape.
80
What does a ductile iron foundry produce?
Castings that can be drawn into fine standards.
81
What does a light metals foundry produce?
Aluminum and magnesium alloys.
82
What does a brass, bronze, and copper foundry require?
Alloys of germanium silver, aluminum phosphor, and bronze.
83
What does a lead, tin, and zinc base foundry require?
Alloys of tin, antimony, copper, and zinc.
84
What is the first and oldest copper casting that ever made in Mesopotamia?
Frog
85
When the cast crucible steel is first produced in India, but the process is lost until 1750 when he reinvents it in England. Who is this man?
Benjamin Huntsman
86
Which country uses the cast iron as their raw material?
China
87
Which country is the first to use cast iron pipe to transport water?
Germany
88
An Englishman who creates the first true foundry flask for sand and loam molding?
Abraham Darby
89
What is the most common metal on earth's crust and it is isolated?
Aluminum
90
In what year that open hearth furnace was developed?
The 19th century
91
Who develops a gear-tilted foundry ladle, increasing worker safety and operational economy?
James Nasmyth
92
In what ages that First electric arc furnace is used in the U.S. at Holcomb Steel Co. in Syracuse, NY?
Early 20th century
93
Type of material use in matrix composites are first poured at International Nickel Company in Sterling Forest, NY, by Pradeep Rohatgi.
Cast Metal
94
A ceramic pot with refractory properties typically made of clay in which metal is melted for casting.
Crucible
95
An American type of malleable iron. The normal fracture has a medium gray outer rim and a very black interior
Blackheart

Foundry and Casting Week 1 (1 decks)

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