Paper 11-059.

pdf, Page 1 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

Effects of Hot Sand and Its Cure

by Use of a Sand Cooler: A Case Study

M. J. Mroczek, T. S. Wozniak, and C. A. Crespo

Weil-McLain, Michigan City, IN

S. L. Neltner and V. S. LaFay

S&B Industrial Minerals, Cincinnati, OH

Copyright 2011 American Foundry Society

ABSTRACT
For as long as molten metal has been poured into molded
sand cavities, foundries have had the problem of that hot
molten metal transferring heat into the sand mold. This
would not be a problem if it were not for the fact that this
sand is re-circulated and is reconstituted with additional
materials and water in order to make green sand molds
once again. This re-circulating process makes hot sand a
problem. When water is added along with additional clay
for re-bonding this sand into molds, the water that is used
to allow the clay to bond is not as effective at elevated
temperatures.
So why employ a process with this associated problem?
The main reason the green sand system is employed is the
fact that it is a very cost-efficient one, because it does re-
circulate and reuses materials.
The only means of eliminating the problem of hot sand is
to either discontinue the use of the re-circulating green
sand system, change to an alternative sand system that
does not re-circulate, or employ some means of cooling
the return sand before its reuse. Due to cost restraints,
most foundries either live with hot sand or take measures
to minimize its affects or take the necessary steps to
actually cool the sand so that it is at a temperature more
conducive to the clay performance temperature range.
the effects of their hot sand. Much has been documented
and published on hot sand because it is so prominent in
green sand foundries. Many individuals have performed
exhaustive studies on the subject of hot sand. So why
does this phenomena persist so strongly in the foundry?
Simply cost. It is very expensive to generate the energy
initially to heat metal into a molten state. In order to
minimize this expense of melting metal; foundries employ
a recycling molding system to help defer some of the cost
of producing a casting. A metal casting facility is made
up of various functional areas. These areas include
melting capability, molding operation (green sand or other
processes), core making, and various mechanical
methodologies to separate the metal cast part from the
molding media. (See Fig 1.) Simply referred to as
Molding, Pouring, Cooling, and Shakeout in a foundry.
This publication will focus primarily on the heat transfer
during the pouring and cooling stages.
This paper is a discussion of the effects of hot sand and
most importantly it shares the actual results of an
operating foundry and its attempt of controlling and
minimizing the negative affects of hot sand primarily by
the use of a sand cooler and innovative sand handling
practices.
Sand Preparation
Patterns
Molding Cleaning, Finishing

Sand Sand Mold Cutoff

Sand Molding
Handling Mixing Finishing Trimming

This paper focuses on one foundrys sand system

operating at elevated temperatures prior to any Mold
Handling
Snagging

mechanical measures and then looks at this same sand Sand Test
Lab
Core
Making
Core
Baking
Dimensional

system after steps have been taken to cool the sand and Chipping

implement improved sand handling systems. Data will be Physical &

Shakeout
Knockout
NDT

Chem Lab Blast

shared to show the effectiveness of sand cooling on the Cleaning
Physical
properties of the prepared sand and the reduction of scrap. Melting/Refectories
Tumbling
Chemical

Metals & Charging Melting

Additives
Pouring
INTRODUCTION/HISTORY Heat
Treating

Metal
Hot sand is not new to the green sand foundry. Actually, Handling

the opposite is true. Rarely does one speak to foundry

personnel who do not have some type of problem with
Fig. 1. Various functional areas of a foundry.
hot sand or have taken the necessary steps to minimize
 Paper 11-059.pdf, Page 2 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

THE PROBLEM OF THE EFFECTS OF HOT SAND

How does the heat transfer from the molten metal to the
sand? Depending upon the metal poured and its grade, the
temperature of the heats can range from 1220-2800F
(660-1538C). When in contact with the green sand mold,
these extreme temperatures transfer some portion of that
heat by conduction, convection and radiation.

Conduction is the heat transfer by actual direct contact.

