Green Sand, moulding

8/12/2019 Green Sand, moulding

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Technical Presentation

Green sand Molding Management

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01 Oct 2011, Suranaree University of Technology,

Nakhon Ratchasima

Prepared by U. Ittipon


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INTRODUCTION

-Green Sand Molding process (bentonite bonded sand)

-Chemical Sand Molding process

CO2 Mold (Sodium Silicate binder)

Types of Molding process

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Shell Mold (Phenoric resin binder)

Furan Resin Mold (Furan resin binder)

Cold Box (Polyurethane resin binder)


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INTRODUCTION

-Reasonable cost.

-Environmental friendly.

-High productivity (Economical)

Why we use Green sand Molding process

Page 5

-Easily adaptable to manual , semi-auto and automatic

molding Machine.


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INTRODUCTION

Green sand Molding process

Jolt Squeeze _Video file

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Automatic Moldingmachine _Video file


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SAND SYSTEM

Core makingNew Sand

ResinsCore wash

Bentonite

AdditivesWater

New Sand

PREPARATIONHomogenization

HydrationMixing

MOLDINGVertical or Horizontal

DustExtraction

CIRCULATION

Aerator

[Increase ofCompactibility]

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Sand Losses

COOLING POURING

Sand extracted

Sand adhering to castings

SHAKEOUT(Drum or Vibratory)

Screening

Magnet.Separator

SYSTEM

Increase of sandtemperature

Burnout of Clayand Sea Coal

Gas emissions


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CASTING DEFECTS

Castings defects relative to Green Sand Moulding could be due to :

- The COMPONENTS of the Green Sand for Moulding

- The PROPERTIES of the Green Sand for Moulding

- The UTILIZATION of the Green Sand for Moulding

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FOUNDRY SAND

SILICA CHROMITE ZIRCON OLIVINE

Formula SiO2 FeO Cr O3 Zr Si O42 (MgFe) O

SiO2

Specific Density 2.65 4.3 4.7 3.5

Bulk density 1.6 2.7 2.8 1.95

Available Materials

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Sinterpoint 1730 2095 >2200 1857

Thermal

conductivity Low High High Low

Reaction

mold/metal High Low Low Low

Utilisation All metals Steel &

Manganese Steel Steel

Disponibility High Very low Very Low Good

Price Low High High Medium


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SILICA SAND

Material used for its Economic advantages andsufficient thermal resistance

Important characteristics: The Grain size

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The Grain surface shape

The thermal resistance

(sinter Point) Silica content


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Main components:SiO2 = Min 98 %

Al2O3 = Max 0.13 %

Fe2O3 = Max 0.06 %

Physical properties:

Grain size Distribution

10

15

20

25

30

35

40

45

50

Individualresiduein%

SILICA SAND

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= .

Hardness = 7

pH = 7

LOI = Max 0.15%

Moisture = Max 0.1%Sinter point = Min.1500 Co

0

5

600 425 300 212 150 106 75 53 Pan

Sieves opening in Microns

AFS No = 55 - 603 Screens Distribution with 80 % min on

cumulative ASTM sieves 50, 70, 100


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AFS GRAIN FINENESS

SILICA SAND

70 AFS

0

10

20

30

40

5060

70

80

90

100

Residue%

72 AFS

0

10

20

30

40

50

60

70

80

90

100

Residue%

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6 20 40 70

140

270

6 20 40 70 140

270

70 AFS

0

5

10

15

20

25

30

35

40

6 12 20 30 40 50 70 100

140

200

270


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Thermal expansion

Temperature Crystallographyof SiO2

Density Expansionrate

SILICA SAND

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Ambient Quarz 2,65 = F (oC)

573 oC Quartz 2,49 1,5%

867 oC Tridymite

1470 oC Cristobalite 2,33 3~5%

1730 oC Amorphous Silica


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Thermal expansion

SILICA SAND

SILICA

ZIRCON

OLIVINE1

2

nsio

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CHROMITE

-1

0

020

0400

600

800

1000

1200

1400

Degrees Celsius

%Exp

Bentonite


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Foundry sand Bentonite

GREEN SAND COMPONENTS

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WaterAdditives

Dead Clay


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RULE OF BENTONITE = THE SAND BINDER

Sand Grains x 3800

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(bridge between sand grains)

Sand Grains

Bentonite


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WHAT IS BENTONITE?

