Table of Contents

1.0 TITLE .............................................................................................................................................. 3

2.0 OBJECTIVES .................................................................................................................................. 3

3.0 INTRODUCTION ........................................................................................................................... 4

3.1 Theory ............................................................................................................................................... 5

4.0 APPARATUS .................................................................................................................................. 6

4.1 Industrial Apparatus .......................................................................................................................... 8

5.0 EXPERIMENTAL PROCEDURE .................................................................................................. 9

6.0 RESULT & DATA ANALYSIS ................................................................................................... 11

7.0 DISCUSSION ................................................................................................................................ 14

8.0 CONCLUSION .............................................................................................................................. 15

9.0 RECOMMENDATION ................................................................................................................. 16

10.0 REFERENCES .............................................................................................................................. 17

 Table of Figures
Figure 1: Sand Casting Process................................................................................................................... 4
Figure 2: Cope and drag .............................................................................................................................. 4
Figure 3: The system of the Carbon Dioxide reacts with sodium silicate to from hard gel ....................... 5
Figure 4: Green sand ................................................................................................................................... 6
Figure 5: Bellow ......................................................................................................................................... 6
Figure 6: Brush ........................................................................................................................................... 6
Figure 7: Wooden slab ................................................................................................................................ 7
Figure 8: Hand rammer ............................................................................................................................... 7
Figure 9: Scriber ......................................................................................................................................... 7
Figure 10: Sprue pin.................................................................................................................................... 7
Figure 11: Machine for Sand Mixture ........................................................................................................ 8
Figure 12: Carbon Dioxide Gas (CO2) ....................................................................................................... 8
Figure 13: Empty Molds ............................................................................................................................. 9
Figure 14: CO2 pressure tank ................................................................................................................... 10
Figure 15: Mold with cavity ..................................................................................................................... 10
Figure 16: Mold ........................................................................................................................................ 11
Figure 17: Top view of the product .......................................................................................................... 11
Figure 18: Front view of the product ........................................................................................................ 12
Figure 19: Side view of the product .......................................................................................................... 12
1.0 TITLE

Carbon Dioxide Molding Process

2.0 OBJECTIVES

- To investigate the principles involved in sand casting process

- To involve in actual procedure in Carbon Dioxide moulding process

- Determine the type of defect occurred in casting process

- Discuss on how to overcome the defect

3.0 INTRODUCTION

In general, casting is a process where molten metal is pour into a mold with intended shape. The molten
metal needed to pour into a mold through a hole pathway called sprue. The metal and mold are cooled
together and then the metal part is removed. Casting usually used for making complex shapes that can be
inefficient and costly to make by others process.

Casting has been known since thousands of years ago where has been widely used for sculpture,
jewellery, tools, and weapons. Over the years, metal casing process can be divided into two types which
is expendable and non-expendable casting.

Back to this experiment, the carbon dioxide molding process has been done. It is a process which
include in sand casting process generally a process to make the sand mold first before pouring the
molten metal. Basically, the mold material is made by using sand whereby the molds is hardened by
blowing gas over the mould. Mould made by sand are cheaper compare to others. The main advantages
of this methods are it reduced a lot of production times as well as lower fuel costs and reduces the
number of box require for making molds. The sand casting process can produce any design shaped parts
including huge components and with complex internal complex passageways.

Figure 1: Sand Casting Process Figure 2: Cope and drag

3.1 Theory
The principle of Carbon Dioxide moulding process based on the fact that if the Carbon Dioxide gas
spread through a sand mix with sodium silicate, the sand will spontaneously become extremely strong
bonded as the sodium become a stiff gel. This be seen the gel responsible for the strength to the mould.
The sand in the process need in dry condition, free from clay, and any contaminants. The suitable sand
mixtures can be fill around the pattern in the flask by hand. Ramming the sand to fully compacted is
crucial to prevent any defect to the mould. When the sand has completely fill up, the ventilation pathway
can be make and forced each pathway with the Carbon Dioxide gasses to harden the sand.

Figure 3: The system of the Carbon Dioxide reacts with

sodium silicate to from hard gel

Below is the formula involve:

4.0 APPARATUS
Material Description
Made of:
 Silica sand
 Bentonite
 coal dust
 water

Figure 4: Green sand

List of equipment Function / Description

 It is used to blow and clean
excessive sand in the mold cavity.
 To make sure the sand fills the mold
completely

Figure 5: Bellow

 It is used for cleaning the casting

flask entirely.

Figure 6: Brush
 List of equipment Function / Description
 To flatten the surface of the sand.
 For press down the sand to be more
compact.

Figure 7: Wooden slab

 The tamper/rammer is used to

compress molding sand.
 The tamper/rammer consists of an
instrument and looks like a hammer
without hands with a flat end and the
other end is blunt.
Figure 8: Hand rammer

 The scriber is used to make hole on

the sand mold.
 The hole is to put the CO2 gas in the
mold.