That is, the metal contacting the mold metal interface of
the mold and this heat is then transferred from direct
contact points between the sand grains. The compaction
or compactablity of the prepared sand will affect this heat
transfer as the sand becomes more compacted; more
.
contact points are available from sand grain to sand grain. Fig. 3. Heat transfer through conduction of contact
Also as the sand grains become finer, more direct contact points and void spaces which allows heat transfer
points are available for this heat transfer by conduction. through convection. Less compaction/ less density
One might also consider that as the sand grains become allows for more venting of heat.
finer, the openness or the permeability of the molded sand
decreases and consequently restricts the heat to vent out
between the voids in the sand grains as well. (Fig. 2.)

Fig. 4. Heat transfer in sand mold by convection and

conduction.

Radiation is the heat transfer by heat radiating from a high

Fig. 2. Heat transfer by conduction through contact
points. Tight compaction/high density; allows less
venting of heat.
Convection is the heat transfer done by the motion of
airflow. If molding sand is in the area of warm or hot air
that is being circulated this can transfer heat to the sand
grains. This transfer of heat through air can come from
space voids between less compacted sand (Figs. 3. and 4).
temperature source but without direct physical contact or
the assistance of forced air flow.
So the returned molding sand gets hot. Two things that
need to be discussed are,
1. How hot is too hot?, and
2. What negative effects are the results of hot sand?
It is generally accepted from previous works and studies
on hot sands that returned sand to the muller should be
no hotter than 100F, or no hotter than 15F above ambient
temperature. This is considered ideal for green sand
preperation.

It has also been documented that having prepared sand

exit the muller below 100F (38C) is necessary to prevent
temperature buildup, as the sand is reused repetitively4.

The relationship between temperature ranges and sand

physical properties is well known. (Fig. 5.)
 Paper 11-059.pdf, Page 3 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

Sand Temperature Sand Properties Even if the sand does appear to be mulled sufficiently, the
hot sand when molded tends to dry out and loose sand
100F - 120F (38C 49 C) Stable Green Sand grains persist as the mold dries out prior to actual metal
Properties. pour. Besides an increase in friability, hot sand also
allows for deterioration in overall strengths.
120 F -140 F (49C 60C) Physical Properties
are diminished. Extra In 1973, J. Scott reported in AFS Transactions that when
Mulling may be sands exceeded 100F (38C) that green compression
required. strength , on average decreased by 10% , dry compression
strength decreased by 50% , wet tensile values decreased
140 F 160 F (60C 71C) Physical Properties by 30% to 40%, and permeability decreased by 15%5.
Uncontrollable. High
friable sand with PROVEN SOLUTIONS TO COOLING SAND
weak strengths.
Having an extended cooling table or allowing the poured
Greater than 160 F (71C) Water evaporates so molds to have enough time to cool below 100F is the
quickly that mulling ideal solution to the hot sand problem. Unfortunately,
is not occurring due to many foundries do not have this luxury and due to ever-
clay not being wetted increasing production rate requirements, sufficient
out or activated. cooling time is not always possible. The solidified
castings are often shaken out from the molds while they
Fig. 5. Sand temperature ranges vs. sand properties. are still described as cherry red hot. Although it is a
good idea to have shakeout as soon as possible in order
When the return sand approaches the elevated not to have the metal in contact with the sand molds, it is
temperatures preparing this hot sand in mullers and important to take some means of cooling the sand down
mixers becomes more difficult. The moisture that is trying before returning it to the muller for re-bonding. (Shakeout
to activate and plasticize the clay in order to make bonds should not be so premature as to affect casting quality due
between the sand grains is actually being used to cool the to castings being too hot and result in batter defects.)
sand. As this water is cooling the sand it drives off the
heat through evaporation in the form of steam. In effect, In the past, several different systems have proven to be
the sand muller will for a period of time act as a sand effective in cooling this hot return sand. These systems
cooler. The time that it takes to lower this and is then include altering the sand: metal ratio or more importantly
subtracted from the overall mulling time which results in the surface area exposure of the molten metal to the
deteriorated sand properties. The sand becomes much molded sand surface in order to minimize the heat transfer
more friable which results in sand inclusions, and there is in the first place. Increasing the initial moisture content of
an increase in cut and wash type defects. The friability the prepared sand also allows for sufficient residual
tests measures the sands tendency to dry out and become moisture to remain in the sand after shakeout; but new
brittle at the mold surface by rotating two prepared sand high pressure molding machines tend to prefer drier
samples against each other in a rotating basket which sands. The use of cooling screens and drums have been
abrades of the sands surface. This abraded sand is then effective in cooling return sand as well as the use of
measured and reported as a percent of the original sample alternating plows/discs and logging chains to turn the
weights. (Fig. 6.) sand over along transport belts and possibly introduce a
moisture source to the sand before it returns to the return
sand bin above the muller.6

