SCIENTIFIC - CASTING OF ENGINE PARTS

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00809A000600220248-3
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 6
• Document Creation Date: December 22, 2016
• Document Release Date: June 28, 2011
• Sequence Number: 248
• Publication Date: April 20, 1949
• Content Type: REPORT

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CLASSIFIt,AfON
CENTRAL IN
INFORMATION FROM
FOREIGN DOCUMENTS OR RADIO BROADCASTS
COUNTRY u
SUBJECT Scientific - Casting of engine parts
HOW
PUBLISHED Nnthly periodical
WHERE
PUBLISHED -bscow
DATE
PUBLISHED ism 1948
LANGUAGE Russian
CD NO.
DATE OF
INFORMATION
DATE DIST.2. Apr 1949
NO. OF PAGES 6
SUPPLEMENT TO
REPORT NO.
THIS IS UNEVALUATED INFORMATION
SOURCE ?ytamebiianwa Ptwyshgammast?. 1e 1, 1948. (Translation requested.)
P. Yefiaav
Orgavteprea
fliglu,ss referred to herein are not reproduced but are available in the original
dopsasnt at CIA_7
8o-celled precision casting open. new paths for the reduetica of labor
espenditure in the production of may parts for nuhines and instruments.
The preoieeaess?of asssursasnts and the smoothness of the surface of the castings
in army ease asi[e their asohanical machining unnecessary. Now, it is possible
tq replace wmall joints with "among. (earlier produced by welding, soldering,
riveting of a large number of uoraer irons, and by plates, clinches, sore", mats,
eta.), and it is also possible to get castings of a high degree of hardness
without sreLaaioal aachiaiag, or with such final operations an grinding or
poll 2614
The fieldr of application of precision crating by the lost was process
art not limited to the assembly4lae output of industrial parts, and they
are spreadiaf to thanproduoticn of cast cutting toads, chill ~a.,tings, press
cos'rie, Oft. ?
The wide application of precision nesting in the automobile and tractor
isnutries prosisea anoracas ekving" in equipment, tools, isstrumrmts, and
skilled workers' energy.
Preeisian Casting by the Lost Was: Method
The amthol is essentially as follows:
First, the prototypes of the part are prepared free a wax nsmpound or
fren an sully fusible alloy, and they are sealed in ceramic casting frame.
Then, the was is melted out of the casting sold, and the hollow of the fora
is filled r th natal.
CLASSIFICATION
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The technological process of precision casting omelets of the following
operations
1. Preparation of the monster model with zone augmentation of meuure-
ments to account for the contraction of the wax and the metal.
2. Preparation of press forms for the casting of wax models (the
prototypes of the parts).
3. Preparation of the wax cospound.
4. Preparation of the temporary wax models.
5. The mounting of the wax models on a herringbone frame with a comm
standard.
o. Preparation of solutions and firo-resistant coatings.
7. Coating, aprinJaIng and drying of the herringbone frame.
8. Preparation of the filler mesa for pouring over of the coated barring-
9. Passing the filler mass over the frame in casting boxes.
11. Calcination of the farm.
12. Preparation of the metal for outing.
13. Filling of the farm with caul.
15.- the cutting off of the pouring channels and the final operations of
preparing, mixtures is to be found in the Instructions for the ProporAtiot-Or
Precision Camtings bLthe "Lost Woe lbthod wcr out the Orgavtopron.
i iparatiai of Press Forms for ibldina of Wax >bdc? s
two aetbodas (1) by pouring an eastly fusible alloy over a master model, and
muter model are a negative ureter model. To obtain such a farm, one half of
the model is buried in a plaster composition and the other half is coverod
with fusible alloy, and than exactly in the sane way the second half to embedded.
As a result the full form (Figure 1) is obtained. If the equipment is available,
Preparation of forms by seshanieal -nn.ans is done by the usual methods need
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The contraction of the wax cce!paund and of the metal during the preparation
of the nester model and of tho press forms prepared by Mechanical means is 1.5-2.5
p t.of thi fixed dimensions of the part.
iklawles or, Vex Models
After the preparation of the press forms, the temporary wax models Meet
be prepared. The production of wax models is one of the moot responsible parts
at the work of precision casting, and as a consequence it demands Most attention.
Several. Methods for the preparations of wax models exist: (1) pNparatieam
0? medals by pouring was compound by the static method (Figure 2)
() pirepasationof war models by pouring wax under pressure (Figure 3) end
p tie of wen models by the introduction of a voese-like coneistemsy
wO essgpesition.Into the hollow of the prose fora with the aid of a syringe
(sigars;~).
