TWO TYPES

1.NATURAL
2. SYNTHETIC

ILICA SAND

HIGH REFRACTORINESS

STRENGTH, STABILITY AND PERMEABILITY FOR THE MOULD

MPURITIES SUCH AS IRON OXIDE, ALUMINA, LIME STONE, MAGNESIA, SO

AND POTASH ARE ALSO PRESENT

ILICA SAND IS SPECIFIED ACCORDING TO

. SIZE (SMALL, MEDIUM AND LARGE SILICA SAND GRAINS)

. SHAPE (ANGULAR, SUB-ANGULAR, AND ROUNDED)

BINDERS
1. Organic
-clay sodium silicate and port land cement
2. Inorganic
-dextrin, molasses, cereal binders, linseed oil and
resins
-20 to 30 percent clay

Blackstrap molasses

MOISTURE
-moisture content in the molding sand varies
generally between 2 to 8 percent
-This is the amount of water required to fill the pores
between the particles of clay without separating
them.
-This amount of water is held rigidly by the clay and is
mainly responsible for developing the strength in the
sand
-The effect of clay and water decreases permeability
with increasing
clay and moisture content

Additives
Additives are the materials generally added to the
molding and core sand mixture to develop some
special property in the sand

1.Coal dust

2.Corn flour
3.Dextrin

Silica flour

4.Sea coal
5.Pitch
6.Wood flour
7.Silica flour

Dextrin
Coal dust

Coal dust-It is usually added in the molding sands for making

molds for production of grey iron and malleable cast

iron castings

Corn flour
-used to increase the collapsibility of the molding
and core sand
-It is completely volatilized by heat in the mould
--leave space between the sand grains
-- decreases the mold expansion and hence defects in

Dextrin

castings
-Dextrin belongs to starch family of carbohydrates
-- that
improves
significantly
strengthsimilar
of the to
mold
behaves
also in a manner
thatand
of
the corn flour
core

Sea coal
Sea coal is the fine powdered bituminous coal which
positions its place among the pores of the silica sand
grains in molding sand and core sand
When heated, it changes to coke which fills the pores and
is unaffected by water
The sand grains become restricted and cannot move into
a dense packing pattern
sea coal reduces the mould wall movement and the
permeability in mold and core sand

Pitch

It is distilled form of soft coal

It enhances hot strengths, surface finish on mold
surfaces and behaves exactly in a manner similar to
that of sea coal

Sea coal

coal pitch

Wood flour
Its relatively long thin fibers prevent the sand
grains from making contact with one another
It can be added from 0.05 % to 2% in mold and
core sand
It volatilizes when heated, thus allowing the
sand grains room to expand.
It will increase mould wall movement and
decrease expansion defects.
It also increases collapsibility of both of mold
and core

Silica flour
Increases the hot strength and finish on the
surfaces of the molds and cores
It also reduces metal penetration in the walls of
the molds and cores

1. Green sand
2. Dry sand
3. Loam sand
4. Facing sand
5. Backing sand
6. System sand
7. Parting sand
8. Core sand

Green sand
mixture of silica sand with 18 to 30 percent clay,
having moisture content from 6 to 8%
It is fine, soft, light, and porous
This sand is easily available and it possesses low
cost
Used for producing small and medium sized moulds
which are not very much complex
it is commonly employed for production of ferrous
and non-ferrous castings

Green sand

Dry sand
Green sand that has been dried or baked in suitable
oven after the making mold and cores, is called dry
sand
It possesses more strength, rigidity and thermal
stability
suitable for larger and heavy castings
Pinhole defect due to moisture content can be
avoided
Castings obtained will possess good surface finish

Loam sand
Loam is mixture of sand and clay with water to a thin
plastic paste
Loam sand possesses high clay as much as 30-50%
and 18% water
Patterns are not used for loam molding and shape is
given to mold by sweeps
Used for large grey iron castings

