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Saint Anna German High School ( Russian : Главное немецкое училище Святой Анны ), usually known as Annenschule ( Russian : Анненшуле ), was a school in Saint Petersburg , Russia founded in 1736 for children of the German population of the city. In 1918, Annenschule became Soviet work school №11, and later school №203. Its alumni included ethnologist Nicholai Miklukho-Maklai , jeweler Peter Fabergé , philologist Faddei Zielinski , teacher and physician Peter Lesgaft , poet and Nobel Prize laureate Joseph Brodsky , actress Elena Granovsky , writer Igor Yefimov , and chess world championship pretendent Victor Korchnoi . In 1975 the specialized high school №239 moved into the building.

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41-657: In 1711, a foundry was established on the left bank of Neva River in Saint Petersburg in order to equip the Russian Army for the Great Northern War . Its operation required skilled employees. Therefore, Peter the Great invited foreign professionals from Switzerland, Holland and Germany. Many of them came together with their families, and they settled together by nationality in settlements called sloboda . A German sloboda

82-538: A furnace is seen as an unfortunate event. Conversely, starting up a new furnace, or one that had been temporarily shut down, is often a special occasion. In traditional bloomeries, several rounds of fuel would need to be burnt away before the furnace was ready to accept a charge of ore. In English, this process became known as "blowing in" the furnace, while a furnace that had to be shut down and went cold had been "blown out", terms that are still applied to contemporary blast furnaces. A reverberatory furnace still exposes

123-445: 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 or uneconomical to make by other methods. Melting is performed in a furnace . Virgin material, external scrap, internal scrap, and alloying elements are used to charge

164-500: A material. Heat treatment techniques include annealing , case-hardening , precipitation strengthening , tempering , and quenching . Although the term "heat treatment" applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. After degating and heat treating, sand or other molding media may remain adhered to

205-430: A mold yields leftover metal — including heads, risers, and sprue (sometimes collectively called sprue) — that can exceed 50% of the metal required to pour a full mold. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus overall melting costs. Heat treating

246-559: A single chamber. Mechanisms, such as bellows or motorized fans, then drive pressurized blasts of air into the chamber. These blasts make the fuel burn hotter and drive chemical reactions. Furnaces of this type include: Even smaller, pre-industrial bloomeries possess significant thermal mass . Raising a cold furnace to the necessary temperature for smelting iron requires a significant amount of energy, regardless of modern technology. For this reason, metallurgists will try their best to keep blast furnaces running continuously, and shutting down

287-424: A single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mold that would otherwise be impossible to achieve. Where the cope and drag separates

328-426: A steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces. Degassing is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal. Gases can form in metal castings in one of two ways: Hydrogen

369-425: Is smelting , where metal ores are reduced under high heat to separate the metal content from mineral gangue . The heat energy to fuel a furnace may be supplied directly by fuel combustion or by electricity . Different processes and the unique properties of specific metals and ores have led to many different furnace types. Many furnace designs for smelting combine ore, fuel, and other reagents like flux in

410-499: Is a factory that produces metal castings . Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron . However, other metals, such as bronze , brass , steel , magnesium , and zinc , are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed. Foundries are one of

451-401: Is a common contaminant for most cast metals. It forms as a result of material reactions or from water vapor or machine lubricants. If the hydrogen concentration in the melt is too high, the resulting casting will be porous; the hydrogen will exit the molten solution, leaving minuscule air pockets, as the metal cools and solidifies. Porosity often seriously deteriorates the mechanical properties of

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492-416: Is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of

533-463: Is called the parting line . When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft . The opposite of draft is an undercut where there is part of the pattern under the mold material, making it impossible to remove the pattern without damaging the mold. The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon

574-567: Is common to paint castings to prevent corrosion and improve visual appeal. Some foundries assemble castings into complete machines or sub-assemblies. Other foundries weld multiple castings or wrought metals together to form a finished product. More and more, finishing processes are being performed by robotic machines, which eliminate the need for a human to physically grind or break parting lines, gating material, or feeders. Machines can reduce risk of injury to workers and lower costs for consumables — while also increasing productivity. They also limit

615-546: Is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to

656-541: Is happening inside the mold or die during the casting process. Metallurgical furnace A metallurgical furnace , often simply referred to as a furnace when the context is known, is an industrial furnace used to heat , melt, or otherwise process metals . Furnaces have been a central piece of equipment throughout the history of metallurgy ; processing metals with heat is even its own engineering specialty known as pyrometallurgy . One important furnace application, especially in iron and steel production,

697-510: Is particularly useful for recycling (still relatively pure) scrap metal, or remelting ingots for casting in foundries . The absence of any fuel or exhaust gases also makes these designs versatile for heating all kinds of metals. Such designs include: Other metallurgical furnaces have special design features or uses. One function is heating material short of melting, in order to perform heat treatment or hot working . Basic furnaces used this way include: Another class of furnaces isolate

738-541: Is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates — which are the channels through which the molten metal traveled to reach the component itself. Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches , bandsaws , or ceramic cutoff blades. For some metal types, and with some gating system designs,

779-569: The amount of material being removed. These steps are done prior to any final machining. After grinding, any surfaces that require tight dimensional control are machined. Many castings are machined in CNC milling centers. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for castings to be used without machining. A few foundries provide other services before shipping cast products to their customers. It

