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15 Devil's face tray 27 match ^K^plate Mould checked and then 7 Free core casting Fig. 1 Fig. 2 The egg-shaped casting shown in Fig. 1 was cast by a fourteen-year-old boy. Fig. 2 shows t w o different egg-shaped castings, one imprisoned inside the other. There is no space wide enough on the larger casting through which the inside egg could be inserted. The castings are not connected, and neither has been cut or fastened in any temporary or permanent fashion. How were they made? Equipment core box (Fig.

8 Box turned over after ramming. Add top-part box and riser Fig. 9 pattern Remove the flat plate 34 9 Polystyrene patterns Within the school foundry polystyrene can be an extremely versatile material. It can either be used singly, to produce castings, or in combination with other materials to increase the scope of projects available. It offers a wide area in which pupils with creative flare can exhibit and develop their talent, and is a natural medium for integration with the art department. It is an ideal material for teachers w h o wish to include foundry work into design-based craft courses.

6). 4 Ram sand into the opening in the core box to produce a core (Fig. 6). 5 Level off the sand to the top of the core box. 6 Remove the G cramp, and lightly tap the core box to loosen the sand. This procedure is called rapping. 7 Carefully remove the box from the sand core (Fig. 7). If the core is large enough it is advisable to place a large vent hole down the middle, using a piece of rod of small diameter, before removing the box. 8 The sand core which has been made from the core box is the shape of the internal hole required in the finished casting plus the shape of the core print which has been placed on the pattern (Fig.

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