Optimizing New Sand and Core Sand Additions in Foundry Green Sand Systems

By Sara Joyce, Vic LaFay, Mark Ziegler | Published August 18, 2005
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The old rule for new/core sand additions is 300 lbs. per ton of metal poured, but that approach
needs to be re-evaluated — and made more exact — for current molding methods and materials.
In order to understand the effect of core sand and the various binder systems on green sand
properties and castings, the new sand's contribution to the dilution must be established. The
objective of this research is to create a model where different amounts of new sand and core sand
are added to system sand, so that the green sand’s properties and casting results can be evaluated.
Initial work by the Green Sand Committee of CISA has shown that certain levels of new sand
can be added, along with new clay/additives, to maintain consistent green sand properties. The
study also found that there are critical levels where major changes in the green sand properties
occur.
The old rule of 300 lbs. of new sand per ton of metal poured needs to be re-evaluated, because it
may not be appropriate for current molding methods and materials. It is the goal of this project to
establish a number that is more precise in terms of percentage or pounds for new/core sand
additions. The number should also provide a standard test for all metals, sands, and binder
systems. By effectively analyzing the effects of new- and core-sand dilution on green-sand
systems and optimizing these properties, casting defects and problems could be reduced resulting
in improved efficiency.
Presently, there are no guidelines to determine new or core-sand additions. Some research has
been performed on core-sand dilution, but no distinction or separation of the sand versus the
binder has been established. When new-sand addition rates were evaluated in the past,
metalcasters were using different core-binder materials and shakeout rates. There have been
numerous developments in metalcasting processes and materials since previous research was
performed. In general, we use less chemical binder by percentage today and formulations have
been designed so that more core-sand dilution occurs by volume. Many chemical binders are
produced with additives that also improve shakeout. With these improvements much more core
sand is introduced into the green-sand system. Under continuing environmental pressure,
chemical binder manufacturers have developed more “environmentally friendly” chemical binder
systems.
There is no current literature that states the effects of new- or core-sand dilution on the system
sand.
There is no current, proven green-sand test that determines the level of core-sand dilution in the
system sand. Many foundries do keep track of the core weights and make informed assumptions
on dilution, based on their own criteria. But, there is no clear distinction between resin-bonded
sand and virgin sand performance as a green-sand additive. It is not clear what effect older
binder systems — much less newer ones — have on the system sand. By analyzing the effects of
new- and core-sand dilution on green-sand systems, and optimizing these properties, casting
defects and problems may be reduced, and casting efficiency may be improved.
New and core sand are additives of green-sand systems, but their effects have not been measured
quantitatively. In order to understand the effect of core sand and the various binder systems on
green sand properties and castings, the new sand’s contribution to the dilution must be
established. The objective of this research is to create a model where different amounts of new
sand and core sand are added to system sand, and the green sand properties and casting results
can be evaluated. It hoped that this project will establish a more exact number in terms of
percentage or pounds for new/core sand additions. It should also provide a standard test for all
metals, sands, and binder systems.
Phase I research includes development of baseline data for various levels of new sand additions
by weight to green sand. Phase II evaluates similar additions of core sand by type and weight.
Phase III includes analysis of casting quality with both new and core sand additions. This
includes varying the new- and core-sand dilution rate above and below recommended rates. The
resulting data will be used to develop a simulation model to predict new and core sand
requirements based on variables such as sand-to-metal ratio, amount and type of binder/cores
used, and metal type. This information also will be used to develop a standard test method.

Testing evaluation
Phase I of the project aimed to evaluate the impact of new-sand addition on a traditional green-
sand molding system. In order to complete this project, a prepared sand mixture was evaluated in
a laboratory environment. This green-sand mixture was prepared with 8.8 pounds (4,008 grams)
of return molding sand from an iron foundry in Wisconsin (round grain silica), and 0.17 pounds
(78 grams) of Preblend used on the foundry’s molding line. The sand mixture was “dry mulled”
for one minute and water was added to the prepared sand mixture for four minutes in order to
meet the targeted compactability of 40% (±2%). This prepared sand mixture was evaluated for
percent moisture; specimen weight in grams; percent compactability; green compressive strength
in pounds per square inch; permeability; wet tensile in newtons per square centimeters; dry
compressive strength in pounds per square inch; cone jolt toughness (represented in number of
jolts); friability as a percentage of methylene blue clay; and loss on ignition as a percentage. The
sand properties were tested at four-minute and eight-minute mull times.
In order to evaluate the impact of “new sand” on a prepared green-sand system, a series of
prepared sand mixtures were produced. The testing laboratory prepared sand mixtures with the
same 9-lb (4,086 grams) batches, except the laboratory removed an incremental amount of return
molding sand from the Wisconsin foundry and replaced it with the desired quantity of new base
sand used in that facility (round-grain silica). The mixtures were mulled again for four and eight
minutes (as indicated) with the same testing completed on the prepared sand to the desired
compactability of 40% (± 2%). The first test run included addition rates of the new sand from 10
to 60%, in increments of 10%. Obviously, the final sand mixture was prepared with a
predominance of new sand versus molding sand. The testing team felt that this is not uncommon
in large automotive foundries with high levels of core-sand dilution. In subsequent test runs,
percentages from 2 to 35% were tested to ensure sufficient addition rates were studied.

