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Serious question, has anyone ever had a core shift right at the pour?
I was running a big gray iron job at the plant in Toledo, a 500-pound gear housing. We had the mold set, cores in place, everything looked perfect. The furnace was tapped, metal was at 2750 degrees, and we started the pour. Halfway through, I saw the cope lift maybe an eighth of an inch. I yelled to stop but it was too late. The whole core assembly shifted inside the mold. We let it cool, broke it out, and the casting was scrap. The boss blamed it on insufficient mold weight, but I swear we used the standard 1000 pounds of weights on top. What's the fastest way you've found to check for a potential shift before the metal hits the sprue?
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the_piper28d ago
That weight sounds light for a 500-pound pour.
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dylanfisher28d ago
Wait, @the_piper, what weight would you expect to see? Like if a normal pour is around 8 pounds per square foot for a 4-inch slab, a 500-pound pour covering 60 square feet seems way off. Are you saying the math doesn't add up, or is the mix design way too light?
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