Flooding the return sand with quantities of prepared

molding sand is another method of cooling this sand (U.S.
Patent No. 3461941).7 Another method utilized is the sand
cooler. This piece of equipment could be a rotating drum
that forces air through hot sand to dissipate the heat and it
may also utilize water as well by allowing the evaporated
water to expel the heat with it.

This case study does address the hot sand remedy by use
of a manufactured sand cooler. The installation and
application as well as the documented results of the sand
before and after the addition of this in-line piece of
equipment follows.
Fig. 6. Friability test unit.
 Paper 11-059.pdf, Page 4 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

CASE STUDY prepared sand also reduces the green compression

strength. The moisture has to be increased in the sand
The Foundry Plant in Michigan City, Indiana, proportionally to the sand temperature to compensate for
manufactures boiler sections cast in green sand molds the water loss due to the high sand temperature.
with cores made in hot-box and cold-box processes.

The boiler sections are manufactured of cast iron class 25

and meet the ASME Boiler & Pressure Vessel Code. Each
section is subject to hydrostatic test and has to meet the
minimum wall thickness of 80% of the nominal value;
therefore, any deep surface defect or discontinuity that
exceeds this requirement would be a reason to scrap the
casting. For instance, if the nominal wall thickness were
0.250 inches (6.35 mm), the maximum permissible
surface defect or discontinuity would be only 0.050
inches (1.27 mm) deep in non-critical areas. In critical
areas, any surface discontinuity is not acceptable.

The present case study has been conducted on the A-Line,

which produces castings of weights between 30lbs to
300lbs (13.6136 Kg) and processes approximately 120
tons/hour of green sand. The sand is mixed and mulled in
a continuous mixer, which normally operates at a
retention time of ~70 seconds. The water and bond
addition into the muller is controlled by a Hartley PM
2552 tester, based on feedback measurements of moisture,
compactability and green compression strength.
BACKGROUND
Fig. 7. Return sand temperature going into the muller
and green compression strength [GCS] of prepared
sand measured by the Hartley tester: a) and b)
Monday GCS and sand temperature after recycling the
sand one time on Saturday, c) and d) Wednesday GCS
and sand temperature
The regression equation is:
GREEN STRENGTH = 25.2 - 0.0470 RETURNSANDTEMP

SAND TEMPERATURE (250 cases used, 4 cases contain missing values)

The return sand temperature measured before the muller,
Predictor Coef SE Coef T P
considerably varied by time. On Fig. 7. are shown typical
sand temperature variations within the same day and also Constant 25.2431 0.4082 61.84 0.000
between days. At the beginning of the shift, the sand RETURNSANDTEMP -0.046988 0.003016 -15.58 0.000
temperature is high (Fig. 7d) because of the stored sand in
the silo maintains the temperature overnight even after a S = 0.657649 R-Sq = 49.5% R-Sq(adj) = 49.3%
weekend shutdown. Then, after a short time of Analysis of Variance
production, the sand temperature starts dropping when
cooler sand from molds left overnight are shaken out and DF SS MS F P
put back in the system. After this short period of cool Source
Regression 1 104.99 104.99 242.75 0.000
sand, the temperature increases rapidly when hot sand
from molds poured in the morning is recycled. After that, Residual Error 248 107.26 0.43
the temperature gradually increases during the day. The Total 249 212.25
sand temperature used to go as high as 160F-180F (71-
82C) during the shift and at the beginning of the day.
GREEN COMPRESSION STRENGTH
If we observe the graphs a) and b) of Fig. 7, the green As it was discussed above, the hot sand reduces the green
compression strength (GCS) measured at the muller compression strength. On Fig. 8. it is shown that there is a
discharge by the Hartley tester, tends to decrease when tendency to increase the proportion of defective parts due
the return sand temperature increases. A statistical to mold-crack as the green compression strength
analysis [displayed below] from one day data shows that decreases. This mold-crack also may result in sand
the relationship is significant between the two variables inclusion defects as it is shown on Fig. 9. On this
(P-value is <0.05), and it indicates that 50% of the particular casting, a surface discontinuity deeper than
variation of the green compression strength is explained 0.050 is not acceptable and the part would be rejected.
by the sand temperature variation. This confirms what already was mentioned in the
literature, that the hot sand results in higher percentage of
If the moisture is included in the equation, the R-Sq scrap. So, the need of cooling the return sand and
increases to 53%. The increase of moisture in the
 Paper 11-059.pdf, Page 5 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