Facing sand
Facing sand is just prepared and forms the face of the
mould
It comes in direct contact with the molten metal when
it is poured
high strength refractoriness
made of silica sand and clay, without the use of used
sand
The layer of facing sand in the mould ranges from 20
to 30mm
A facing sand mixture for Green sand moulding of
cast iron consist of 25 percent fresh and specially
prepared sand, 70 percent old sand and 5 percent sea
coal.

cking Sand (Floor sand or Black Sand)

Used to back up the facing sand and to fill the whole
volume of the flask
Does not come in direct contact with the pattern
Repeatedly used moulding sand is usually employed
(so black in colour)
Main purpose is to reduce the cost of the moulding

System Sand
This sand is used in mechanized foundaries for filling
the entire flask
No facing sand is used here
Used sand is cleaned and reactivated by the addition
of water and binders and special additives. Its known
as system sand
Strength, permeability and refractoriness higher than
that of backing sand

Parting Sand
Used to ensure that the mould sand does not stick to
the pattern and cope and drag parts.
Helps to remove pattern easily without causing any
damage to the mould
This is clean clay-free silica sand

Core Sand
Used for making cores
This is silica sand mixed with core oil which is
composed of linseed oil, resin, light mineral oil and
other binding materials

roperties of moulding sand

1. Porosity or permeability
2. Flowability or Plasticity
3. Collapsibility
4. Adhesiveness
5. Cohesiveness or strength
6. Refractoriness

MOLDING PROCESSES
Conventional Molding Processes
1.Green Sand Molding
2.Dry Sand Molding

Methods of Green Sand Moulding

1.Open- sand method

2.Bedded in method
3.Turn over method

SKIN DRIED MOULD

HIS PROCESS OF MOULD MAKING MOISTURE FROM THE SURFACE LAYER O

LD IS DRIED BY USING GAS TORCHES OR HEATERS

DEPTH OF ABOUT 6-25MM IS DRIED

ADVANTAGES OF BOTH GREEN AND DRY SAND MOULDINGS ARE ACHIEVE

TIME REQIURED FOR DRYING IS LESS THAN IN THE CASE OF DRY SAND M

SO LESS EXPENSIVE THAN DRY SAND MOULDING PROCESS

VERY LARGE MOULDS CAN BE PRODUCED

LOAM MOULD

M IS CLAY AND SAND MIXED WITH WATER TO FORM A THIN PLASTIC MIX

PPED STRAW AND HORSE MANURE IS ADDED TO GET ADEQUATE POROSI

LIED AS PLASTER TO THE ROUGH STRUCTURE MADE OF BRICKWORK

CT SHAPE IS GIVEN BY ROTATING SWEEP FIXED TO A CENTRAL SPINDLE

T IRON PLATES AND BARS ARE USED TO REINFORCE BRICK WORKS

M MOULDS MAY ALSO BE PREPARED USING SKELETON PATTERN MADE O

SURFACES OF LOAMS ARE BLACKENED AND DRIED BEFORE BEING ASSEM

LOAM MOULDING WITH A SWEEP PATTERN

Carbon-Dioxide Gas Molding

This process was widely used in Europe for rapid
hardening of the molds and cores which are made up of
green sand
The mold making process is similar to conventional
molding procedure
The mould material which comprises of pure dry silica
sand free from clay, 3-5% sodium silicate as binder and
moisture content generally less than 3%

