Foundry sand (high silica sand) testing is a process used to determine if the foundry sand has

the correct properties for a certain casting process. The sand is used to make moulds and coresvia
a pattern. In a sand casting foundry there are broadly two reasons for rejection of the casting
metal and sand.
The defects arising from the sand can be prevented by using sand testing equipment to measure the
various properties of the sand.

Process[edit]
The testing process is divided into three stages: sampling of the bulk material, sample preparation,
and testing.[1]
It done at three different points of the process: upon first arrival from the supplier, en transport for
processing (usually on a conveyor), and after processing. In each situation it is important to take a
representative sample by mixing the sand or by taking multiple samples in different locations. Also,
the sample must be stored in an airtight container to keep from spoiling it.
There are more than 25 basic tests, however only the important ones for the given casting process
are used. The basic tests measure the following parameters: wet tensile strength, cone jolt, friability,
moisture content, permeability, green compression strength, compactability, loss on ignition, volatiles
content, grain size & distribution, dust (dead clay) content, and active clay content. Each of these
tests can lead you to obtain specific characteristics of sand which can be crucial quality of casting.
[2]

Advanced testing tests for other parameters, such as splitting strength, shear strength, and high-

temperature compression strength.

Sampling

PREPARATION OF FOUNDRY SAND FOR TESTING:

4.2 Preparation of Natural Motllding Sand:
Tempering by Mechanical Mixing - Dry about 2-kg sample of sand as given in 4.2.1.
Place the dried sand in the laboratory mixer and add sufficient water to produce the
desired moisture content plus an additional amount to allow for evaporation during
mixing. Water should be added gradually within 30 seconds while the mixer is
operating. time should be 5 minutes.
SECTION 2 METHOD OF PHYSICAL TESTS FOR FOUNDRY MOULDING SANDS
DETERMINATION OF MOISTURE CONTENT
Increasing water percent leads to increase in compressive strength to a point
referred to as temper point. Further increase in water will lead to decrease in
compressive strength .

Direct We igh t Me th od
Procedure - Weigh accurately about 100 g cf sample of sand in a tared covered
porcelain dish. Dry it in a uniformly heated oven between 105 and 1lOC for about
one hour. Cool to room temperature and weigh. Repeat the process of drying and
cooling till constant weight is attained.
Calculate the percentage moisture by the following formula:
Moisture content = A/B X 100
determination on three separate samples and take the average of three test results
as the moisture content of the sand.
Determination of clay content:
Changing to total amount of clay contents can alter the compressive strength of the
sand , and other physical properties, higher clay percentage up to 12% will result in
increase in strength.
DETERMINATION OF TENSILE 8TRENGTh: ( green & Dry )
A@m zt u~ -Dead weight type of universal sand strength testing machine or spring
type of sand strength testing machine. 11.1.2 Test Qecimen - A specially designed
specimen tube shall be used for making the standard test specimen (see 5.2 ). It
shall be a twopart tube designed so that the specimen may remain in the tube
during testing and the two halves of the tube readily separate approximately at the
middle of the specimen when it fails
Procedure - Place the rammed specimen contained in the specimen tube in the
specimen tube holder and hold firmly by means of two clamp screws. ApplV a
uniform load along the axis of standard test specimen at the rate not exceeding I.5 f
O-5 gf/ mm* per minute until the specimen breaks. Record. the breaking Ioad in
grams and caIculate the tensile strength in kgf/ cm& by dividing the breaking load
with area of rupture section.
An average of three tensile tests shall be taken. If the test result of one of the three
varies more than 10 percent from the average of three, this result shall be
discarded and another specimen tested.
DETERMINATION OF BULK DENSITY
Determination of Bulk Density
Procedure -Take 500 g ,of tempered sand mixture as prepared under 4 and allow it
to fall in a one-litre measuring cylinder through a perforated disc rotating slowly at
the 1 000 ml mark. After the whole sand has dropped into the measuring flask, even
out the sand surface by slightly pressing with the perforated disc. The ratio of the
mass of the sand to the volume occupied by it will represent the bulk density before
compression in grams per millilitre ( g/ ml ).

DETERMINATION OF GREEN MOULD SURFACE HARDNESS

Green mould surface hardness is the &stance offered by the surface of a green sand
mould to penetration .by a loaded plunger. I .l Apparatns- Standard mould surface
hardness tester. I 1X1.1 Test SpeGimn - The standard test specimen specified in 5
shall be used. 18 IS : 1918 - 1966 15.1.2 Procedure - B&g the unloaded plunger of
the tester in contact with the mould surface. Apply the load to the plunger and read
the hardness number, on the graduated dial of the testing apparatus.