820-544: The beginning of the 20th century, Annenschule consisted of boys' and girls' gymnasiums, realschule , an elementary school and an orphan house. In 1905-1906 a new building was built on the other side of the Saint Anna Church. After the October Revolution , on October 18, 1918, Saint Anna School was nationalized, and by decree of Sovnarkom it was included in the government education structure. The Soviet work school

861-436: The casting surface. Numerous materials may be used to clean cast surfaces, including steel, iron, other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder, and many others. The blasting media is selected to develop the color and reflectance of the cast surface. Terms used to describe this process include cleaning, bead blasting, and sand blasting . Shot peening may be used to further work-harden and finish

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902-423: The casting. To remove any mold remnants, the surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The cleaning media strikes the casting surface at high velocity to dislodge the mold remnants (for example, sand, slag) from

943-487: The entire casting manufacturing route. Casting process simulation was initially developed at universities starting from the early ' 70s , mainly in Europe and in the U.S. , and is regarded as the most important innovation in casting technology over the last 50 years. Since the late ' 80s , commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what

984-433: 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 harmful 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

1025-401: The furnace must be designed for temperatures over 1,600 °C (2,910 °F). The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces ) or coke . The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola , induction furnace, or EAF, while

1066-505: The furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy . Alloying elements are either pure forms of an alloying element, 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

1107-480: The iron-cast grille of the Summer Garden ) built the stone Church of Saint Anna, which survived until recently. In 1867, there were 537 boys and 307 girls. There was a lack of classrooms to accommodate such numbers, so in 1868 the new building was built. The school reached its highest point during the period from 1884–1910. During these 26 years the school was expanding: from 1153 students in 1884 to 1733 in 1908. At

1148-403: The largest contributors to the manufacturing recycling movement, melting and recasting millions of tons of scrap metal every year to create new durable goods. Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and reuse sand, which is another form of recycling. In metalworking , casting involves pouring liquid metal into a mold , which contains

1189-498: The metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve in gasses. During the tap, final chemistry adjustments are made. Several specialised furnaces are used to heat the metal. Furnaces are refractory-lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces , cupolas , reverberatory , and crucible furnaces. Furnace choice

1230-430: The metal. An efficient way of removing hydrogen from the melt is to bubble a dry, insoluble gas through the melt by purging or agitation. When the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the surface. Chlorine, nitrogen, helium and argon are often used to degas non-ferrous metals. Carbon monoxide is typically used for iron and steel. There are various types of equipment that can measure

1271-489: The potential for human error and increase repeatability in the quality of grinding. Casting processes simulation uses numerical methods to calculate cast component quality considering mold filling, solidification and cooling, and provides a quantitative prediction of casting mechanical properties, thermal stresses and distortion. Simulation accurately describes a cast component's quality up-front before production starts. The casting rigging can be designed with respect to

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1312-400: The presence of hydrogen. Alternatively, the presence of hydrogen can be measured by determining the density of a metal sample. In cases where porosity still remains present after the degassing process, porosity sealing can be accomplished through a process called metal impregnating . In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in

1353-749: The reaction chamber, where metal or ore is combined with reagents, to a stream of exhaust gases. However, no fuel is directly added to the chamber, and combustion occurs in a separate chamber. Furnaces of this type include: In metallurgy, furnaces used to refine metals further, particularly iron into steel, are also often called converters : Just as other industries have trended towards electrification , electric furnaces have become prevalent in metallurgy. However, while any furnace can theoretically use an electrical heating element , process specifics mostly limit this approach to furnaces with lower power demands. Instead, electric metallurgical furnaces often apply an electric current directly to batches of metal. This

1394-413: The required component properties. This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete casting system also leads to energy , material, and tooling savings. The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making, heat treatment , and finishing. This saves costs along

1435-444: The sprue, runners, and gates can be removed by breaking them away from the casting with a sledge hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required to produce castings in

1476-408: The surface. The final step in the process of casting usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape, and surface finish. Removing the remaining gate material, called a gate stub, is usually done using a grinder or sander . These processes are used because their material removal rates are slow enough to control

1517-482: The type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: In a foundry, molten metal is poured into molds . Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines to pour molten metal. Traditionally, molds were poured by hand using ladles . The solidified metal component

1558-414: The type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 °C (932 °F). Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel-based alloys,

1599-569: Was established on the base of the school. Teaching in German was first reduced, and later eliminated. In 1934 the school was split, with school №32 (later №203) occupying the newer building, and school №11 (later school №189) staying in the old building. In 1975 the city's specialized high school №239 with advanced programs in physics and mathematics moved into the old building. 59°56′42″N 30°21′04″E  /  59.945°N 30.351°E  / 59.945; 30.351 Foundry A foundry

1640-502: Was formally open. That was the beginning of Annenschule. In 1734–1740, the new temple was built in place of the old one. 1740 was the year in which Empress Anna Ioanovna died and bequeathed a sum of money for building of the new temple. Therefore, it was decided that the church would have the name of Saint Anna. The school also received the same name. From that time it was called "School of St. Anna", Annenschule in German. In 1775–1779, architect Yury Felten (best known for his work on

1681-428: Was located in the area close to today's Liteyny Prospekt , and had a strong Lutheran community. In 1720–1722, a wooden Lutheran church was built on the edge of the sloboda. Its first pastor started to teach German to the children. Soon these classes became popular, and Shatner started a campaign to build a dedicated building for the school. With the help of Jacob Bruce the school was built, and on January 3, 1736, it

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