Casting the New Metallurgy of Cast Metals Second Edition by John Campbell | PDF Free Download
Metal castings are fundamental building blocks, the three-dimensional integral shapes indispensable to practically all other manufacturing industries.
Although the manufacturing path from the liquid to the finished shape is the most direct, this directness involves the greatest difficulty.
This is because so much needs to be controlled simultaneously, including melting, alloying, moulding, pouring, solidification, finishing, etc.
Every one of these aspects has to be correct since failure of only one will probably cause the casting to fail. Other processes such as forging or machining are merely single parts of multi-step processes.
It is clearly easier to control each separate process in turn. It is no wonder therefore that the manufacture of castings is one of the most challenging of technologies.
It has defied proper understanding and control for an impressive five thousand years at least. However, there are signs that we might now be starting to make progress.
Naturally, this claim appears to have been made by all writers of textbooks on castings for the last hundred years or so. Doubtless, it will continue to be made in future generations.
In a way, it is hoped that it will always be true. This is what makes casting so fascinating. The complexity of the subject invites a continuous stream of new concepts and new solutions.
The author trained as a physicist and physical metallurgist, and is aware of the admirable and powerful developments in science and technology that have facilitated the progress enjoyed by these branches of science.
These successes have, quite naturally, persuaded the Higher Educational Institutes throughout the world to adopt physical metallurgy as the natural materials discipline required to be taught.
Process metallurgy has been increasingly regarded as a less rigorous subject, not requiring the attentions of a university curriculum.
Perhaps, worse still, we now have materials science, where breadth of knowledge has to take precedence over depth of understanding.
This work makes the case for process metallurgy as being a key complementary discipline.
It can explain the properties of metals, in some respects outweighing the effects of alloying, working and heat treatment that are the established province of physical metallurgy.
In particular, the study of casting technology is a topic of daunting complexity, far more encompassing than the separate studies, for instance, of fluid flow or solidification (as necessary, important and fascinating as such focused studies clearly are).
It is hoped therefore that in time, casting technology will be rightly recognized as a complex engineering discipline, worthy of individual attention.
The author has always admired those who have only published what was certain knowledge. However, as this work was well under way, it became clear to me that this was not my purpose.
Knowledge is hard to achieve, and often illusive, fragmentary and ultimately uncertain. This book is offered as an exercise in education, more to do with thinking and understanding than learning.
It is an exercise in grappling with new concepts and making personal evaluations of their worth, their cogency,
and their place amid the scattering of facts, some reliable, others less so. It is about research, and about the excitement of finding out for oneself.
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