Bentonite is a type of clay whose main constituent isMontmorillonitebelonging to the smectite group.

CLAYS(app. 200 types)

1/1 GROUP

Primary layers 7

2/1-1 GROUP

Primary layers 14

2/1 GROUP

Primary layers 10

Sub-groups and families Sub-groups and families Sub-groups and families

Other Clays family

[Tetrahedral - Octahedral Tetrahedral] Layers

Other Clays family Other Clays family

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SMECTITE FAMILY

Sub-groups and families

MONTMORILLONITE:

Other Clays family Other Clays family

Clays Classification

Division : particles size less than 2 microns

Appearance : no symmetrical particles with lamella tendency.

Dispersion : possibility to make colloidal suspension with more orless stability in water

Chemical formula : alumina silicates

[Hydrated Alumina and Magnesia silicates]

[Rk: 1 micron = 10,000 Angstrom units ()]


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Natural Treasure

WHAT IS BENTONITE?

Montmorillonite has been identified in France by Mr. Damour and Mr. Salvetat

in 1847 on a small mine nearby Montmorillon city (France).

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The first industrial exploitation at the beginning of the 20th Century started at a

mine located near Fort Benton in Wyoming province (USA). This explains the

origin of the term Bentonite which was first a trade name.


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Bentonite is a relatively soft stone,

formed over geological time by the

natural alteration of volcanic tuffsdue to acid or alkaline rain.

WHAT IS BENTONITE?

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Ca++

Aluminium dioctahedral layerApp.10

LATTICE STRUCTURE

Na+ Na+

Silicon-Oxygen tetrahedral layer


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a+a+

Na+

Aluminium dioctahedral layer




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In the nature, existing exchangeable cations are:

calcium => Natural Calcium Bentonite

sodium => Natural Sodium Bentonite

BENTONITE MINES

Most exploitable mines in the world are Natural Calcium Bentonite

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,

cation by Na cation .

This operation is called ACTIVATION PROCESS that consist in

mixing bentonite with soda ash, combining specific moisture, mechanical

treatment and temperature conditions.

After activation, processed bentonites are called:

Activated Sodium Bentonites.

By passprocess

By passprocess andcharacteristics


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BENTONITE : LAYERS STRUCTURE

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The space between the layers is maximum with Na-Ions


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BENTONITE - MILLING

Granules

Box Feeder

Cyclonesystem

[ Material Flow Milling ]

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Finish Product

Raymond

Mill

QualityControl

QualityControl


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BENTONITE : FROM MINING TO FOUNDRY

Mining StockingExploitation

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Activation Drying Milling(PM 12)

Packing


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BENTONITE : FROM MINING TO FOUNDRY

Raw Material

Drying

Activation / Extrusion

Raw Material Stocking

Mining Exploitation

Mining Exploration

Granules

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Finish Products Stock

Milling / Drying

Granules Stocking

Finish Product

Packing

Delivery to Foundry Industry

QualityQualitycontrolcontrol

Foundry


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BENTONITE : LABORATORY CONTROL

Swelling VolumeSwelling Volume Water contentWater content Particle sizeParticle size

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Wet Tensile Strengths & Green Compression StrengthsWet Tensile Strengths & Green Compression Strengths

Methylen Blue RetentionMethylen Blue Retention VDG PVDG P 6969NormNorm

MethodMethod


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swelling volume ml / g

20

BENTONITE : MAIN CHARACTERISTICS

-Swelling: one of the main characteristics of Montmorrillonite is to fix water molecules between thelayers which causes the inner structural water. Swelling highly depends on the nature and quantity of the

exchanged cations but also on the % of Na2CO3 for Activated Sodium Bentonites.

