701. Q.—Will you explain the process of casting cylinders?
A.—The mould into which the metal is poured is built up of bricks and loam, the loam being clay and sand ground together in a mill, with the addition of a little horse-dung to give it a fibrous structure and prevent cracks. The loam board, by which the circle of the cylinder is to be swept, is attached to an upright iron bar, at the distance of the radius of the cylinder, and a cylindrical shell of brick is built up, which is plastered on the inside with loam, and made quite smooth by traversing the perpendicular loam board round it. A core is then formed in a similar manner, but so much smaller as to leave a space between the shell and the core equal to the thickness of the cylinder, and into this space the melted metal is poured. Whatever nozzles or projections are required upon the cylinder, must be formed by means of wooden patterns, which are built into the shell, and subsequently withdrawn; but where a number of cylinders of the same kind are required, it is advisable to make these patterns of iron, which will not be liable to warp or twist while the loam is being dried. Before the iron is cast into the mould, the interior of the mould must be covered with finely powdered charcoal—or blackening, as it is technically termed; and the secret of making finely skinned castings lies in using plenty of blackening. In loam and dry sand castings the charcoal should be mixed with thick clay water, and applied until it is an eighth of an inch thick, or more; the surface should be then very carefully smoothed or sleeked, and if the metal has been judiciously mixed, and the mould thoroughly dried, the casting is sure to be a fine one. Dry sand and loam castings should be, as much as possible, made in boxes; the moulds may thereby be more rapidly and more effectually dried, and better castings will be got with a less expense.
702. Q.—Will you explain the next operation which a cylinder undergoes?