improving the mechanical properties was evident in order marginal increased of the GCS in ~8%. The drawback
to improve the quality of the castings. was the variation increase of the moisture and
compactability.
Scatterplot of Mold-Crack Defect vs Green Compression Strength
0.25
After that, and for approximately 45 days prepared sand
was diverted and put back into the return sand of the
Proportion of defective parts

0.20 same A-Line system .7 Initially the green compression

strength increased but it was not sustained consistently
0.15
day-to-day. Also the day-to-day and within the same day
0.10
variability of the moisture and compactability did not
improve. The sand temperature went up to 150F~160F
0.05 during the day.
0.00
MOISTURE IN THE PREPARED SAND
24 25 26 27 28 29
Green Compression Strength [psi]
30 31
The prepared sand moisture measured at the molding line
N = 77 averaged 3.44%. The total process variation (6 x Standard
Jan-Aug 2007
Deviation) of the moisture was 1.70% (from 2.60% to
Fig. 8. Scatter plot of the proportion of defective parts 4.30%). Low moisture content resulted in low
because of mold-crack defect versus the average compactability and more friable mold surface (Fig. 10).
green compression strength (lab test) on the GO-
boiler back section.
Histogram of Moisture [Lab test]
Normal
Before sand cooler Jan-Aug 2008
3.44
350 Mean 3.442
StDev 0.2858
300 N 1145

250
Frequency

200
Sand inclusion
150

100

Causes 50

0
2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8
Moisture [%]

Fig. 10. Green sand moisture distribution before the

Cracked molds sand cooler installation.

Inefficient mulling because of hot sand also led to

Fig. 9. Sand inclusions caused by cracked mold
surface. GO-boiler back section.
To increase the mechanical properties of the sand, the
extra mulling time in a continuous mixer was not a viable
option, nor the increment of bond. Then, a few different
trials were made to try to increase the strength of the
molding sand and reduce the sand temperature:
increase the moisture content in order to achieve a desired
molding sand compactability. Due to the variability of
the process, the moisture in the sand went up to the levels
that may cause casting defects. It was determined, on a
particular casting used for the study, that there is an
important relationship between the moisture and the scrap
due to burn-on defect, a very severe sand adherence that
cannot be removed at the blast. (Fig. 11).

One of those was recycling the sand through the muller

one time in the weekend and every night before the start
of the shift. This practice did not show a significant
improvement on the green strength except for Monday
morning, but along the day, as it was expected, the return
sand temperature increased and the GCS decreased. On
the next days of the week, in spite of recycling the sand
prior to the start of the shift, the green strength continued
declining. Figure 7 shows Monday and Wednesday
return sand temperature and the GCS.

In addition, it was tried to add approximately 2% of

Fig. 11. An example of typical burn-on defect.
prepared sand into the return sand from the batch muller
of B-Line during the production shift. This showed a
 Paper 11-059.pdf, Page 6 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

Figure12. shows that the increase in moisture will cause In September 2008, the installation of the sand cooling
an increase in burn-on defect. system (MU-MUR) manufactured by SPACE SRL of
Scatterplot of Burn on vs Moisture Mean
Italy was completed. The system has the following
0.14
features:
Proportion of defective parts [Burn on]

0.12
Continuous sand weighing system.
0.10 Complete control of the mixing by moisture,
0.08 weighing, and temperature sensors installed in the
sand stream.
0.06
Capable to control up to three variable speed screw
0.04 feeders, for dosing of additives, such as bond.
0.02 Calculation of the amount of water to be added with
automatic compensation of evaporation losses
0.00
generated by temperature, mixing time, storage time
3.0 3.2 3.4 3.6 3.8 4.0
Moist Mean [%] and ambient conditions.
All useful information concerning equipment
Fig. 12. Scatter plot of the proportion of defective
parts because of burn-on (GO-back boiler casting
operation is displayed on a screen, including graphic
section) versus average of molding sand moisture (lab trends of main process variables, and appropriate
test) on the GO-boiler back section. messages and alarms.

