Recommendations

The following are some important recommendations that need to be considered in molding
preparation and pouring experiment :

1) Type of sand casting

i) There are two type of sand casting which are green sand casting and dry sand
casting that can be applied to form the product.
ii) For green sand casting, it is mainly composed of sand (silica), 6-8% of clay
binder (e.g : bentonite) and 2-3% of water and additives (sea-coal, starches and
cellulose).
iii) In contrast, for dry casting, only one or more coatings of refractory is applied
(silica, zircon, graphite).
iv) Alternatively, instead of using green sand casting, we can apply dry sand casting
to produce the product, as dry casting produces stronger molds due to present
of additives and other materials (e.g : gilsonote, glutrin, corn flour and
molasses).
v) Besides, for green sand casting, the condition is moist and not dried up before
molten is poured. In contrast, for dry sand casting, the sand mold is baked before
filled (~300F or 150C). Thus, the surface finish for dry sand casting is better
than green sand casting.

2) Reparing defects to obtain better surface finish

i) Based from the result obtained, we can observe that the casting experienced a
sand holes defect, which looks like small middle holes with sand grain in the
internal or on the surface of castings.
ii) Sand holes defect may have occur due to sand crush or sand drop, which was
caused by the mechanical force on the sand molds or sand cores. Thus, it will
cause the embossing metal blocks, at the same time, the position where the sand
blocks drop to will have sunk holes after sand blasting.
iii) Sand holes defect can be repaired by applying metal-filled glue, that contain
quartz and metal components. So, after filling the casting surface with this glue,
it will have a certain harness and it can stand further machining process and a
temperature of 125C to 200C.
3) Proper pouring process
i) Based from the result, we can tell that the casting experienced a pouring material
defect (cold shut) from the presence of crack with round edges on the surface of
product.
ii) Cold shut occurs when a misrun (metal start freezing before reaching the
farthest point of mould cavity) show up at the centre of the casting for a casting
with gates at its two sides. This defect are due to lower fluidity of the molten
metal or small thickness of casting.
iii) In order to counter the cold shut defect, we can change the composition of the
molten metal or raise the pouring temperature.

4) Surface finish
i) Based from the result, we can observe that the final product has a rough casting
surface. The rough surface may have formed due to higher pouring temperature
or the use of coarse sand grains in mould material or no use of mould wash.
ii) In order to prevent this defect, we can choose appropriate grain sizes with proper
mould wash.
iii) Next, the casting also experience a joint flash defect, which is a thin projection
out of the surface of metal casting. Joint flash can be eliminated during cleaning
and grinding process of the product in order to obtain a better surface finish.