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Material cost.
Materials to be cast.
However, the most commonly used material of all is the refractory moulding
sand. As compared to permanent molds, the refractory sand molds can cast
high melting point materials and bigger objects whereas permanent molds
produce small castings better quality and dimensional accuracy.
3.2. Refractory sands
They are:
(i) Silica Sand
(ii) Magnesite,
(iii) Zircon,
(v) Olivine
(vi) Sillimanite
(vii) Graphite/carbon
(iv) Dolomite
Refractory sands (especially silica sands) are the best molding materials because
they maintain their shape and other characteristics even at very high
temperatures while they are in contact with molten metals. Even when packed
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as the mold cavity, they remain sufficiently porous or permeable to give vent to
the mold gases. They can be moulded into intricate shapes, they are chemically
immune to molten metals, and they can be used separately for masking moulds
and are inexpensive. They can be made available without much difficulty.
However silica sands have the disadvantage of high thermal expansion or
volume increase at 1063F.
3.3.Moulding sand:
The principle material used in the foundry shop for moulding is the sand. This
is because it possesses the properties vital for foundry purposes.
Source: All sands are formed by the breaking up of rocks due to the action of
natural forces such as frost, wind, rain, heat and water currents. Rocks,
however, are very complex in their composition and sands contain most of the
elements of the rocks of which they are fragments. For this reason moulding
sands in different parts of the world vary considerably.
Principle ingredients: The principle ingredients of moulding sands are
(a) Silica sand grains: Silica in the form of granular quartz, itself a sand, is
the chief constituent of moulding sand. Silica sand contains from 80 to 90
percent silicon dioxide and is characterized by a high softening temperature
and thermal stability. It is a product of the breaking up of quartz rocks or the
decomposition of granite, which is composed of quartz and feldspar. The
feldspar, when decomposed, becomes clay. However, silica sand grains impart
refractoriness, chemical resistively and permeability to the sand. They are
specified according to their average size and shape.
(b) Clay: Clay is defined as those particles of sand that fail to settle at a rate of
25 mm per minute, when suspended in water. Clay consists of two ingredients:
fine silt and true clay. Fine silt is a sort of foreign matter or mineral deposit and
has no bonding power. It is the true clay which imparts the necessary bonding
strength to the mould sand, so that the mould does not lose its shape after
ramming. Most moulding sands for different grades of work contain 5 to 20
percent clay.
(c) Moisture: Moisture, in requisite amount, furnishes the bonding action of
clay. When water is added to clay, it penetrates the mixture and forms a
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microfilm which coats the surface of flake shaped clay particles. The bonding
quality of clay depends on the maximum thickness of water film it can
maintain. The bonding action is reduced and the mould gets weakened if the
water is in excess. The water should be between 2 to 8 percent.
(d) Miscellaneous materials: Miscellaneous materials that are found, in
addition to silica and clay, in moulding sand are oxide of iron, limestone,
magnesia, soda and potash. The impurities should be below 2 percent.
Sources:
(i)River beds,
(ii) sea,
(iii) Lakes,
(iv) Desert
Types:
(i) Natural Sands (ii) Synthetic Sands (iii) Loam Sands.
Ingredients:
(i) Refractory sand grains (ii) Binders (iii) Water (iv) Additives.
3.3.1. Natural Sands
Natural moulding sands, called as green sands are taken from river beds or are
dug from pits. They posses an appreciable amount of clay which acts as a bond
between the sand grains and are used as received with water added. The
quantity of clay mineral present affects strength, toughness and refractoriness
of the sand.
Natural moulding sands are also obtained by crushing and milling soft yellow
sandstone, carboniferous rocks, etc. during milling clay aggregates break down
and clay particles get uniformly distributed over the sand grains. Due to their
ease of availability, low cost and high flexibility of operation natural moulding
sands are used for most of the ferrous and nonferrous light castings.
Characteristics
(i) A natural sand can be used for making molds as soon as it is received from
its source.
(ii) A natural sand contains binding materials (5-20% clay).
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(iii) A natural sand needs only water (5-8%) to mix before making the mold.
(iv) Natural sands can maintain moisture content for a long time.
(v) Natural sands possess a wide working range for moisture.
(vi) Natural sands permit easy patching and finishing of molds.
(vii) Natural sands may contain considerable organic matter.
(viii) Natural sands are less refractory as compared to synthetic sands.
(ix) Natural sands are employed for casting cast iron and non-ferrous metals.
(x) Natural sand involves lesser cost as compared to synthetic sand.
(xi) Natural sand needs lesser control as compared to synthetic sand.
(xii) Natural sand molds can be easily repaired
(xiii) Natural sand when mixed with bentonite gets its properties Improved and
is called Semi synthetic sand.
3.3.2. Synthetic Sands
A Synthetic sand consists of:
(a) Natural sand (base) with or without clay.
(b) Binder (say bentonite).
(c) Moisture.
Thus synthetic sand is formulated sand. Sand formulation is done in order to
acquire certain desired properties not possessed by natural sands. These sands
are used for casting steel and other ferrous and non-ferrous alloys.
These sands are basically high silica sands containing little or no binder (clay)
in natural form. They occur as loose or poorly consolidated deposits of
sedimentary origin, dunes blown inland from the coast or accumulated
deposits in estuaries and rivers along the coast. They are also made in foundry
by first crushing quartzite sandstone and then washing and grading these to
yield a sand grade of requisite shape and grain distribution. The desired
strength and bonding properties of these sands are developed by separate
additions such as bentonite, water and other materials. This allows greater
flexibilities in the content of properties such as green and dry strength,
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permeability and others that can be easily varied at will. In fact, therefore,
synthetic sands are more expensive than natural sands.