Transforming the proportion of defective parts data, we The sand cooling system processes the return sand
can see a better linear relationship between the burn-on coming straight from the shakeout after passing through a
and moisture content in the sand. (Fig. 13) rotary screen. The cooled sand with partial addition of
bond is stored for approximately 1-2 hours in a silo prior
to the mulling-mixing operation in a continuous mixer
Scatterplot of Burn on [transformed data] vs Moist Mean
0.7 Fits
controlled by a Hartley system.
Regress
0.6 Lowess

0.5
EFFECT OF THE SAND COOLING ON THE
GREEN SAND PROPERTIES
Transf. Burn on

0.4
0.3
0.2
0.1
0.0
-0.1
3.0
Fig. 13. Scatter plot of the transformed proportion of
defective parts because of burn-on versus average
moisture of molding sand. R-Sq=59.4% or r=0.77
The increase in moisture in the sand is also related to the
increase of bond addition as preblend. All additives
contained in the preblend will absorb water in some
degree. This is explained by analyzing the relationship
between moisture and active clay (MB clay), which their
The majority of the sand properties that are displayed on
the next graphs were taken from the tester. The mean
difference between the laboratory and the Hartley testing
for green compression strength is expected to be 6 - 7 psi
and for the compactability is expected a mean difference
of 12%.
3.2 3.4 3.6 3.8 4.0
Moist Mean [%]
Sand temperature
The daily average return sand temperature is plotted on
Fig. 14. The return sand temperature considerably
decreased since the installation of the sand cooler.
Average temperature went up to 160F (71C)in summer
2008, as we can see on the graph below, and for similar
period in 2009, the maximum average temperature
reached 120F (49C).
Scatterplot of Sand temperature Mean vs Date

positive linear relationship also is significant, and the R- 160

Sand temperature [F degree]

Sq is 26% (or r = 0.51). 150

140
130

APPLICATION OF THE SAND COOLER 120

110
100
BRIEF DESCRIPTION OF THE SAND COOLING 90
SYSTEM 80

In the second half of 2007, it was decided that the

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installation of a sand cooler was necessary to improve the

Date
mechanical properties of the green sand and for Return sand to the Muller
improving the quality of our products. Fig. 14. Return sand temperature going into the
muller.
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AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

GREEN COMPRESSION STRENGTH, MOISTURE, Scatterplot of Moisture Mean vs Date [Hartley]

AND MULLER EFFICIENCY 3.4

The reduction of the return sand temperature resulted in 3.2

an increase of the green compression strength. This 3.0

Moisture Mean
confirms our previous discussion of the negative effect of 2.8

2.6
the sand temperature on the mechanical properties of the
2.4
green sand. The GCS has increased in approximately 40% 2.2
measured by the tester and 25% based on laboratory 2.0
testing. The GCS continuously increased since the

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installation of the sand cooler. The maximum GCS was
obtained with partial addition of bond (50%-70%) into the Date

sand cooler, starting in December 2008. This bond

addition in the sand cooler, without increasing the amount Fig. 17. Daily moisture mean measured at the muller
of active clay in the sand, raised the GCS beyond the discharge by the tester tester
maximum desired of 26 psi. (Fig. 15)
The muller efficiency has increased from approximately
55% to 75% (Fig.18.). This 35% increase in efficiency
Scatterplot of Green Comp. Strength Mean vs Date [Hartley]
value is mainly driven by the increase in GCS.
30.0
Green Comp. Strength Mean [psi]

27.5
26 Scatterplot of Muller Efficiency Mean vs Date
25.0 0.9
23.5
22.5
21 0.8

Muller Efficiency Mean

20.0

17.5 0.7

15.0
0.6
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Fig. 15. Daily green compression strength mean
measured at the muller discharge by the Hartley
Date
tester.
Fig. 18. Daily average of muller efficiency. Muller
The working bond follows the GCS pattern. It increased efficiency=working bond/available bond active clay
since the sand cooling installation. (Fig. 16). and green compression strength-to-MB clay ratio

