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Major production of castings is in sand molds. About 4 to 5 tons of molding sand may be required to produce 1 ton of castings. Poor molding sand ------ poor castings. Attention to preparing, controlling, handling, and properly using the sand. Several different types of molding sands are used. Usually green sand.
3. HOT STRENGTH: Hot molten metal Metallostatic pressure of the liquid metal bearing against the mold walls may cause mold enlargement, or if the metal is still flowing, erosion, cracks, or breakages may occur unless the sand posses adequate hot strength. 4. PERMEABILITY: Steam and other gases The mold must be permeable, i.e. , porous to permit the gases to escape.
5. THERMAL STABILITY: Heat from the casting causes rapid expansion of the sand surface at the mold-metal interface. The mold surface may crack, buckle, or flake off (scab) unless the molding sand is relatively stable dimensionally under rapid heating. 6. REFRACTORINESS: The absence of melting, softening, or adherence of the sand to the casting makes for better casting surface and easier cleaning of the casting. Ferrous alloys ---- sand with high refractoriness.
7. FLOWABILITY: The sand should pack well/flow under load. Sands of low flowability may result in non-uniform hardness. Soft molds --- enlargement of the casting or roughness of the casting surfaces. 8. PRODUCE GOOD CASTING FINISH: Finer sands ----- a smoother casting surface.
9. COLLAPSIBILITY: Heated sands -------- hard and rocklike. Difficult to remove from the casting May cause the contracting metal to tear or crack. 10. THE SAND SHOULD BE REUSABLE. 11. EASE OF SAND PREPARATION AND CONTROL. ** Economic production of good casting.
Generally the purest silica sand, 99.8+ percent SiO2 is considered the most refractory and thermally stable. Excessive amounts of iron oxide, alkali oxides and lime can cause objectionable lowering of the fusion point in some sands. The shape of sand grains may be rounded, angular, or subangular depending on their geologic history. Compounded grains are agglomerated particles of angular or sub-angular sands. Mixed origin new molding sand addition of new silica sand disintegrated cores reclaimed sand
Clay:
2 to 50 percent With a suitable water content, it is the principal source of the strength and plasticity of the molding sand. Binder Natural molding sand ------- sand + clay in minerals Synthetic molding sands
Essentially aggregates of extremely minute crystalline, usually flake-shaped particles that can be classified on the basis of their structure and composition into a few groups which are known as clay minerals. Single clay minerals Mixtures of clay minerals Clay minerals : bentonites, fire clays (kaolinites) and special clays (halloysite, illite)
Water:
1.5 to 8 percent Activate the clay ----------- develop plasticity and strength. Water in molding sand is often referred as tempering water. Water in excess -------- free water The rigid clay coatings of the sand grains may be forced together ---------- develop strength. Free water ----- lubricant --- makes the sand more plastic and more moldable though the strength may be lowered. Control of water in sand (clay) is very important.
SPECIAL ADDITIVES
Cereals: *finely ground corn flour or *gelatinized and ground starch from corn. *0.25 to 2.00 percent *Increase green or dry strength and collapsibility. Ground Pitch: *by-product of coke making. *up to 2.0 percent *improve hot strength and casting finish on ferrous castings
Sea Coal: *2 to 8 percent. *A finally ground soft coal. * Grey and malleable iron molding sands. * Improve the surface finish. *Improve ease of cleaning the castings. Gilsonite: *About 0.4 to 0.8 percent. *A mineral * Improve casting finish Fuel Oil: *A little fuel oil is sometimes used as a replacement for a small percentage of water, thus lowering the total percentage of moisture present.
Wood Flour:
*0.5 to 2.0 percent *Enhance thermal stability. *Control the expansion of sand by burning out at elevated temperature
Silica Flour:
*Pulverized silica, finer than 200 mesh, is called
Iron Oxide:
*0.25 to 1.0 percent *To obtain added hot strength.
Perlite:
*An aluminum silicate mineral *0.5 to 1.5 percent * Better thermal stability of the sand * Riser insulator
Molasses, Dextrin:
*Cane or blackstrap molasses, unrefined, and containing 60 to 70 percent sugar solids, may be used for increased dry strength. * Dextrins may also be used for the same purpose
PROPERTIES OF GREEN SANDS Properties depends on several factors. i) The sand ingredients. ii) The methods of preparing the sand for molding. iii) The method of molding employed in using the sand. iv) Variables related to the casting such as weight, shape, kind of casting alloy and gating design.
Effects of Clay:
** Water is necessary to activate the clay.
Grey-iron sands ----- 20 to 80 psi dry strength Hot strength of 50 to 80 psi at 1100 F, with less than 0.030 in. per in. expansion is desired. Aluminum castings --- only green and dry strength have appreciable importance since castings are poured at low temperatures.
WATER:
Close control of the moisture content of molding sand. Optimum tempering water. Water causes ------- the clay to develop higher dry strength. The bonding action is attributed to adsorbed water rigidly held by the clay. With its adsorbed water, the clay coatings on the sand grains can be wedged together if sufficient force (ramming) is applied. Free water, un-adsorbed, can lubricate the coated sand grains and permit a greater bulk density to be reached.
SAND DEFINATIONS
Silica Sand: White, washed and dried, silica sand grains of high purity, 99.8+ percent SiO2. Bank Sand: Sand from glacial or sedimentary deposits occurring in banks or pits usually containing less than 5 % clay. Lake Sand: A sub-angular sand, from lake areas. System Sand: employed in a mechanical sand preparation and handling system. Heap Sand: Sand thought of as being heaped on the floor when it is prepared for use. Facing Sand: A specially prepared sand used next to the pattern and backed up with heap or system sand.
Backing Sand: Molding sand used to back up facing sand and not used next to the pattern. Bonding Sand: Sand high in clay content used to add clay to a molding sand. Sharp Sand: A sand substantially free of bond, Lake sands Sand Additive: Any material added to molding sands for a special effect. Loam: A mixture of sand, silt and clayey particles in such a proportions as to exhibit about 50 % sand grains and 50 % silt and clay.