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Introduction
Foundry sand is high-quality uniform silica sand that is used to make molds and Cores for ferrous and nonferrous metal castings. The metal casting industry annually uses an estimated 100 million tons of foundry sand for production. Over time, foundry sands physically degrade until they are no longer suitable for molds and discarded. These have remarkably consistent composition and are typically considered a higher quality material than typical bank run or natural sands used in construction. Currently, an estimated 28% of discarded sand is reused in primarily construction related applications, while the remaining sand is disposed of in landfills.
the
refractoriness. The presence of alkalis K20, Na20 is undesirable; refractory clays provide high temperature bond in sand.
Moisture content -Clays should preferably have 6-12% moisture as determined by loss in
weight on drying for 4 h. at 105-110"C.
pH Value -8.2 indicate good clay. 8 g of clay is taken in 100 ml of distilled water for pH
measurement.
Bonding Properties
Chromite sand -Chromite sand is a solid solution of spinels. It has a very high
fusion point (1,850 C (3,360 F).
Chamotte sand -Chamotte is made by calcining fire clay (Al2O3-SiO2) above 1,100
C (2,010 F). Its fusion point is 1,750 C (3,180 F)
EXPERIMENTAL WORK
In order to envisage the characteristics of foundry sand, the following laboratory investigations were carried out.
A basic set of parameters to test are:
Fineness number (grain size/AFS Number) of the base sand