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5

10

15

17

0

5

10

15

0 2 4 6 8

activation rate : % soda ash


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-Swelling:


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% Na2CO3activation changes according to the origin and content of Montmorrillonite


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Control of the Activation = Wet Tensile Strength


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- Montmorillonite content:The montmorillonite content is improperly associated to the measurement of the Methylene Blue

Retention. Other methods are difference of density or X-ray diffraction. A calibration is possible to make a

link between the % of Montmorillonite and the MB retention. Professionals agreed to call bentonite, all

clays with Montmorillonite content over 60%.

- Methylene Blue Retention = method based on the retention capacity of Montmorillonite by

the molecules of dyestuff the Methylene Blue. In fact, this test indicates the specific surface of bentonite.


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- Water content:2 types of water must be considered in case of Montmorillonite:

- Bonding water (existing in the lattice network structure)

[ evaporation from 100 OC ] = important factors because:

- Exceeding, it can lead to plugging in the pneumatic transport system

- Too low means bentonite will be difficult to re-hydrate


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- Constitution water in the macroscopic primary layers network

[ influence on the durability of bentonite - evaporation around 500 OC ]


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- Particle Size: measure of the sieve residue at 75m with specific equipment.


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- Too coarse particles can affect the speed of the water absorption.

- Too fine particles can affect the consumption of bentonite (lost in dust collectors)


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- Carbonates content:The purpose is to determine the Total carbonates. (all carbonates existing in the bentonite ie. Na, Ca, Mg,

etc). This process is not to control the activation level but the consistency of the bentonite.

[The volume of CO2

given off when attacked by hydrochloric acid. Results are expressed in CaCO3

].

- Cohesion characteristics:

The ur ose is to measure the bindin ca acit of bentonites. These characteristics will be measured b


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introducing another component - Silica sand.

Rk = Control receipt on bentonite = VDG P 69 Din Method as mixture of 100 parts silica sand (AFS 55-

60) with 5 parts bentonite and necessary water to get 45% Compactibility.

- Test of Compressive Strengths, Shear Strengths, Wet Tensile strengths.

BENTONITE MAIN CHARACTERISTICS


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- Durability:Capacity of the bentonite to loose its water more or less quickly.

3 methods can be applied:

1- Testing the cohesion characteristics on bentonite heated at 550OC (1/2 H in ventilatedfurnace) based on the VDP 69 Din Method. Durability is the % of drop between the characteristics

before and after heating.


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- .

0

50

100150

200

250

300

350

400

450

0 100 200 300 400 500 600 700 800

temperature C

MBR

mg/g

bentonite 1

bentonite 2


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WaterAdditives

Dead Clay


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When molten metal is poured, the moulding sand undergoes somemodification that influence casting quality:

Liquid metal could penetrate in the green sand interstice

(Metal penetration defects)

The mould atmosphere is wet and couldoxidize the metal.

LUSTROUS CARBON FORMER

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the casting surface alteration.

Solution :Addition of Lustrous

Carbon Former


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Feature Coals Resins

LOI, %

Sulphur content, %

Nitrogen content, %

92 to 96

0,4 to 0,8

1,2 to 2,6

98 to 100

0,1 to 0,3

0,1 to 3,0

Basic data for Coals and resins (asphalt) suitable for the production of lustrous carbon:

LUSTROUS CARBON FORMER

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Volatiles, %

Swelling Index

(according to DIN 51741)

Lustrous Carbon, %

Surface quality

34 to 40

2 to 7

9 to 14

Moderate to very good

76 to 98

0

36 to 44

Only in combination with

sea coal, good toexcellent, especially with

thin wall castings.


