3. Read and translate the text into Ukrainian analyzing lexical transformations.

Foundry is a technology of casting metals into shapes by melting them into a liquid, pouring the molten metal into a mold, and removing the mold material or casting after the metal has solidified as it cools. Foundry is also the place where this process takes place. Started as early as 3600 BC, the foundry industry has flourished very well and is likely to grow further playing a vital role in the industrial development. Castings are used for a variety of industrial and commercial applications which include automobiles, plumbing fixtures, train locomotives, airplanes etc.

Melting.

Melting forms the first step towards manufacturing a product. Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are added to the alloys to modify their properties for specific applications. They are used either in pure form like electrolytic nickel or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and other extraneous metal oddments produced within the facility.

The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made.

What is Casting? 

Casting can be defined as a process of manufacturing that involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult, unfeasible or uneconomical to make by other methods. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting.

‘Non-expendable’ mold casting is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.

Continuous casting is a casting method, in which the steps of pouring, solidification and withdrawal (extraction) of the casting from an open end mold are carried out continuously. Cross-sectional dimensions of a continuous casting are constant along the casting length and they are determined only by the dimensions of the mold cavity. The length of a continuous casting is limited by the life time of the mold. Continuous casting technology is used for both ferrous and non-ferrous alloys.

Traditional continuous casting processes use stationary (or oscillating) molds, in which the solidified bar moves relative to the mold surface. Friction caused by the movement results in formation of micro-cracks and other defects in the surface regions of the casting. Lubricating oil supplied to the mold surface and self-lubricating graphite molds decrease the friction/sticking and reduce the defective surface zone. The metals continuously cast are aluminum, copper, and steel. Depending on the mold position (vertical or horizontal) continuous casting machines may be vertical or horizontal.

Centrifugal casting is a method of casting parts having axial symmetry. The method involves pouring molten metal into a cylindrical mold spinning about its axis of symmetry. The mold is kept rotating till the metal has solidified. The rotation speed of centrifugal mold is commonly about 1000 RPM (may vary from 250 RPM to 3600 RPM). True- and semi-centrifugal processing allow 30 to 50 pieces/hr. The batch processing has an upper limit of around 9000 Kg (practically). Centrifugal casting technology is widely used for manufacturing iron pipes, bushings, wheels, pulleys, bi-metal steel-bronze bearings and other parts possessing axial symmetry.

Die-casting can be defined as a process, in which the molten metal is injected into the mold cavity at an increased pressure up to 30,000 psi (200 MPa). The reusable steel mold applied in the die casting process is called a die. The molten metal injection is carried out by a machine called die casting machine. Die casting is a highly productive method of casting parts with low dimensions tolerance and high surface quality. It is usually used where finer parts are needed.

Permanent mold casting (gravity die casting) is a casting process involving pouring molten metal by gravity into a steel (or cast iron) mold. The permanent mold casting is similar to the sand casting process. In distinction from sand molds, which are broken after each casting, a permanent mold may be used for pouring of at least one thousand and up to 120,000 casting cycles with the rate 5-100 castings/hour. Manufacturing metal mold is much more expensive than manufacturing molds for sand casting or investment casting. Minimum number of castings for profitable use of a permanent mold is dependent on the complexity of its shape. Ferrous and non-ferrous metals and alloys are cast by the permanent mold casting process. They are aluminum alloys, copper alloys, magnesium alloys, zinc alloys, steels and cast irons.

Expendable mold casting can be referred to as a standard classification inclusive of the following: sand casting, plaster casting, plastic casting and concrete casting.

Sand casting is amongst the simplest and most popular casting types used since ages. It involves pouring a molten metal into a sand mold. The bonding of sand takes place by use of clays (as in ‘green sand’) or ‘polymerized oils’, or ‘chemical binders’. Recycling is easily possible.

Plaster casting (for metals). There is no difference between plaster casting and sand casting, except the fact that plaster is used in place of sand. Similarly, there are also plastic and concrete castings.

4. Distinguish the terms:

1) foundry vs casting

2) die casting vs permanent casting

3) dross vs slag

4) gravity vs pressure

5. Translate the sentences paying attention to different contextual meanings of the words in bold.

1. This alloy can be cold chamber pressure die cast using a similar process to that used for making aluminium pressure castings.

2. It has been developed for use as a general-purpose foundry alloy.

3. The casting properties of ZL12 enable it to compete favourably with other cast metals such as iron, brass, bronze and aluminium alloys.

4. Because the zinc alloys are cast at relatively low temperatures, life of the graphite molds are increased, adding to the economics of the process.

5. Foundrymen have for a long time recognized the benefits of casting metal into graphite permanent molds.

6. Graphite is known for its excellent thermal stability and it will not warp or distort when used as a die.

7. The zinc alloys used with graphite permanent molds are relatively new products developed specifically for sand and permanent mold nonferrous foundries.

8. The rapid chilling effect of graphite makes the process sensitive to metal and die temperature variations which can affect castability.

9. New molds are sprayed with a graphite aerosol which acts as a mold release and helps break metal surface tension during casting.

10. These foundry grades are gaining popularity with nonferrous foundries because they are easy-to-cast, low temperature materials with clean, energy-saving melting characteristics.

6. Match the words making up multi-component terms & translate them

1. sand	a) speed
2. life	b) time
3. transport	c) casting
4. rotation	d) vessel
5. surface	e) cavity
6. master	f) alloy
7. die	g) cycle
8. cast	h) mold
9. casting	i) quality
10. mold	j) iron

7. Complete the text with prepositions if necessary. Translate into Ukrainian analyzing lexical transformations.