Discussion

1. Sand casting is widely used in foundry industry. Automobiles industry especially in

manufacturing section, where the component such as wankel rotor, shafts, cylinder
blocks are mainly use casting method. Mostly the economical ways are sand casting.
Most of automobiles component as mention before are made of aluminium or cast
iron as they provide lighter, durable and cheap building cost. Sand casting method
also used in mining industry. It can be gold or silver. The gold bar usually make from
the casting method. They pour the molten gold to the mold to create gold bar. The
component for mining machine such as cutting rotors, gears and track chain are
made from cast iron that undergo casting process. In propeller component industries,
components such as fan blades and pump impeller are manufactured by sand
casting processes. This is also includes component such as pump house, impeller
and turbo charger. There is also a material in magnesium and aluminium that use
sand castings method to produce components and parts in aerospace and aircraft
industries for its resistance to corrosion and endurance. Sand casting almost
compulsory and industrial basic method to create a component in foundry process.
2. There is several difficulties that occurs during the process of sand casting. The
process for preparing the sand mixture need proper measurement for each material.
This measurement to ensure the good sand moulding. There are no proper ratio for
sand mixture and we need to follow best measurement for each material mixture
from the past sand casting process, as a result, we cannot ensure the final moulding
is the best sand moulding as they might be another proper mixture ratio for the
excellent solid sand moulding result. Another difficulties that we found to be a most
problem is, the pattern that has been clamped are very fragile. When the sand has
been inserted to the pattern box, the sand need to be compacted by wood bar. This
process need to be done properly as they can damage the pattern inside the box.
Applying carbon dioxide to the sand mould can be difficult to. The user has to handle
the process properly while introducing carbon dioxide by having a gradual increase in
application of carbon dioxide instead of introducing it randomly.

Conclusion,
For the conclusion, the sand casting process were successfully done. The top riser
mold is shaped according to the pattern size. The pattern also suffers no damage from the
compacting process. The process were done solely according to the procedure and the time
taken for sand hardening is about 10 second for each holes punched on the sand. The use
of CO2 gas is passed through a sand mix containing sodium silicate as a result of which, the
sand immediately becomes extremely hard and strongly bonded as sodium silicate becomes
a stiff gel. This process were carefully done and tested the sand hardening before the
pattern taken out from the sand and the results are brilliant. This sand casting should be fully
prepared for moulding process as they are completely precise on shape and size.

Refferences

Books
Campbell, John (1993). Castings. Butterworth-Heinemann. p. 49. ISBN 0-7506-16962.
Website
Metal Casting Techniques - Vacuum ("V") Process Molding,
http://www.engineershandbook.com/MfgMethods/vacuumprocessmolding.htm
retrieved 2015-10-25.
Ebooks
"Beneficial Reuse Of Spent Foundry Sand" (PDF). 1996.
http://www.cwc.org/industry/ibp951fs.pdf