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ECOSILLustrous carbon former, (sea coal)Lustrous carbon former, (sea coal)is added to green sand in order to :is added to green sand in order to :

prevent metal penetration.

obtain a smooth casting surface.

lessen the incidence of expansiondefects (silica sand dilution).

reduce the mould-wall movementand formation of shrinka e

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cavities.

create excellent breakdowncharacteristics of the mould uponshakeout.

reinforce and to stabilise thegreen strength properties ofmoulding sand.

A S


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To improve moulding sand properties as:

- Elasticity (sand deformation)

ADDITIVES

Organic Carbohydrates - Starch

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-

In specific cases, could compensate the expansion of silica grains (in

fact to reduce expansion defects as scab, rat tail, veining, etc)



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WaterAdditives

Dead Clay

WATER


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WATER

One of the most influent element.

Development of the Moulding Sand Properties

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Contains impurities that affect the bentonite properties

WATER : INFLUENCE OF SALTS


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NaNa++

NaNa++

WATER : INFLUENCE OF SALTS

Salt de-actives the

bentonite electrostatic

Normal

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NaNa++

NaNa++

ClCl--

bonding properties

COMPOSITION : INFLUENCE OF WATER


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COMPOSITION : INFLUENCE OF WATER

De-activation phenomenon could be verified by the WTS test.

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COMPOSITION


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COMPOSITION

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Dead Clay

AdditivesWater

DEAD CLAY


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The part of bentonite heated above 500OC loses its structural water and settles itself on

the sand grain.

This bentonite loses permanently its properties and becomes a dead clay.

At each sand circulation, a part of the sand grains is coated by this dead clay. This isthe Oolitisation process .

Dead clay reduces the expansion of the green sand and permits to fix a part of the free

Oolitisation process

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water n t e mo .

Dead Clay

High Oolitisation Low Oolitisation

COMPOSITION


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100 % = (Silica sand+Dead Clay) + (Active Clay+Combustibles) + Water

RefractoryAbsorbents

Catalyst

GREEN SAND MOULDING FORMULA

100 % = SiO2 + DC + AC + LOI+ H2O

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The Green Sand Formula depends mainly on:

- the type of sand plant (mixer, cooling system, etc..)

- the type of moulding process

- the type of shake-out process- the materials used (new sand, bentonite, additives, etc)

- the castings produced (sand/metal ratio, type of metal, etc..)

COMPOSITION


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100 % = (Silica sand+Dead Clay) + (Active Clay+Combustibles) + Water

GREEN SAND MOULDING COMPOSITION

Generally, the moulding sand is made up with :

Iron Castin s Steel Castin s

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SiO2= 75% to 85% SiO2= 75% to 85%DC= 5% to 8% DC= 6% to 9%

AC= 6% to 10% AC= 8% to 12%

LOI= 3% to 5% LOI= 2% to 3%H2O= 2% to 4% H2O= 2% to 4%

CONTROL THE COMPOSITION


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1- Active Clay (using Methylene-blue method)

The AC determines the quantity (in %) of bentonite that is able to bond the sand

grains. The AC represents the bentonite that could absorb a methylene-bluesolution.

The AC content mainly depends on:

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The type and origin of bentonite(MB retention of the bentonite in use in the

sand system) up-date its value regularly and calibrate each new MB solutionbefore dosage

The durability of the bentonite (thermal resistance)

The type of metal pouring (grey iron, ductile iron, steel, etc..)

The Foundry equipments (molding process, mixing process, cooling process,

shake-out process)



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2- Loss on Ignition (LOI)

The LOI determines any element burnt at 900oC that is the combustible materials

in the green sand system. In fact, LOI relates to the carbon former (seacoal), thestructural water of bentonite, the carbonless of core sand, etc.

LOI permits to estimate the exchange of sea coal in the sand system.