Testing results
Evaluation of primary sand testing properties: Most foundries use compactability testing and
moisture content as the primary quality-assurance control. The tests can be evaluated “in-line”
with controls at the mulling and molding areas or in the laboratory testing facility. With this
concept in mind, the comparison of these properties is critical. The relationship of the moisture
requirement to the desired compactability is critical. Figure 1 compares the compactability
measurement of the prepared sand mixture (after four minutes mulling) versus the moisture
requirement to meet 40% (±2%) with the varying amounts of the new sand addition. (See Figure
1 on p. 47.)
The comparative data shows that as the quantity of new sand increases the moisture level
required to produce the desired compactability (40%, ±2%) decreases. This results in an increase
in the compactability-to-moisture ratio. This is logical because the addition of new sand does not
have the oolitic layers on the regular molding sand, which requires an increase in moisture
content to meet the desired compactability.
It has been documented in the AFS publication, Back to Basics: A Green Sand Primer, that a
“well mulled green sand for high-density molding will often display a compactability-to-
moisture ratio of 10.5 to 12.1. The test data in this study reveals this to be true up to the 40%
level of new sand addition. Considering the desired compactability-to-water ratio referenced and
the information determined in this investigation, the sand addition has an impact on molding-
sand properties.
Evaluating “secondary” testing properties: A typical foundry will rely on certain green-sand
testing methods used daily in their process control areas. These include (but are not limited to):
green compressive strength, specimen weight, permeability, and methylene blue clay tests. For
this testing protocol, the investigators held the methylene blue clay content constant so that there
was little or no impact on this investigation. Therefore, the comparison of data found in Figure 2
(see p. 52) is a comparison of the impact that additions of new sand have upon the green
compression strength, specimen weight, and permeability.
To gain a better understanding of the specific data developed in the laboratory investigation,
Figure 3 (see p. 52.) is a graphic presentation of this information gathered in the testing
laboratory when the specimen weight evaluation was completed.
This series of testing evaluations was not unexpected. It is logical to assume that as the new-sand
addition increases, the specimen-weight density should increase. The green compressive strength
and the permeability should have changed accordingly.
Evaluating additional testing properties: A green-sand testing laboratory has many “tools”
available to help understand the characteristics of molding sand. In this investigation the
following additional tests were conducted: wet tensile properties, cone jolt toughness, friability,
loss on ignition, and dry compression strength. These test methods have been investigated at
length and referenced in AFS Transactions and other publications. Figure 4 (see p. 53) is a
representation of the resulting data at multiple mulling considerations (four and eight minutes.)
As stated previously, the data resulting from the testing evaluations were not unexpected. The
wet tensile test is an excellent method for evaluating the molding sand “just below” the surface.
Any time there is an increase in the sand’s wet tensile properties, it is a “good thing”. When
evaluating the cone jolt toughness properties, the test is a good method for determining the
“toughness” of the molding sand (or simply the ability to “draw” a deep pocket of sand.)
Similarly, an increase in this physical property is a “good thing.”
When evaluating results of the friability test, note that the lower number, the better are the
effects. When new sand is added to molding sand, it has been observed in actual foundry
conditions to increase the friability percentage. This investigation observed a decrease in
friability, and this should be considered “desirable.” The loss on ignition test was a good
indicator of the sand dilution study itself. As expected, as more new sand is added to molding
sand, the loss on ignition should become lower.
The reason for this decrease in the loss on ignition is that the oolitic layers that occur on molding
sand contribute to the material’s volatility. For this investigation, the final property evaluated
was the changes in the dry compression strength. The increase in the dry compression strength
can be related to the bonding characteristics of the clay itself. Figure 5 (see p. 53), Figure 6 (see
p. 58), and Figure 7 (above) illustrate some of the changes in properties that occurred at various
new-sand dilution rates.

New sand addition study conclusions

The foundry industry consumes a large quantity of new sand. Regardless of the type (round-grain
silica, lake sand, etc.), it is important to understand the impact that large quantities of new sand
will have on the molding sand properties. In general:
• Moisture content should decrease.
• Compactability-to-moisture ratio should increase.
• Specimen weight should increase.
• Green compression strength should decrease slightly.
• Permeability should increase.
• Wet tensile properties should increase.
• Cone jolt toughness should decrease.
• Friability should decrease up to 30% new sand additions.
• Loss on ignition should decrease.
• Dry compression strength should increase up to 30% new sand additions.

Future testing
As stated, the CISA Green Sand Committee will continue the work on this project with particular
emphasis to the dilution of core sand into green sand. In order to understand the impact that
“core sand dilution” has on green-sand molding properties, it was important to study the
relationship that new sand has on green sand simply within the parameters of “dilution.” Many
times core-sand dilution is blamed for negative effects on the molding sand, without considering
the simple concept of the dilution of sand into the molding sand itself. This investigation was
designed to supply information to our understanding of dilution by any source (new sand or core
sand) of materials into molding sand.
Sara Joyce, Mark Ziegler, and Vic LaFay are members of the Casting Industry Suppliers Assn.
Green Sand Committee.
Sara Joyce is vice president of technical support for Badger Mining Corp. Mark Ziegler is
director of foundry technical sales with Unimin Corp. And, Vic LaFay is vice president of
research and technical development with Hill & Griffith Co.
The authors express thanks to CISA and its member companies for their contribution to this
proje