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Bentonite Tests in Lab Oj , but in practice?-one of the causes could be.

The Bentonite Suppliers test the Bentonite with good quality Water , otherwise Gel
Index does not come as specified. Using this argument, it is obvious inference tbat
Water going to The Mixer should not be HARD.If it is HARD , it does not Allow full
swelling of BENTONITE & than you need more BENTONITE. I am not Sure of my
comments are helpful to you or not?
Pl give feed back.
Efffect of type of water in the Wet Tensile Strength (WTS) at green sand molding lines.
Edomar ManskeFoundry Professional. Procurement, Sales and Technical Advisor.
Working at Whirlpool SA - Embraco Foundry Unit.
What the influence of the water source in the WTS properties? From artesian well there are different
type of salts and from the outside source the chlorides are high. Which effect is worst? Is there any
paper discussing the subject? Thanks to everybody.

MOLD HARDNESS vs PERMEABILITY.

balraj seth
Foundry and Industry Consultant
Top Contributor
Permeability of sand is dependent on quality of silica sand, quantity of bentonite and
lustrous coke and amount of fines from return sand whereas hardness of mould depends
upon many factors and quality of mixed sand is one of them.There is need to fully
understand sand system and its parmeters.
PADUBIDRI JAYARAMAN
General Manager at INDIA PISTONS LIMITED
Sand mesh size you are using and the amount of fines in the sand system addresses your
permeability.coarser sand with less fines improves permeability.
Mould hardness....Machine condition to get rigid moulds and binder percentage plays key
role .

Umesh Sakhavalkar
technical manager at quality castings ltd
The permeability depends on fines and size distribution while hardness depends on binder
quality and content.So there is an indirect correlation but to improve permeability I would
reduce fines rather than hardness.
balraj
balraj seth
Foundry and Industry Consultant
Top Contributor
Sand though consist of sand,binder, LC,moisture but need thorough knowledge because
parameters to control are numerous.Low value commodity carrying lot o load on its head.
Shailesh Bhanse
Foundry Manager at Gautam Dhatu Pvt. Ltd. Ahmednagar
Keeping all parameters constant, if hardness is lowered, permeability increases.
Thanks
Padmanabhan Sathyan sathyan
General Manager at AMI Foundries
Gas escaping. What type of gas is it. Is it from the molding material or the air inside the
mold.
Air in the mold has to be released easily through vents and the risers.
But the mold material gas has to go out through the permeability.
We must have a better control on the raw material and the LOI and fineness in the sand.
More the amount of volatile material in Molding sand more the gas.

Mold hardness should not be reduced. For many reasons. You will get over weight castings
due to swelling. Poor dimension of casting, you can have sand erosion, metal penetration,
rough surface and so on.
IT IS ALWAYS BETTER TO HAVE A BETTER SAND SYSTEM TO HAVE A BETTER
CASTING.
Bhargav Shukla
Jr. Engineer at Magotteaux
Dear,Roushan,
There ain't any relationship between mold hardness and permeability. You have to take
control over your sand system, mainly over sieve size and distribution. Hardness depends
mainly on your binder system while permeability depends on sand quality.
If sand is of proper fineness and if you provide proper venting system, then there is not any
problem for gas entrapment in casting.

If possible then don't reduce mold hardness, it will cause other problems.
Thank you

PADUBIDRI JAYARAMAN
General Manager at INDIA PISTONS LIMITED
As said earlier the machine condition,,sand properties are critical for
mould hardness,
GAS.....due to metal, mould or core.....apart from venting and
permeability condition of the core.,control gas from the metal, .ladle
condition and the ambient temperature(winter...moisture absorbtion will be
more in cores) and in charge materials should not be in rust condition and coated steel,
painted scrap should be avoided in charging.
Foundry is the industry where the discipline is needed and systems should work to control
process variation which will help to control rejections.
Low mould hardness will result in swelling...out of dimension...shrinkage...rough surface and
what not.
Gren Rudd
Pres/GM at Camp 10 Ski Area
Permeablity is related to to the composite molding media materials. Mold hardness is a
reading of resistance to penetration by the hardness testing indentor. The mold hardness
taken on a squezzer produced mold Can be the same as the mold hardness taken on a high
pressure molding produced mold ( a bit unusual but it can occur) the difference between a
squeezer produced mold and a high pressure produced mold is found in the difference in
density between the tow types of molding. The squeezer mold will diminish in density as you
get further away from the parting line. The high pressure mold will still have some reduction
in density as you move away from the parting line but the amount it diminishes is much less.
A more reliable comparison can probably be made using a mold strength test via a
penetration type tester.
Generaly speaking the higher the density the lower the permeablity. If you need high density
then you have to take other steps to (a) reduce the amount of gas being produced or (b)
increase the mechanism for the the gas to get through the sand media or (c) a combination.
Dont forget that you will be generating or can be generating a condensate layer as you
move away from the mold metal interface and this condensate layer also reduces the ablity
for gas to pass through the media.
Don Clarke
Sr. QA Consultant at American Aluminum Casting Co.
Fines in your system will contribute more to a lack of perm that mold hardness. A hard mold
from an automatic molding machine using AFS 60 will have a better perm that a softer mold
from a squeezer using AFS 120 and having 4% left on your pan and 4-5% left on your 270
screen.

Gren Rudd
Pres/GM at Camp 10 Ski Area
Its all about particle size distrubution to get maximum density for lowest perm. Maximum
density and lowest perm is not a good situation-under those conditions you will also have
expansion defects.

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