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The LOI content mainly depends on:

The type and origin of sea coal (composition of the original sea coal added in

the sand system),

The quantity and type of core sand


The Foundry equipments (shake-out process and dust collectors)



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3 Water content

The Water Content is one of the most important and easiest test. Water content

affects every properties of green sand, but mainly permits to swell the bentonite.

The test represents the water loss at 105oC.

Control sometimes its pH, conductivity (


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4 Silica and Dead clay content

The silica and dead clay represent the refractory part of the green sand.

Dead clay is the bentonite that has lost its structural water.

The Silica content mainly depends on:

The type, origin and quantity of foundry sand and core sand in the system. (Vs

the sintering point of original foundry sand)

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The Dead clay content mainly depends on:

The type, origin and durability of the original bentonite added in the sand

system,


The quantity of silica sand added in the system.


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PROPERTIES


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First ControlFirst Control

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Compactibility = Plastic or not?

Water content = Dry or wet sand? Temperature = Hot or cold?

Strengths = Brittle or not?

PROPERTIES : COMPACTIBILITY


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The compactibility indicates the water tempering degree of the green sand moulding.

Represented by a percentage number, the compactibility test determines the

decrease in height of a loose mass of sand under the influence of a controlled

compaction.

The compactibility is directly related to the sand quality or the performance of a molding

sand mixture.

The following factors affect the compactibility :

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The mixing time (calibration and mulling energy)

The Active clay and LOI levels

The inert fines (fines from silica absorbing water)

The quality of Bentonite (Swelling capacity, water holding capacity)

The quality of sea coal (type of coal and coke transformation capacity )

The used of starch and Cereals (change the bonding properties) Video. file

COMPACTIBILITY


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40

42

44

46

Dry sand

OK

Wet sand50 mm1

Compactibility %

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32

34

36

38

Sand Specimen CompactibilityWater Content %

PROPERTIES : COMPACTIBILITY


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40

42

44

46

Compactibility %

7 % 8 % 9 %

Active clay (MBR) %

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32

34

36

38

Water content %

PROPERTIES : STRENGTH


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The mould sand strength can be expressed by several standard tests :

Green Compression Strength :

Wet Tensile Strength

Dry Compression Strength

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But also : green shear strength, resistance to fissuring, resistance to abrasion,

etc

They depend on the composition and the preparation of the moulding sand

PROPERTIES


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Green compressive strength - GCS: (N/cm2)The working strength of molding sand is a combination ofcompressive strength and deformation or mold plasticity ( Keep mold

wall stability).The most influential factor in controlling GCS is the temperingmoisture eneral com osition t e and amount of Bentonite binder

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and degree of mulling ( Active clay and moisture ratio)Green tensile strength: mostly effect to mold wall stability ofhorizontal molding on cope side.

Green Shear strength: mostly effect during remove the pattern or putcore in Mold.

Test Simpson _Video file Test Rid _Video file Test Shear _Video file


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Strengths: Problem zones of bentonite bonded sand


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Form Compacted moulding sandCondensation zoneForm - Dried and Burnt moulding sandLiquid Iron

Strengths profile during the heat penetration into mouldsStrengths profile during the heat penetration into moulds

Heat penetration intoFoundry Mold

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FormForm-- Dried sandDried sand

FormForm Tempered MoldingTempered Molding

sandsand

StrengthsN

/cm2

FormForm-- Dried sandDried sandPermeability

Distance to the liquid metal (mm)Distance to the liquid metal (mm)

Molten

Metal

Molten

Metal

Dry tensile strengths

Green strengths

CondensationCondensation

zonezone

CondensationCondensation

zonezone FormForm Tempered MoldingTempered Moldingsandsand

Permeability through different zones of moulding during pouring processPermeability through different zones of moulding during pouring process

WTS Area

- - - - Effect of Starch

PROPERTIES : PERMEABILITY


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The permeability indicates the ability of the gas to escape through the mould

The permeability is directly related to the sand composition

The following factors affect the permeability :