As Compared to Natural Sand, Synthetic Sand
(i)
(ii)
(v)
(vi)
greater
freedom
in
the
control
of
properties.
.
(ix) Is more suitable for use in mass production and mechanized foundries.
(x)
Requires less storage space because one type of sand may be sufficient for
producing castings of different types.
collapsibility,
adhesiveness,
cohesiveness
or
strength
and
pattern in the mould. Good flowability is very essential where energy for
compaction during ramming is transmitted through the sand mass as in
machine moulding. Flowability increases as clay and water content increases.
(c) Collapsibility: After the molten metal in the mould gets solidified, the sand
mould must be collapsible so that free contraction of the metal occurs and this
would naturally avoid the tearing or cracking of the contracting metal.
(d) Adhesiveness: The sand particles must be capable of adhering to another
body i.e., they should cling to the sides of the moulding boxes. It is due to this
property that the sand mass can be successfully held in a moulding box and it
does not fall out of the box when removed.
(e) Cohesiveness or strength: This is the ability of sand particles to stick
together. Insufficient strength may lead to a collapse in the mould or its partial
destruction during conveying, turning over or closing. The mould may also be
damaged during pouring by washing of the walls and core by the molten metal.
The strength of moulding sand must, therefore be sufficient to permit the
mould to be formed to the desired shape and to retain this shape even after the
hot metal is poured in the mould.
This property of the sand in its green state is known as green strength. A
mould having adequate green strength will retain its shape and will not distort
or collapse even after the pattern is removed from the moulding box.
The strength of sand that has been dried or baked is called dry strength. It
must have then strength to withstand erosive forces due to molten metal and
retain its shape.
The strength of the sand (mould cavity) above 212F is called hot strength. In
the absence of adequate hot strength, the mould may enlarge, break, erode or
get cracked.
(f) Refractoriness: The sand must be capable of withstanding the high
temperature of the molten metal without fusing. Moulding sands with a poor
refractoriness may burn on to the casting. Refractoriness is measured by the
sinter point of the sand rather than its melting point.
(g) Other requirements: In addition to the above main characteristics, the
moulding sand should also possess the following properties:
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It should have a better bench life, i.e., the ability of the moulding to retain
its properties during storage or while standing.
due to the addition of coal dust and burning on coming in contact with molten
metal.
(f) System sand: In mechanical foundries where machine moulding is
employed so-called system sand is used to fill the whole flask. In mechanical
sand preparation and handling units, no facing sand is used. The used sand is
cleaned and reactivated by the addition of water binders and special additives.
This is known as system sand. Since the whole mould is made of this system
sand the strength, permeability and refractoriness of the sand must be higher
than those of backing sand.
(g) Parting sand: Parting sand is used to keep the green sand from sticking to
the pattern and also to allow the sand on the parting surface of the cope and
drag to separate without clinging. This is clean clay free silica sand which
serves the same purpose as parting dust.
3.5. Core sand:
A core may be defined as any projection into the mould and is made up of core
sand. It forms the internal or external surfaces of casting. Core sand is a
suitable sand mixture employed for making cores. Cores are made separately,
are baked and are suitably placed and positioned in the mould cavity.
3.5.1. Core sand properties:
High Collapsibility so that the core gives way easily as the casting cools and
shrinks. High collapsibility avoids the introduction of hot tears and cracks
in the cast metal.
Core sand should be able to impart good smoothness and finish to the core
surfaces.
Good Friability so that core crumbles and falls apart when it must be
removed from the casting.
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Core sand should be able to retain its properties during storage (bench life).
Core sand should be able to resist the effects of molten metal, like erosion,
thermal shocks etc.
(ii)
Zircon
Olivin
(v)
Chamotte
(iv)
Carbon
Because of their higher melting points and vibrated bulk density, Zircon and
olivin in certain cases are preferred over Silica sand for making cores. However
Silica is the most widely used core base sand. Coarse white silica sand of high
refractoriness is employed for making cores in steel foundries. Whereas, Finer
bank and lake sands are preferred for making cores in cast iron and nonferrous foundries. While, Coarser and finer sands may sometimes be mixed for
making cores. This mixing increases size distribution and strength, but permeability gets reduced.
b) Core binders:
A core binder, holds sand grains together, gives strength to cores, makes cores
to resist erosion and breaking and imparts adequate collapsibility to cores.
Core binders are of the following types
(i)
Organic binders
(ii)
Inorganic binders
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(iii)
Other binders.
Core oil
Cereal Binders
Pitch
Wood Flour
Protein Binders
(ii) Inorganic Binders: They are Fire clay, Bentonite, Silica flour, Iron oxide,
etc. These binders develop green strength, baked strength, hot strength and
impart smooth surface finish. They are finely pulverized materials. They greatly
increase the amount of oil necessary in oil sand mixes.
(iii) Other Binders:
They are Portland Cement and Cements (i.e. rubber cements) which
hardens at room temperature.
Water, in a core sand mixture, water content may vary between 2.5 and
7.0%. Binders and additives work only in the presence of moisture.
Optimum quantity of water develops good green strength, edge hardness,
scratch hardness and good tensile strength after baking. Excessive moisture
adds to difficulties in the making and baking of cores.
(in case of solid powder) and by Dipping, Spraying, and brushing in case of
Liquid Coatings
3.5.4. Core Material:
Selection of The selection of a core sand mixture for a definite application
depends upon:
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