At' t, ant widely used is the preparation of wax models under a
i with applicationof pressurQ up to 5-6 atmsrphe-oa and also by the
*Weductles into the pries fora of the wax compound !a a grease-like form
Mdar pro sur. up to 3 atmosphur%s
Thecempouna used for production of wax models is prepared by us from
vex, paraffin, and esreein mixed in strictly defined proportions. The ft
are lubricated with a mixture of castor oil and alcohol.
The storage of wax models requires special cabinets and a constant
temperature.
Pk_-* aratim of Wax Wale by Method of Protragivsnita ih'awiml) Mond llsohi ziV
The bores, caused by the points of tote form, which appear on the surface
of tie wax model, must be carefully eliminated. The devices used for this
aarpose are illustrated in Figures 5-7. The action of these devices is based an
the principle of elim.nating the burrs by drawing and machining of the surfaces.
The now devices are employed in giving the model a speeirie form, and
for finishing its dimensions. Finissing dimensions and obtaining form ccmeiets
of tie removal of the excess of wax by means of cutting tools. The cleanness
of the surface depends on the quality of the cutter, its condition during cutting,
and the quality of the wax. Dirty wax sticks to the cutting edge, and the hard
particles scratch the surface of the model.
F
From Figure 6 the possibility of the application of devices for wax
models not having the forms of the rotating body can be noted.
Tne operation of joining wax models in a group by affixing them to a
came standard is called the joining to a herringbone frame (Sketch 8).
In order to guarantee the fast descent if the wax mixture when it is being
melted ant of the form, the models are attached to the standard with a little
slant to them.
The operation of affixing than is a very laborious one. Therefore,
when the form is being planned, one should Strive to provide for the pouring
channels, and the standard to be poured off along with the model, as shows
in Figure 9.
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Coatings for Steel Casting
At
The derivation of the coating for casting in steel is more complicated
than that for aluminum and copper alleivs. The greatest difficulty is
encountered in the derivation of high-fire-resistant, neoracking coatings capable
of withstanding more than 1,2000 C, and which will not scorch on the surface.
For coating the standards in aluminum and copper casting, the agglutisaat
eaped is typsum, but for steel casting it is unsuitable. In this case (stool),
the agglutimant is a hydro ized solution of ethyl ether of orthosilicic said
(ethyl silicate).
The preparation of the coating consists of the following operations: (1
(1) preparation of a hydroliaed solution of ethyl silicate (accordIng to
a definite recipe); (2) prefrration of fire-resistant powders; and (3) prepare--
tisa;of the coating.
lire-rosistannt powders are washed and baked at a temperature of 900-1,0000 C
before using.
It is . ucc?amded that powders of varied utain and materials be store.'
separately,,aealid, and labeled with information indicating the grain and the
satgriala therein.
In the capacity of fire-resistant powders we find "marshalit," quartz meal
from fused quartz glass, quartz meal from quartz sand, zirconium oxide, and
mixtures of the above-mentioned materials.
The coatings are prepared in the following manner: Into a hydrolized
solution of ethyl silicate is poured a fire-resistant powder and the whole
is carefully mixed. As soon as the effervescence ceases, the coating is
performed. It is beat to eliminate the effervescence under vacuum.
We prepared the mixture with "mershalit" and a hydrolized solution of
ethyl silicate.
Casting and Sprinkling of Herringbone Frames
The coating of the frames is a very responsible operation. On the accuracy
of its fulfillment depends the smoothness of the surface of the casting.
Before coating, It is necessary to inspect the from to be certain that
the os-!img cannot seep through anywhere and create a pellicle or sharp edge.
Pellicles and sharp edges wash away during the pouring of metal, and form
stoppages (cL impurities) in the castings.
After inspection of the frame, it is immersed !n a container with pre-
pared carting, as shown In F gore 10. If during the coating, bubbles of air
appear on the surface of t )h frame, it Is necessary to shake the frame and
to cover it anew with the coating.
It is not recommended that quick movements be made with the from sizes
the farming bubbles are inclined to adhere to the models, and the surface of
the casting '.rns out coarse.
Before the coating has had time to harden, the frames are sprinkles with
nand sifted through a 30-40 mash sieve, as shown in Figure U.