Scatterplot of Working Bond Mean vs Date [Hartley]

The increase in GCS led to reduce the amount of active
5.5 clay in the prepared sand. As we can see on Fig.19, the
5.0
amount of active clay (measured by Methylene Blue
method) used prior to the sand cooler was approximately
Working Bond Mean

4.5
9.0% +/- 1.0, and it has been reduced to 7.5% +/- 1.0 in
4.0
June 2009. This decline of MB clay observed on the right
3.5
side of Fig. 19 (June) relates to the reduction of GCS and
3.0 working bond for the same time-period (Fig. 15 and 16
2.5 respectively).
2.0
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Date

Fig. 16. Daily average of calculated working bond.

Working bond = (15.29* GCS)/(132.1-Compactability)

The reduction of the sand temperature also resulted in a

reduction of moisture in the prepared sand. The average
reduction of moisture is approximately 0.6 % [Lab test].
Similar reduction is observed on the Hartley
measurements (Fig. 17).
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AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

Scatterplot of MB Clay Mean vs Date Scatterplot of Compactability Mean-to-Moisture Mean ratio vs Date
11 22

Compactability/Moisture ratio
20
10
MB Clay Mean

18

9
16

8 14

12
7

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Date
Hartley data
Date
Fig. 21. Daily average of Compactability-to-Moisture
Fig. 19. Daily average percentage of active clay in the ratio.
prepared sand (MB clay).
PERMEABILITY
The GCS-to-MB clay ratio is a very interesting metric. If The green sand permeability has increased significantly
we observe the trend in June of 2009 (right side of the by approximately 29%. (Fig. 22) This confirms previous
plot), this trend does not follow the decline of GCS and findings mentioned in the literature5 that the hot sand
working bond observed on Fig. 15 and 16. The values of above 100F negatively affects the permeability. The
the GCS-to-MB clay are maintained despite the reduction reduction in bond addition also may have contributed to
in active clay. It means that for 1% of active clay, the the permeability increase.
developed GCS has been maintained. (Fig. 20).
Scatterplot of Permeability Mean vs Date
Scatterplot of Green Comp. Strength Mean [Hartley]-to -MB Clay ratio vs Date 180

170
3.5
160
Permeability Mean
Hartley GS Mean/MB Clay

3.0 150

140

2.5 130

120
2.0 110

100
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06/1/2009
07/1/2009

Date

Date
Fig. 22. Daily average of green sand permeability.

Fig. 20. Daily average of Green Compression

Strength-to-MB clay ratio. GREEN COMPRESSION STRENGTH VERSUS
SAND TEMPERATURE ANALYSIS
COMPACTABILITY AND COMPACTABILITY-TO- The regression analysis of the GCS mean versus the
MOISTURE RATIO return sand temperature mean, including all data before
The desired compactability of the sand at the point of use and after the sand cooler installation, shows that the linear
was maintained at 32% +/- 4% before and after the sand relationship is significant. The variation of sand
cooler installation. Therefore, the compactability at the temperature explains 79.4% of the variation of the GCS
tester has not changed either. However, the (Fig. 23).
compactability-to-moisture ratio increased considerably
as it is shown on Fig. 21. This means that the mulling-
mixing system is able to develop the desired temper of the
sand with less amount of water. The ratio has increased
approximately from 14 to 18 (Hartley data). Based on the
laboratory testing, the ratio increment has been from 8-9
range to 10-12 range.
 Paper 11-059.pdf, Page 9 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

MB clay Mean 1.9423 0.2050 9.48 0.000 1.1

Fitted Line Plot
Green Comp. Strength Mean4 = 40.98 - 0.1525 Sand temperature Mean2
Regression
95% C I S = 1.12199 R-Sq = 64.7% R-Sq(adj) = 64.2%
30
Green Comp. Strength Mean

