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The programme, filmed on location at F H Lloyd and co., looks at the manufacture of two large steel castings made by the sand moulding technique. It looks particularly at the company's quality cont...rol procedure.
Metadata describing this Open University video programme
Module code and title: T352, Materials processing
Item code: T352; 11
First transmission date: 26-06-1979
Published: 1979
Rights Statement:
Restrictions on use:
Duration: 00:24:00
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Producer: Barrie Whatley
Contributors: Bill Cotterhill; Ken Reynolds
Publisher: BBC Open University
Keyword(s): Box mould; Casting defects; Core assembly; Dinorwic pumped storage system; Electric arc furnace; Facing and backing sand; Water turbine stay ring guide vanes
Footage description: Over film of some castings at the F H Lloyd steel foundry, Ken Reynolds introduces the programme. Reynolds examines a wood pattern from which a sand mould for a casting is made. He explains how shrinkage is anticipated and dealt with at this stage. Film of a sand mould being prepared using a sand slinger machine. Reynolds explains the process of the mould being closed and the molten steel alloy being poured. Film of the casting being removed from the mould and being cleaned and fettled. Commentary by Reynolds explains these processes. Using an animated diagram showing the turbine stay ring at the CEGB power station at Dinorwie, Wales, Reynolds points out the difficulty of casting this job. Colin Woodhouse, Bill Cotterhill and Ken Reynolds discuss the specifications of the stay ring and how the mould for this job was prepared. Shot of the moulding pit in which the mould is assembled. Reynolds goes on to explain why 'chills' are introduced into the mould to control shrinkage. In order to explain the need for very strict quality control for the Dinorwie job, John Wallett discusses the extreme working environment of the finished turbine. Reynolds goes on to describe the method for removing impurities from the alloy and how the quality and composition of the alloy are determined. Film of the furnace and of molten alloy being tapped. Ken Reynolds discusses the treatment given to the casting after its removal from the mould. Shots of casting undergoing heat treatment. Shots of surface cavities due to impurities being filled by welding. Reynolds goes on to describe methods used to determine the internal quality of the casting, x-ray and ultrasonic scanning. Shots of these tests being conducted. Finally Reynolds discusses the need for measuring machining the casting before delivery to the customer. Shots of a measuring table and machine tools. Colin Woolhouse sums up.
Master spool number: 6HT/72676
Production number: 00525_5335
Videofinder number: 1438
Available to public: no