Feed Line A — Mould Side
Sand Preparation01
AFS fineness
Moisture %
Reclaimed ratio
Sieve / AFS / permeability / strength tests
Reclaimed sand % not fixed
Mould & Core Making02
Pattern draft
Mould hardness
Gating/riser design + cope-drag alignment
No numeric hardness accept value
Mould Coating03
No. of coats2–3 (typ.)
Thickness
Dry time/coat
Refractory wash, dried before close
Liquid/filler per coat unconfirmed
Feed Line B — Metal Side
Melting & Ladle04
Tap temp1610 °C
Ladle preheat900 °C
InsulationHusk
Max hold time
Husk cover slows heat loss, tap→pour
No max hold time / ΔT limit set
Chemistry Control05
Checks/heat3 stages
Spec standard
Melt-down / intermediate / pre-tap sampling
Standard cited only generically
Tapping & Pouring06
Min pour temp
Pour rate
Controlled-rate pour + temp check
No min. pour temperature stated
Solidification07
Cooling time
Cooling rate
No cooling time/rate/curve defined
Shakeout08
Timing
No shakeout timing/temp criteria
Fettling & Cutting09
MethodLPG flame
Standoff dist.
Flame cut gates/risers + grind/fettle
No HAZ standoff distance defined
Test Coupons10
BasisUp to 100%
Criticality rule
Chem/Tensile/Yield/Elong/Hardness/Impact/Fatigue
"Critical component" criteria undefined
Finishing & NDT11
MethodsMPI/LPT/UT/RT
Flaw limits
Shot blast + dimensional + NDT suite
No numeric accept/reject flaw size
Heat Treatment12
Type
Temp/hold/cool
Normalize / Normalize+Temper / Quench+Temper
No temp/time/cooling-rate values given
Default Numbers by Stage
Values with a figure come from the process document. Everything else is left open for you to fill in.
| Stage | Parameter | Value | Source / Note |
|---|---|---|---|
| 01 Sand Prep | AFS grain fineness no. | Not in document | |
| 01 Sand Prep | Permeability | Not in document | |
| 01 Sand Prep | Moisture % | Not in document | |
| 01 Sand Prep | Compactability % | Not in document | |
| 01 Sand Prep | Green/dry mould strength | Not in document | |
| 01 Sand Prep | Reclaimed sand ratio | Doc: "fixed by procedure," no figure given | |
| 02 Mould/Core | Pattern draft allowance | Not in document | |
| 02 Mould/Core | Mould/sand hardness range | Not in document | |
| 03 Coating | Number of coats | 2–3 (typ.) | User input; doc doesn't confirm count |
| 03 Coating | Coating thickness | Not in document | |
| 03 Coating | Drying time per coat | Not in document | |
| 04 Melting/Ladle | Tapping temperature | 1610 °C | Document §3.4 |
| 04 Melting/Ladle | Ladle preheat temperature | 900 °C | Document §3.4 |
| 04 Melting/Ladle | Ladle preheat method | Diesel-fired | Document §3.4 |
| 04 Melting/Ladle | Insulation cover material | Paddy husk / equiv. | Document §3.4 |
| 04 Melting/Ladle | Max holding/transfer time | Not in document — flagged risk area | |
| 05 Chemistry | No. of checks per heat | 3 | Melt-down/bath, intermediate, pre-tap — §3.5 |
| 05 Chemistry | Governing spec standard | Doc only says "e.g. EN, AAR, or national" | |
| 06 Tapping/Pour | Minimum pour temperature | Not in document | |
| 06 Tapping/Pour | Pour rate | Not in document | |
| 07 Solidification | Cooling time/rate | Not in document | |
| 08 Shakeout | Shakeout temp/timing | Not in document | |
| 09 Fettling | Cutting method | LPG flame cutting | Document §3.7 |
| 09 Fettling | Safe standoff distance | Not in document | |
| 10 Test Coupons | Inspection basis | Up to 100% | Criticality-dependent — §3.8 |
| 10 Test Coupons | Criticality criteria | Not in document | |
| 11 Finishing/NDT | NDT methods | MPI / LPT / UT / RT | Document §3.9 |
| 11 Finishing/NDT | Flaw acceptance limits | Not in document | |
| 12 Heat Treatment | Treatment type options | Normalize / +Temper / Quench+Temper | Document §3.10 |
| 12 Heat Treatment | Temp / hold time / cooling rate | Not in document — doc's own closing note flags this |
Quality Control — IQC / IPQC / OQC
Incoming, in-process, and outgoing checks for each stage, shown separately from the process flow above.
| Check type | Description |
|---|---|
| IQC | Fresh sand — sieve/weigh method (AFS grain fineness by sieve analysis; moisture by weight loss on drying) |
| IPQC | Blended sand — permeability test, compactability test, green/dry strength (compression/shear) |
| OQC | Qualified sand — final moisture & strength check before release to ramming |
| Check type | Description |
|---|---|
| IQC | Pattern dimensional check on receipt/reuse |
| IPQC | Mould hardness/compaction during ramming; visual check for cracks, loose sand |
| OQC | Assembled mould — cope-drag alignment (pin fit, parting line match), cavity visual inspection before closing |
| Check type | Description |
|---|---|
| IQC | Incoming wash — viscosity / specific gravity check |
| IPQC | Coating thickness & uniformity during application |
| OQC | Dryness verification (no residual moisture) before mould closes |
| Check type | Description |
|---|---|
| IQC | Charge material / scrap chemistry check before melting |
| IPQC | Bath temperature monitoring during melt cycle; ladle preheat temp check |
| OQC | Tap temperature verification (thermocouple/pyrometer) before tapping |
| Check type | Description |
|---|---|
| IQC | — (this stage is itself the check) |
| IPQC | 3-stage spectrometric sampling with documented correction calculations |
| OQC | Final chemistry certificate cross-checked against specification limits |
| Check type | Description |
|---|---|
| IQC | Ladle condition / preheat re-verification before use |
| IPQC | Pour stream visual monitoring for turbulence / premature freezing |
| OQC | Pour temperature log; confirmation of full, sound mould filling |
| Check type | Description |
|---|---|
| IQC | — not defined in document |
| IPQC | Cooling time monitoring (if an internal schedule is defined) |
| OQC | Casting removed intact; no shakeout-induced damage |
| Check type | Description |
|---|---|
| IQC | Gate/riser location verification against drawing |
| IPQC | Cutting operation monitored to avoid HAZ near critical sections |
| OQC | Dimensional check + surface visual post-fettling |
| Check type | Description |
|---|---|
| IQC | Coupon confirmed cast from same heat/pour as production casting |
| IPQC | Sample preparation for mechanical/chemical testing |
| OQC | Test results vs. spec; accept / reject / re-heat-treat disposition |
| Check type | Description |
|---|---|
| IQC | Casting received post-fettling, confirmed ready for shot blast |
| IPQC | NDT scanning in progress (MPI / LPT / UT / Radiography) |
| OQC | Final dimensional report + NDT sign-off |
| Check type | Description |
|---|---|
| IQC | Furnace calibration check; pre-treatment casting condition confirmed |
| IPQC | Temperature / time monitoring during treatment cycle |
| OQC | Post-HT hardness and/or microstructure verification |