Figure 9: Scriber

 It is a conical shape rod of wood.

 It is embedded in the sand and then
removed to produce a hole.
 The hole called a runner is where the
molten metal is poured into the

Figure 10: Sprue pin mold.

4.1 Industrial Apparatus

List of Industrial Equipment Function / Description

 To mix the sand with silica sand,

water and sodium silicate.

Figure 11: Machine for Sand

Mixture

- Carbon Dioxide blow into the sand

mix with sodium silicate, the sand
will spontaneously become
extremely strong.

Figure 12: Carbon Dioxide Gas

(CO2)
5.0 EXPERIMENTAL PROCEDURE

Molding Process
1) The empty molds that are joined together with the model are prepared. Thus, the molds are cleaned
from dust and sand to produce a perfect mold.

Figure 13: Empty Molds

2) A sand mold is formed by compressing the sand into each half of the mold. The sand is poured
into each half of the mold that contained the model which is a replica of the outer shape of the
casting.

3) The sand is packed inside the mold using a manual tool along with the pattern. Excess sand is
periodically removed to form a perfect mold shape.

4) 12 holes are formed at the top of the compacted sand using a scriber to allow the carbon dioxide
to flow through the sand.
5) Then, the carbon dioxide (CO2) gas is injected into each hole for 60 seconds to fill the sand mold
using the CO2 pressure tank.

Figure 14: CO2 pressure tank

.

6) Finally, the pattern are removed together with the flasks and the remaining cavity is formed in the
sand mold.

Figure 15: Mold with cavity

6.0 RESULT & DATA ANALYSIS

Figure 16: Mold

Figure 17: Top view of the product

Figure 18: Front view of the product

Figure 19: Side view of the product

Figure Defect
Crack

Porosity

Swell

Buckle
7.0 DISCUSSION

The result has sown some of the things to be discuss including the defects on the mould and product. The
mould shows a little bit of crack on the side as a result of improper ramming. The unity of the sand is
lacking which caused it to happen. This is because the sand doesn’t completely combine and leading some
empty parts. When the CO2 was blown, the empty parts will be harden which then leads to cracking the
other surface.

Secondly, the product has defects which is porosity, swell and buckle. Porosity is trapped air or gases
which cause bubbles on the surface or inside the smelter. During the melting process, the gas bubbles are
formed when the material cools and solidifies in the mould. This is because the molten metal may contain
a large amount of dissolved gas in its liquid form but not in its solid state.

After that, swelling also happens to be one of the defect on the product. Swelling is under the influence of
metallostatic forces, the mould wall can recede causing swelling in the dimensions of the casting. As a
result of the swelling, the foundry supply requirements increase to which the correct choice of elevation
must participate. The main cause of this. The defect is an inadequate assault of the mould.

Lastly, buckle also can be found on the product. Buckle refers to a long, rather superficial, broad, V-
shaped depression that occurs in the surface of a flat melting of a high temperature metal. At this high
temperature, an expansion of the thin layer of sand on the face of the mould takes place before the liquid
metal on the face of the mould solidifies. As this expansion is obstructed by the balloon, the face of the
mould tends to protrude.
8.0 CONCLUSION

From the experiment, we can say that the objectives have been achieved, so that the process of preparing
the sand mould has been completed correctly. The defects of the mould model are known and we discussed
on the causes and on the theory about it. The preparation of the mould is a hard process in which each
phase must be carried out with care, from mixing water to green sand, from ventilation and then the
combination of the cope and drag. From the result, defects in the mould pattern occur when the mould is
not carefully prepared, such as poor ventilation and crushing, weak mould material and method also the
ratio of the separation agent.
9.0 RECOMMENDATION

This experiment need some improvements in the future so that less defect can be avoided. Some on of
the recommendations are;

- Precisely mix the sand mixture with the correct ratio

- Compact the sand as compact as possible to prevent empty spaces in the mould

- When in ramming process, a proper ramming technique is required to avoid cracking

- CO2 ¬need to be inserted within 1 minute not more or less to get one good mould

- Be careful when separating the mould from the flask to avoid any defects

- Pouring the material with adequate speed to control the air inside the core.
10.0 REFERENCES

1) Sand Casting process retrieved from Wikipedia.

https://en.wikipedia.org/wiki/Sand_casting#Basic_process

2) Metal Casting Process retrieved from Dr Juri Lecture Note

3) C02 Foundry process retrieved from VJP website

http://www.vjp.in/co2-moulding.html

4) Cope and drag retrieved from Wikipedia.

https://en.wikipedia.org/wiki/Cope_and_drag

5) Casting Defect retrieved from Wikipedia.

https://en.wikipedia.org/wiki/Casting_defect

6) Casting defects retrieved from Mechanical Invention Defect

http://mechanicalinventions.blogspot.com/2012/11/different-types-of-castings-defects.html