MANUFACTURING
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The general sources of receiving molding sands are the sea shores, rivers, lakes, deserts and granular elements Advertisement
of rocks.
Molding sands can be classified mainly into two types namely natural or synthetic.
Natural molding sands contains sufficient amount of binder material. Whereas synthetic molding sands are
prepared artificially using basic sand molding constituents (silica sand in 85-91%, binder 6-11%, water or moisture
content 2-8%) and other additives in proper proportion by weight with perfect mixing and mulling in suitable
equipment’s.
undesirable. The silica sand can be specified according to the sand grain size and the shape (angular, sub-angular
and rounded) of the sand.
1.2 Binder
Binders can be either inorganic or organic substance. Binders included in the inorganic group are clay sodium
silicate and port land cement etc. In foundry shop, the clay acts as binder which may be Kaolinite, Ball Clay, Fire
Clay, Limonite, Fuller’s earth and Bentonite. Binders included in the organic group are dextrin, molasses, cereal
binders, linseed oil and resins like phenol formaldehyde, urea formaldehyde etc. Binders of organic group are
mostly used for core making. Among all the above binders, the bentonite variety of clay is the most commonly
used. However, this clay alone can’t develop bonds among sand grins without the presence of moisture content in
molding sand and core sand.
1.3 Moisture
The amount of moisture content in the molding sand varies from 2 to 8%. This amount is added to the mixture of
clay and silica sand for developing bonds. This is the amount of water required to fill the pores between the
particles of clay without separating them. This amount of water is held rigidly by the clay and is mainly responsible
for developing the strength in the sand. The effect of clay and water decreases permeability with increasing clay
and moisture content. The green compressive strength first increases with the increase in clay content, but after a
certain value, it starts decreasing. For increasing the molding sand characteristics some other additional materials
besides basic constituents are added which are known as additives.
1.4 Additives
Additives are the materials generally added to the molding and core sand mixture to develop some special
property in the sand. Some commonly used additives for enhancing the properties of molding and core sands are
coal dust, corn flour, dextrin, sea coal, pitch, wood flour, silica flour.
1.4.3 Dextrin
Dextrin also belongs to starch family of carbohydrates that behaves also in a manner similar to that of the corn
flour. Dextrin increases dry strength of the molds.
1.4.5 Pitch
Pitch is distilled form of soft coal. It can be added from 0.02 % to 2% in mold and core sand. Pitch enhances hot
strengths, surface finish on mold surfaces and behaves exactly in a manner similar to that of sea coal.
3.1 Adhesiveness
Adhesiveness is a property of molding sand to get the stick or adhere to foreign material such sticking of molding
sand with the inner wall of molding box.
3.2 Cohesiveness
Cohesiveness is property of molding sand by virtue which the sand grain particles interact and attract each other
within the molding sand. Thus, the binding capability of the molding sand gets enhanced to increase the green, dry
and hot strength property of molding and core sand.
3.3 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. In absence of
collapsibility property the contraction of the metal is hindered by the mold and thus results in tears and cracks in
the casting. This property is highly required in cores.
3.7 Permeability
Permeability is also termed as porosity of the molding sand in order to allow the escape of any air, gases or
moisture present or generated in the mould when the molten metal is poured into it. All these gaseous generated
during pouring and solidification process must escape otherwise the casting becomes defective. Permeability is a
function of grain size, grain shape, and moisture and clay contents in the molding sand. The extent of ramming of
the sand directly affects the permeability of the mould. Permeability of mold can be further increased by venting
using vent rods.
3.8 Refractoriness
Refractoriness is defined as the ability of molding sand to withstand high temperatures without breaking down or
fusing thus facilitating to get sound casting. It is a highly important characteristic of molding sands. Refractoriness
can only be increased to a limited extent. Molding sand with poor refractoriness may burn on to the casting surface
and no smooth casting surface can be obtained. The degree of refractoriness depends on the SiO2 i.e. quartz
content, and the shape and grain size of the particle. The higher the SiO2 content and the rougher the grain
volumetric composition the higher is the refractoriness of the molding sand and core sand. Refractoriness is
measured by the sinter point of the sand rather than its melting point.
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