PLASTER MOULDING

MOULD IS PREPARED IN GYPSUM OR PLASTER OF PARIS

LASTER OF PARIS MIXED WITH TALC, ASBESTOS, FIBRES, SILICA FLOUR

WATER TO FORM A SLURRY

LASTER SLURRY IS POURED OVER METALLIC PATTERN CONFINED IN A FL

MOULD IS VIBRATED AND SLURRY ALLOWED TO REST

ATTERN IS REMOVED AFTER SETTING TIME OF ABOUT 30 MINUTES

MOULD IS DRIED BY HEATING IT IN OVEN FOR ABOUT 200 DEGREE CENTIG

NSERTS AND CORES ARE THEN PLACED

OPE AND DRAG MATCHED BY GUIDE PINS

MOLTEN METAL IS THEN POURED INTO THE MOULD

ASTING IS COOLED SHAKEN OUT AND MOULD IS DESTROYED

ADVANTAGES OF PLASTER MOULDING

ARPING AND DISTORTION CAN BE AVOIDED

GH DEGREE OF SURFACE FINISH AND DIMENSIONAL ACCURACY THUS M
COST IS REDUCED
GHLY SUITABLE FOR REPRODUCTION OF FINE FORM AND DETAILS(ORNA
CASTINGS, STATUES, JEWELLERY ETC)
LIMITATIONS

OW PERMEABILITY OF PLASTER OF PARIS

UITABLE ONLY FOR NONFERROUS CASTING ( PLASTER OF PARIS DESTROY
EGREE CENTIGRADE)

CERAMIC MOULDING
-SPECIALLY DEVELOPED CEREMIC AGGREGATES AND A
LIQUID CHEMICAL BINDER(ALCOHOL BASED SILICON
ESTER) IS USED(IN THICK SLURRY)
-THE SLURRY IS POURED OVER THE REUSABLE SPLIT
AND GATED METAL PATTERN
-THE SLURRY FILLS UP ALL THE CAVITIES AND
RECESSES BY ITSELF (NO RAMMING OR VIBRATION OF
THE MOULD IS REQUIRED)
-THE PATTERN IS WITHDRAWN AFTER IT SETS IN ABOUT
3 TO 5 MINUTES
-THE CEREMIC MASS IS THEN REMOVED FROM THE
FLASK
-ITS THEN HEATED TO ABOUT 980 DEGREE IN A
Note: A mixture of fine grain zircon (ZrSiO ),
FURNACE TO REMOVE THE LIQUID BINDER 4
aluminum oxide, fused silica, bonding agents, and
water, creates a ceramic slurry

ADVANTAGES OF CERAMIC MOULDING

1. HIGHEST PRECISION AND EXTREMELY HIGH FINISH
2. SUITABLE FOR ALL TYPES OF CAST METALS
3. CASTINGS DO NOT REQUIRE ANY RISER, VENTING OR
CHILLING AS THE COOLING RATE IS VERY SLOW
4. ANY ORDINARY PATTERN OF WOOD, METAL OR EPOXY
RESIN MAY BE EMPLOYED
5. USED FOR MAKING DIES, IMPELLER OF PUMPS, PARTS OF
AIRCRAFTS, ATOMIC REACTORS ETC

LIMITATIONS

. THE PROCESS IS EXPENSIVE

. THE MOULD MATERIALS ARE HIGH IN COST AND EXPENDABLE

SAND TESTING
1. GRAIN FINENESS TEST
2. MOISTURE CONTENT TEST
3. CLAY CONTENT TEST
4. PERMEABILITY TEST
5. COMPRESSION STRENGTH TEST
6. MOULD AND CORE HARDNESS TEST

CORE

es are separate shapes of sand used for producing hollow interior of the
ting or a hole through the casting

main constituents of the core sand are pure silica sand and a binder
higher values of permeability sands with coarse grain size distribution are used.

main purpose of the core binder is to hold the grains together, impart strength
d sufficient degree collapsibility

Functions or objectives of Core

1 .Core produces hollowness in castings in form of
internal cavities.
2. It must be sufficiently permeable to allow the easy
escape of gases during pouring and solidification.
3 .It may form a part of green sand mold
4 .It may be deployed to improve mold surface.
5 .It may provide external under cut features in
casting.
6 .It may be inserted to achieve deep recesses in the
casting.
7 .It may be used to strengthen the mold.
8 .It may be used to form gating system of large size