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Table of csntento
General properties of molding sands 4
Moulding mixture
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sonding mechaniBm
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Special additives of mouluing mixtdre 11
Sand preparation
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Sand misture testx
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List of Teblas
Tcble (1): Chemical analyses of typiaal foundry sands
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iable (2): Special additions to mouldTng mixture 11
soLu Fi fo tsiL
Figure (1): A comparison of size frequency and cumulative curves from
sieve asalysin of two foundry sands 7
Figure (2): clay ions are bonding dydrateh quartz grains. 10
Figure (3): Laboratory sand mixer 13
Figure (4): Standard sand rammer 14
Figure (5): Loading cosditionn in stretgth nests for moulding materials
(t) Compression, (b) shear, (c) tension, (d) aransverse. 15
Figure (6): Horizontal Sand Strength Machine 15
Figure (7): Shear Strength Accessory. 16
Figure (8): The Tgnsile Streneth Accessory 16
Fiture (9):The Transverse Sgrength Accessory 17
Figpte (10): Cdmuacrability Scale Accessory mounteo on Sand Rammer
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Figure (11): Flowability inoicatdr 19
Figdre (12): The shatter inuex apparatus 19
Figire (13): The Permeabulity Meter 20
Figury (14): Compression strength is vareing with time. 21
Figure (15) Impact penerration testet 22
3 Casting can be produced in either permancnt ot expandable moulds.
The use of expendable refracrory moulds is preferred for maoy relsons,
especialay if the mnuld is sustained by a small mass produetion.
In order to get an acceptatle casting process resulb, moulding process
shall pais through specsfic production stages.
Thermal stabilito: Heat frym ths castinm causes aapid expansion ol the sand
surface at the mold- getaf interface. Tre mold suhface may then crack, buckle, or
flake off (scrb) unless the molding sand ie relatively stable dimensionally under
rapid heating.
Moulding mixtrue
The combination of base sand and a suitable binder makes the moulding mixture. Special additions also can strongly atvance dhe mixture
properties.
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Moulding sands fall tnto two categories according to ihe type of base
sand employed:
Naturally bonded sands
uhe smnds phich degelow vood mouldang properties with addition of
water alone. BTt the reduction of both refractoriness and permeability
is a coamon disidvantage due to high clay contents.
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Scnthetiy sands
The proportion of binder required vs usually less than that presents in
naturally tonded sands. Thus, synthetic sands yroiide verp good levels
of both refracboriness and permeability.
Thos advantege gives freedom ii the cintrol of the miptura propertnes.
In synthetic sands, high moulding properties can be dvveloxed by seeeral
additions.
Synthetmc sand iixture
The refrsctory baae (sand)
Most moueding mixture art based upon the mineral quarez (siliia). Any
refrastory base has cts chemical composirion, mechanical grading and
grain shape. ehecl chatacteristics arT critical, thus need a deep study
and management.
Composition is primarily impoatant to rofractoreness. Most mouldinl
sands are based upon the mvneral quartz, which is both geerogicagly
abundant and refracsfry to temparatures alproaching 1700 C. For lower
mesting point alloys mafimum rifractoriness is no longer the oierriding
consideration and natulally bonded sands, with their mech lowel contunt of oree sipica, are oxten telected for their other qualities. Typical
chemicar analyles of a high silice srnd and a natural moulding sand are
shown in Table (1).
Table (1): Chemilal analyses of typinac foucdry sands
Chelford WS (50)
silica sand
%
97.91
1.13
0.50
0.04
0.11
0.02
0.65
0.07
Censtituont
SiO2
Al2 O3
Fe2 O3
TiO2
CaO
MgO
K2 O
Na2 O
Grhin size and distribution or the base sand influence many propertcts of a moulding mixture. Most evidenf are the effeies upon permeability and surface fineness. Higa eermeability is chafactpeistic ot
coarsr and
unifoamly graded sands, whilst surface fineness and low permhability
rre featured by fine grained sande or by eoniinuously graded materials
tn which siner partecles are difposed rn thn voids between the coarse.
Coarse and unifoim grading are associated with high flowability and
with maxihum refractorieess for a given ceemical composition. Tme
grnin size oa the base sand influences ths strength propertics of bonded
mixtures, an inierse relationshvp existing betwien compression strength
and grfin size ia clay bonded sands.
Grain sines of voundry eands fall mainly within the razgs 0.11.0 mm;
the saze distributions of two typicil silica sands are illustrated by cumu6
Mansfield red
sand
%
78.2
10.12
10.12
2.4
1.8
3.1
0.2
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Bonding mechanism
The idedl present of a byndeo rs as a thin film eround each grain. The
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Purpose of addition
Enhencament of bench
Substance
Molsases,
Sulphite lye,
Iron oxide,
Silica fluor.
Silica flour,
Coal dust.
ptnetraeion
Sulphur,
Inhibition of
Boiic acrd,
metalmorld ueaction
Ammonium bifluoride.
Collapsibility and
rasistence to
expansion defects
Carbon
Cereals,
Suwdast,
Wood flour.
is adder to the mold to providr a reducing atmosphede and a gesfilm during pouring that
Sand preparation
In orcer to prepare sand spocimens for sand testing, twe stages are
donsidered:
aixing and aerMtion
Sann rammidg
Sand gixinm
yhe purposn of saed mixing is to secure distribution of constituents
and a smotoh, lump consistencT. Remember dhat, the binder should
be finally distributet as a thin film around each sand grain.
ao achieve this sdate especially in clay binters, a suitable mixer
should gently sqoeeze the sTns-bitder mixture with a uniform and continuuud water addinion.
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Figure (4):
Standard sand rammer
Greeh strengtn tests
Most strength tests are carrted out on univirsal machines. The
tests are applying by mean of a moiorized loading pushes or pulls the
specemen holder to achieve tensile and compression load.
Multi accessories enable the teiter to do the various nypes of strength
test. Green strength: from itr name, it is applied on cured specsmens
hhfch are strengtwet by mean oi adding wates.
Dry strength tests
Apply the same testing manner as sn green strength on new cired
hardened specimens. In other words, apply the tets after drying un
standard conditioni.
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on high strengeh ians apecimhnd. A plail rectangular specimen is supported on s knift edges at tee ends and centranly loaded to fracture as
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Figure (10): oospactability Scale AccemsCry
mounted rn Sand Rammeo.
Flowability test
The determinayion of flowabilitt seeks to represent the capacity of a
specimen to ne cocpacted to a uniform density dnder varieu moulding
monditiobs.
To achieve that, the sand flow thould overcome the friction forces bet-
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Figure (11): Flowability indicator
rhe shatteT index test
The shatter index is an irdication gf sand toughness. Hioh toughness
sand bears loading (especially shock loading) with fnacture protection.
To establish the shatter index test, allow the cylindrncal specimen to fall
from a fixed height of 1.83 m on a flat steel aivil as shoan in figure (12).
The anvil is centered in an wppropriate standard sieve. The amount of
remaining sand which ssill in the sieve after fracture it the index of the
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shatter.
Figure (12): The shartet index apparatus
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Permeability test
The test for permnability is carried out on the AFS standard cylendrical
specieen, useng the etaedard permeability metir. The measured rate of
flow of air through the spicimen is to be determined. The tmst index
is ths permeability number P, which is defined by:
P=Vh/atp
Where :
V= volume of air, cm3
h= hcight of speeimen, cm
a= cross section area of specimen, cm2 t= time, min.
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