This operation is indispensable for the following reasons: '1; :o create
a gas jacket for the free passage of gases tram the coating, (2' ') prime the
coating for the filler, and (3) to eliminate fissures farming on the coat"ng.
IAI
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After every coating, the fram is subjected t,i air drying for 1-2 hours.
Pouring the Filler Over the Coated Frame
Pouring the filler over the frame in the casting molds consists of: f
(1) setting up the frame and the r-' boxes on the bottcs plate, (2) preparing
the filler, and (3) pouring the finer over the frame in the mold box.
The coated frame is not on the bottom plate and covered with the mold ben.
A waste tube my be used as a mold box, but it is better to bay sold boxes
made of fire-resistant alloys.
The affixing of the frame to the bottom plate is accomplished by: (1) the
soldering of the wax base to the bottom plate (Figure 12), (2) setting it
up e' a peg (Figure 13), and (3) affixing by the shaft which rues through the
standard of the wax models (Figure lh).
The ho1low of the bottom plate is covered with waste wax to prevent
the eersaie which is pouring in from flowing cat at the bottom.
After; the asseaely of the f?sme and mold bcm- an the bottom plate, the
cere*eic filler is poured Into it.
The filler used for casting is prepared as follows: into a hydrolized
solution of ethyl silicate diluted with water, is poured a mixture of sand
and "marshalit" and the whole slowly stirred. As soon as the mass reaches a
fluid comsistenoy, the pouring takes place.
The setting of the filler in the mold boxer, takes place on a vibrating'
table (rigare 15). Vibrating time is 15-30 minutes. As practice has shown,
the use of sealing cmpounds (espansive, incidentally) is not absolutely
obligatory in all cases. The customary molding compounds and also fillers
Sir* fully satisfactory results.
Melting the Wax Oat of Ceramic Foams, Drying and Baking of Forms
The drying of the poured mold boxes lasts from 10-20 hours, after which
the foams are placed for 4-10 hours into a drying cabinet for additional
dtying, and for melting the wax out.
The form should not be overheated during the melting out of the wax since
in overheating, the moisture forms a larEe amount of vapor which, if not
c1is:inated, can destroy the farm.
Daring the drying of the iota, and the melting out of the wax, the form
malt stand vertically with the pouring cup downward.
The further drying and thu :oaating of the form takes place with the
temperature of the oven gradually increasing to the final temperature 000-+.,000? C.
The rvesting of the forms should not be hurried. Better results are
achieved with tue length of tae process established according to the Omwnt
cal ceramic in tb mold box.
rbmriag of Metal Into the Forms
Ae soon as the foams are finished, the pouring takes place. The u-3
methods of melting and pouring may be employed. Devices used in the casting
of proclaim ports are shown in Figures 16-16.
WN~ItAt
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Castis Obtained and the Accuracy of Their Production
Finished parts and framee are shown in figures 19 and ^c0. Among the
individual parts, where wax mountings were employed, the accuracy of castings
measuring 50 mm came out to within *0105 mm - 0.08 mm.
Among parts of 100 mm where mountings were not utilized the dimensions
came out to within k 1).25 mm.
To guarantee more rigid tolerances, it is necessary to take into account
the following factors:
1. Uniformity of the wax compounds and their temperatures during pouring.
2. Uniformity of the pressure applied during the casting of the vat models.
3. Uniformity of the composition of the fire-resistant materials,
of the processes of drying and baking of form., of the temperature of the forma
during pouring and finally, of the metal which Is being poured.
b. Uniformity of the pressure applied during pouring.
At present, the Orgavtoprom is drafting a manual setting forth the dimensiiae
of contraction for the production of parts with more rigid tolerances.
The comparative complexity of the technological process of precision
casting demands a clear orgi*nizaticn of production, a careful linking of the
individual technologies, and the attentive and accurate fulfillment of
preosduree and processes. The latter refers mostly to the preparation of
wax models and frames, and to processes of drying and baking.
All this is achieved through the responsible practices of workers and demands
no special technological preparation of their part.
More qualified labor and better technological equipment is necessary for
the production of press forms for the casting of wax models.
The operation of pouring metal into the mold braes is not complicated
and can be successfully completed by any of the following methodst static
pouring, under pressure, IL a vacuum, csntrifugal, or combined methods.
Like every new technique, precision casting by the lost vat method
deemuds, at present, further refinement, technological -quipeeent, and
indispensable, cheap chemicals, all of which will significantly simp`if, its
introduction into indw,t-y,
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