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Page No
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CONTENTS
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I-VI
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PREFACE
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INTRODUCTION
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1 - 2
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CHAPTER I - ENGINEERING MATERIALS
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3 - 32
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I.1. Introduction
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3
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I.2. Classification of engineering materials
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4
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I.3. Non-metals
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4
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I.3. 1. Organic non-metals
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6
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I.3. 2. Inorganic materials
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6
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I.4. Metals
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6
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I.4. 1. Non-ferrous metals/alloys
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8
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I.4. 2. Ferrous metals alloys
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9
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I.4. 2.1. Pure iron
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9
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I.4. 2. 2. Pig iron
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10
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I.4. 2. 3. Wrought iron
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10
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I.4. 2. 4. Cast iron
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11
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I.4. 2. 4. 1. Grey cast iron
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11
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I.4. 2. 4. 2. White cast iron
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11
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I.4. 2. 4. 3. Malleable cast iron
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12
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I.4. 2. 5. Steel
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12
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I.4. 2. 5. 1. Carbon steel
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13
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I.4. 2. 5. 2. Alloy steel
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13
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I.4. 2. 5. 2. 1. Stainless steel
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13
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I.4. 2. 5. 2. 2. Tool steel
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13
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I.4. 2. 5. 2. 2. 1. High speed steel
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13
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I.4. 2. 5. 2. 2. 2. Heat- and rust resisting steel
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14
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I.5. Properties of engineering materials
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14
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I.5. 1. Thermal properties
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14
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I.5. 2. Electrical properties
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15
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I.5. 3. Magnetic properties
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15
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I.5. 4. Chemical properties
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16
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I.5. 5. Optical properties
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16
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I.5. 6. Physical properties
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16
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I.5. 7. Mechanical properties
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17
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I.5. 8. Alloying elements and their effects on mechanical properties
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21
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Page No
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I. 6. Structure of steel and cast iron
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25
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I. 6. 1. Solid solution
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25
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I. 6. 2. Micro-constituents of steel and cast iron
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26
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I. 6. 3. Iron -Carbon equilibrium phase diagram
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28
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CHAPTER II - EXTRACTIVE METALLURGY
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33 – 78
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II. 1. Introduction
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33
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II. 2. Blast furnace
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35
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II. 2. 1. Principle
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35
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II. 2. 2. Construction
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35
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II. 2. 3. Charge
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38
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II. 2. 4. Operation
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38
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II. 2. 5. Chemical reactions
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39
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II. 3. Cupola furnace
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44
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II. 3. 1. Construction
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44
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II. 3. 2. Operation
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46
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II. 3. 3. Cupola repair
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52
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II. 3. 4. Application
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52
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II. 3. 5. Batching example
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53
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II. 3. 6. Advantages and Disadvantages
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54
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II. 4. Crucible process
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54
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II. 5. Open - hearth furnace (Siemens-Martin-furnace)
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55
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II. 5. 1. Construction
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55
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II. 5. 2. Operation
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56
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II. 5. 3. Open hearth similar furnaces
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58
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II. 5. 3. 1. Air furnaces
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58
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II. 5. 3. 2. Non crucible furnaces
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59
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II. 6. Bessemer converter
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60
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II. 6. 1. Construction
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60
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II. 6. 2. Operation
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60
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II. 7. Oxygen furnaces
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63
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II. 7. 1. L-D process
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63
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II. 7. 2. L.D-A.C process
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65
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II. 7. 3. Kaldo process
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65
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II. 8. Electric furnaces
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65
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II. 8. 1. Electric Arc furnaces
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65
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II. 8. 1. 1. Electric Direct-arc Furnaces
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65
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Page No
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II. 8. 1. 2. Electric Indirect-arc Furnaces
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68
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II. 8. 1. 3. Arc resistance furnaces
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69
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II. 8. 2. Resistance furnaces
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69
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II. 8. 2. 1. Direct resistance furnaces
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69
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II. 8. 2. 2. Indirect resistance furnaces
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69
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II. 8. 2. 3. Resistance- radiation-furnaces
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70
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II. 8. 3. Induction furnaces
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70
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II. 8. 3. 1. Core-type Induction Furnaces
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70
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II. 8. 3. 2. Coreless-type induction furnace
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72
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II. 9. Furnaces for non-ferrous metals
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74
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II. 9. 1. Coke heated furnace
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75
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II. 9. 2. Boiler furnace
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76
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II. 9. 3. Oil heated crucible furnace
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76
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II. 9. 4. Electric heated furnace
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77
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CHAPTER III – CASTING
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79– 112
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III. 1. Introduction
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79
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III. 2. Pattern making
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79
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III. 2. 1 Pattern materials
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80
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III. 2. 2 Types of pattern
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81
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III.3. Moulding sand
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82
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III. 3. 1. Classification of moulding Sand
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83
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III. 3. 2. Grain shape and size of moulding sand
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84
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III. 3. 3. Types of moulding sand
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85
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III. 3. 4. Properties of moulding sand
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86
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III. 3. 5. Sand preparation
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89
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III. 3. 6. Sand testing
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91
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III. 3. 7. Elements of sand mould
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94
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III. 3. 8. Technology of making sand mould
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98
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III. 3. 9. Types of moulds
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100
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III. 3. 10. Core moulding
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103
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III. 3. 10. 1. Core materials
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103
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III. 3. 10. 2. Core making
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104
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III. 3. 10. 3. Types of core
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106
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III. 3. 11. Casting defects
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107
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