The water content

The silica sand AFS index and its repartition

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The Active clay, dead clay and LOI levels

The inert fines (fines from silica absorbing water)

The used of starch and Cereals

The moulding machine

The shake-out

Green Sand Molding test report


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Green Sand Molding test report


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Materials Consumption Vs Cast Iron Quality


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Iron Sand ratio

Heat penetration into mold

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New sand Consumption

Bentonite Consumption

Coal Dust Consumption


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FOUNDRY

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MOULD

Pouring


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Condensation ofthe water:

Formation of wet layers


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Heat Radiation from liquid metal


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Reducing Atmosphere

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Formation of aLustrous carbon filmLustrous Carbon FilmLustrous Carbon Film

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Gas Cushion


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FOUNDRYCCASTINGCASTING

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ASTING

SAND BURNT Wet layers

Influences : Iron Sand Ratio

Foundry Example


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Foundry Example

Iron-Sand ratio = 1:10

Sand Replenishment = 90 kg/t Fe

Bentonite consumption = 45 kg/t Fe

Coal dust consumption = 18 kg/t Fe

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Influences

Foundry Example


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y p





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Influences

Foundry Example


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y p





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Bentonite-bonded molding sand Balance


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Why a Balance is necessary:

to maintain a constant composition of the green sand molding

to stabilize the properties of the green sand molding

to control the right utilization of the green sand molding

to simulate a specific future condition or future phase of

development


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Circulation system General principle


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From this relation, it can be determined how high the percentage of a newly added material is,at a specific time.

Core makingBentonite New Sand

Application to the sand circulation system


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New SandResins

Core washSea CoalWater

PREPARATIONHomogenization

Hydration

Mixing

MOLDINGVertical or Horizontal

DustExtraction

CIRCULATION1. Time needed per sand circulation

2. Number of circulations per working

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Sand Losses

COOLING POURING

Sand extracted

Sand adhering to castings

SHAKEOUT(Drum or Vibratory)

Screening

Magnet.

Separator

Burnout of Clayand Sea Coal Increase of sand

temperature Gas emissions

SYSTEM

time (hour/day/shift).

3. Exchange rate of materials percirculation at a specific time



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When considering the total moulding sand system,

-A0is thetotal amount of sand in the systemas [sum of the sand in the machine bunkers, in the usedsand silos, on the cooling conveyor, etc].

-BZis thesum of all additivesas [new sand +recovered core sand + bentonite + sea coal]

-Bnis thepercentage of all new additivesin the total sand system aftern circulations.Bn is the part of the total sand that has been exchanged by the total new additives after ncirculations.

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Circulation: During a circulation x parts of Material (B) is added to an amount of Material (A) andthe same quantity (x parts) is drawn out of the system. After this both materials are homogenised.

Addition:Material (B) is added, x is the quantity added as a percentage of the amount of material(A).

Exchange: After n circulations there remains 100% material (B). Material (A) is completelyexchanged.



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UTILIZATION : green sand circulation report

The green sand circulation system report : essential


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driver for technicians

Follow the consumption

of your additives in kg/Tof liquid metal0

510

15

20

25

30

35

40

seacoalandbentoniteconsumption

0

20

40

60

80

100

120

140

160

180

sandsconsumptio

New sand 2 2. 0. 0. 7. 20 35 42 482416 15 1120 15 4. 1. 5.

J

a

n

F

e

b

M

a

r-

A

p

r-

M

a

y

J

u

n

J

ul

-

S

e

p

O

ct

-

N

o

v

D

e

c

J

a

n

F

e

b

M

a

r-

A

p

r-

M

a

y

J

u

n

FOUNDRY XXX - Additivesconsumption in kg/T of liquid metal

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Be aware of :

-Sand system circulation speed

-Regeneration of additives

-Changes of additives formula

Core sand 62 61 6253 58 61 53 63 7860 68 81 52 67 7162 57

Seacoal 5. 5. 7. 7. 8. 10 7. 7. 6. 9. 5. 6. 6. 5. 5. 5. 6.

