INTRODUCTION: A method of plaster molding in which a plaster-water
mixture is poured over a pattern, after which the mold is steam-treated, allowed to set in air, dried in an oven, and cooled for use in casting certain alloys.
CORE ITEM, KEY FEATURES AND PROCESS: Molds are dehydrated in an
autoclave (pressurized oven) for 6 to 12 hours and then rehydrated in air for 14 hours.50% plaster of Paris and 50% sand is mixed with water. The mixture is poured over the casting pattern and let set. After the pattern is removed, the mold is autoclaved in steam, (placed in an oven that uses hot steam under high pressure), and then let set in air. The resulting mold will easily allow the escape of gases from the casting. It is done with a mixture of sand, gypsum, asbestos, talc, sodium silicate, and water, sand being the bulk ingredient and gypsum being the binder. The slurry is poured around the pattern in suitable flasks or metal core boxes, after standing for 6 hours, the molds are assembled and autoclaved in steam and dried in air. The molds are finally put in oven. The advantage of plaster molds are that nonferrous casting can be made with good surface finish and dimensional accuracy. Tolerance of +0.055 in. on small casting and +0.015 in. on large castings such as rubber-tire molds can be obtained. Metallurgical quality in aluminum castings is also claimed for Antioch process, because metal chills can be embodied in the mold.
ADVANTAGES:
More uniform grain structure is created
More intricate designs can be made
DISADVANTAGES:
It can only be used with lower melting temperature non-ferrous
materials, such as Aluminium, Copper, Magnesium, and Zinc Its long cooling time restricts production volume
APPLICATIONS:
In industry parts such as valves, tooling, gears, and lock components
may be manufactured by Antioch Process in manufacturing Also useful for prototypes and short run production of aluminum and zinc parts Cost-effective casting process for complex components
REFERENCES:
Materials and Processes in Manufacturing (9th ed.), Degarmo, E. Paul; Black,
J T.; Kohser, Ronald A.
Manufacturing Engineering and Technology (5th ed.), Kalpakjian, Serope;