The aim of this project is to produce aluminum pots through sand casting process.  The cast process involved drawing of element to be cast, making of pattern and core boxes, moulding of pattern, and core boxes, moulding or pattern, moulds assembling, melting of a metal pouring into the mould, solidification and cooling of metal in the mould cast knockout and separation of gate runner and riser, casting surface cleaning, removal of core. This process is use to produce metallic article (alloys) of desired shape, dimension, composition and specified properties from molten metal Poured into  a mould whose internal space (impression) reproduce the configuration and dimension of the cast article, with maximum accuracy.        


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2.0     Literature Review

2.1     Casting

2.2     Die Casting

2.3     Sand Casting

2.4     Sand

2.5     Types of sand mould

2.6     Quality of green sand

2.7     Pattern

2.8     Mould-making or production


3.1     Process taken  in production of Aluminium pots

3.2     Procedure for Heating the Metal Aluminium Pot

3.3     Pouring the molten metal (Aluminium) in the mould


4.0     Cleaning, Fettling and Inspection Method, Defects

4.1     Cleaning of Casting and Assessment

4.2     Fettling of Castings


5.0     Conclusion and Recommendation

5.1     Conclusion

5.2     Recommendation



1.0     INTRODUCTION       

          Aluminium pots are made from Aluminium scap. The shape of the Aluminium pots yard according to the    purpose for which they are produced.

          Hence there are various shapes of Aluminium pot such as cylindrical flat bottom pots spherical bowel pots e.t.c. In some cases means of production of the pots also determine their shapes.

          The pots being reported on are spherical bowel pots and circular called the mouth joined together with a narrower neck. They also possess two EAR-LIKES Handle used. For lifting when loaded. The mouth is covered with a circular lead having a handle as its center.        

          The cast aluminum pot serves several functions its versatility accounts   for its popularity in  many local villages, households where it serves as the primary family cooking utensil, Normally it is suspended from a tripod itself is typically constructed of 75mm diameter tree limbs about two mm  long.

          Prior to the usual of an aluminum reduction plant operation in the country. Local residents used pots made of Aluminum, which came from a distant place. It did not take long for the local entrepreneur to determine that a similar pot made of aluminum was much lighter, had much better heat transfer characteristic, and provided an improved and uniform thermal dispersion into the substance being cooked. These attributes are  important economics consideration where fuel is both scarce and expensive.

          It is some what ironic that the formerly discarded and displaced cast iron pots are used as the pattern for the  sand  moulds made for casting  the aluminium. Such a cast iron pot used for pattern purposes is visible, which shows the  sand mould  being prepared.

          The major aspect in preparation of aluminum cooking pot include preparation of sand, melting and pouring of the molten and finally into already prepared mould and finally the removal of the solicited casting from the sand and its dressing. After the metal had been poured the end product of the foundry operation is known as casting and may vary from a fraction of a kilogram to several tones. Various materials used in the furnace for the production of .aluminum cooking pot includes the materials that `can withstand very high temperature without causing any damage by heating. This materials as called refractory material such as crucibles used in the melting of aluminum scraps. Its should posses properties such as high mechanical strength and chemical stability at elevated temperature so as to withdraw the action of metabolic  melt oxide slag and fluxes.

          The major aspect of preparation of aluminum cooking pot includes preparation of sand, melting.

          Fire clay has sufficient mechanical strength and chemically stable to be used as a lining materials in furnaces for melting of aluminum scraps.

Fluxes are also added during melting of metal inform and control the composition of slag with the required physical and chemical  characteristics of the slag. Parting powder is also added to separate a content of moulding flask or boxes from one another. Surface dressing powder mould against the action of the molten metal and to help to produce good surface on casting.

Surface dressing powder used in the casting of aluminum cooking pot is talc, plumb ago and  coal dust can also be used.