bentonite 33 32 2528 29 25 29 28 2730 24 29 30 26 3032 30

UTILIZATION : Data collection (example)

ADDITIVE RATIO ON JANUARY-FEBRUARY 2007


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Total mix Sand Bentonite Sea coal Core Sand Melting Sand Bentonite Sea Coal Core Sand

- Mt - Recovery

08/01/2007 590 5900 6490 1180 13367 140.6 41.97 46.17 8.39 76.1 118.05 46.17 8.39

09/01/2007 587 5870 6457 1174 14631 154.0 38.12 41.94 7.62 76.0 114.14 41.94 7.62

10/01/2007 519 5190 5709 1038 13529 122.4 42.39 46.63 8.48 88.4 130.80 46.63 8.48

11/01/2007 522 5220 5742 1044 9901 118.2 44.18 48.60 8.84 67.0 111.22 48.60 8.84

12/01/2007 579 5790 6369 1158 10890 136.5 42.41 46.65 8.48 63.8 106.23 46.65 8.4815/01/2007 673 6730 7403 1346 12034 147.7 45.56 50.12 9.11 65.2 110.74 50.12 9.11

16/01/2007 529 5290 5819 1058 8978 127.4 41.53 45.69 8.31 56.4 97.93 45.69 8.31

17/01/2007 599 5990 6589 1198 15304 160.7 37.27 41.00 7.45 76.2 113.45 41.00 7.45

18/01/2007 577 5770 6347 1154 12820 141.4 40.80 44.88 8.16 72.5 113.31 44.88 8.16

ADDITIVE RATIO ON JANUARY-FEBRUARY 2007Consumption Consumption ratio ~ kg per Mt Melting ~

Date Total Sand Total Bentonite Total Seacoal- kg - Actual

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. . . . . . . .

22/01/2007 635 6350 6985 1270 11017 145.2 43.74 48.11 8.75 60.7 104.44 48.11 8.75

23/01/2007 632 6320 6952 1264 11581 153.1 41.29 45.42 8.26 60.5 101.83 45.42 8.26

24/01/2007 646 6460 7106 1292 10765 151.0 42.77 47.05 8.55 57.0 99.80 47.05 8.5525/01/2007 621 6210 6831 1242 10633 151.1 41.09 45.19 8.22 56.3 97.36 45.19 8.22

26/01/2007 597 5970 6567 1194 10066 148.7 40.14 44.15 8.03 54.1 94.28 44.15 8.03

28/01/2007 250 2500 2750 500 6411 58.6 42.64 46.90 8.53 87.5 130.11 46.90 8.53

29/01/2007 523 5230 5753 1046 8348 126.2 41.46 45.60 8.29 52.9 94.40 45.60 8.29

30/01/2007 533 5330 5863 1066 8566 120.2 44.34 48.77 8.87 57.0 101.34 48.77 8.87

31/01/2007 570 5700 6270 1140 11241 151.8 37.56 41.31 7.51 59.3 96.81 41.31 7.51

TOTAL 10828 108280 119108 21656 212250 2599

AVG 570 5699 6269 1140 11171 136.8 41.79 45.97 8.36 66.02 107.81 45.97 8.36

SD 90.61 906.10 996.71 181.22 2232.13 22.77 2.33 2.56 0.47 10.76 10.85 2.56 0.47

UTILIZATION : Consumption report (example)

FOLLOW-UP OF THE CONSUMPTION'S RATIO

Foundry sand SPEC = 150-250 kgkg / Mt of liquid Metal pouring


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Bentonite SPEC = 40-60 kgkg / Mt of liquid Metal pouring

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Foundry sand SPEC = 150 250 kg

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Sea coal SPEC = 15-20 kgkg / Mt of liquid Metal pouring

UTILIZATION : GSB calculation(example)


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Green Sand, moulding

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