95% PI

S 1.60374
R-Sq 79.4%
25 R-Sq(adj) 79.3%
Analysis of Variance

20 Source DF SS MS F P
Regression 2 348.08 174.04 138.25 0.000
15
Residual 151 190.09 1.26
Error
80 90 100 110 120 130 140 150 160 Total 153 538.17
Sand temperature Mean
Hartley data through June 25-09
N= 275
Source DF Seq SS
Fig. 23. Regression analysis of green compression Sand temperature Mean 1 235.06
strength versus return sand temperature. MB clay Mean 1 113.02

GREEN COMPRESSION STRENGTH VERSUS This analysis is indicating that the green compression
SAND TEMPERATURE AND ACTIVE CLAY [MB strength is also significantly affected by the variation of
CLAY] AFTER THE SAND COOLER the active clay content. The interpretation of the
For an average sand temperature range between 85F and regression equation is that if the sand temperature-mean
123F, with the sand cooler, the Fig. 24 shows that there is increases by 10F, maintaining the MB clay constant, the
an important linear relationship between two variables: GCS mean decreases by 1.34psi. If the MB clay increases
GCS vs. return sand temperature, and GCS vs. active clay by 1%, maintaining the sand temperature constant, the
content (MB clay). The R-Sq are 42.3% and 37.1% GCS mean increases by 1.94psi. This significant effect of
respectively. the active clay on the GCS was not observed prior to the
Scatterplot of GCS vs Sand temperature mean, MB Clay mean installation of the sand cooler. If we look at again the
7 8 9 plots of sand temperature, GCS and MB clay on Fig. 14,
Sand temperature Mean2 MB Clay Mean 15 and 19 respectively, we can observe that the decline in
30 GCS in June (right side of the plot) corresponds to a
Green Comp. Strength Mean

reduction in active clay and to a slight increase of sand

28
temperature.
26
IMPACT ON THE QUALITY OF THE PRODUCT
24
Chronic casting defects such as sand inclusions and
22 related defects were significantly reduced after the
installation of the sand cooler. See Fig. 25.
20
80 90 100 110 120

Fig. 24. Scatter plot of green compression strength,

return sand temperature, and active clay [MB clay]
after the sand cooler installation.

However, if a multiple linear regression is performed,

with the GCS as a response variable, and sand
temperature and MB clay as predictor variables, the
analysis shows that the relationship is significant and the
R-Sq increases up to 64.7%:

The regression equation is

Green Comp. Strength Mean = 23.5 - 0.134
Sand temperature Mean + 1.94 MB clay Mean Fig. 25. An example of typical sand inclusion defect.

The chart below (Fig. 26.) shows that the scrap due to
Predictor Coef SE Coef T P VIF
Constant 23.509 2.356 9.98 0.000
sand inclusions was reduced by 70% on the GO-boiler
back section used for the study.
Sand -0.13406 0.01234 -10.87 0.000 1.1
Temp Mean
 Paper 11-059.pdf, Page 10 of 10
AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA

CONCLUSIONS

This study has illustrated that cooling the sand prior to the
mulling-mixing process increases the green sand
properties significantly. The partial addition of bond in
the sand cooler improved the sand properties beyond of
what was achieved only with the return sand cooling. This
was done without an overall increase in the amount of
active clay in the sand system.

The development of green compression strength by a unit

Fig. 26. Scrap reduction of molding sand related
defects on the GO-boiler back section.
Similarly, the burn-on scrap was reduced on the same part
by more than 90% (Fig. 27). On this particular casting no
other process change was performed, so the scrap
reduction is mainly attributed to the green sand properties
improvement.
percent of active clay increased significantly in more than
40%. Likewise, the compactability developed by a unit
percent of moisture increased in approximately 20%.
The improvement in the green sand properties has
impacted positively on the reduction of systemic castings
defects such as sand inclusions, burn-on and leaks due to
inclusions.
The reduced sand temperature range after the installation
of the cooler still has a significant effect on the green
compression strength. The effect of the active clay
variation on the green compression strength has become
important. Then, the GCS change can be achieved by
varying the amount of active clay in the system.

The return on investment (ROI) on the installation of this

sand cooling system is estimated to be 3 years.

ACKNOWLEDGEMENTS

The authors would like to thank Weil McLain and S&B

Industrial Minerals for permission to publish this work.

Fig. 27. Burn-on scrap reduction on GO-boiler back REFERENCES

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