Challenges and Future Prospective of Alternative Materials to Silica Sand for Green Sand Mould Casting: A Review

Sadarang, Jatin; Nayak, Ramesh Kumar; Panigrahi, Ishim

doi:10.1007/s12666-021-02370-y

Cited by 6 publications

(5 citation statements)

References 115 publications

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“…Sand casting is one of the basic metal processing methods, extensively employed in sectors such as aerospace, aeronautics, power equipment, automobiles, mechanical manufacturing, etc. [ 1 , 2 , 3 , 4 ]. Currently, there is a growing demand for high-end castings such as single-crystal blades, rocket barrel bodies, missile hulls, etc.…”

Section: Introductionmentioning

confidence: 99%

Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures

Xu,

Kang,

et al. 2024

Materials

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Casting, as a fundamental process in metal forming, finds widespread applications in the manufacturing industry. The advent of 3D printing hollow sand mold technology presents a novel method for casting technology to revolutionize traditional dense sand molds, offering increased flexibility in achieving quality control and improvement in casting processes. Consequently, this study delves into an examination of the mechanical strengths of 3D-printed sand molds with complex hollow structures and further investigates the influence of hollow sand mold concession on castings. The results indicate that compressive and high-temperature residual tensile and bending strengths vary in hollow structures. Multi-layer shells have greater high-temperature residual tensile, compressive, and bending strengths than truss hollow sand molds with roughly the same hollow volume fraction. Compared to dense sand molds, hollow sand molds, which have a lower mechanical strength, have better retractability, which helps reduce the residual stress and crack tendency of castings. The breaking of hollow structures is limited to local areas, unlike the penetrative cracking of dense sand molds. The I-beam-shaped casting test results indicate that a hollow structure is beneficial for the preservation of the integrity of a sand mold during the casting process. Compared to dense and truss hollow molds, a multi-layer shell hollow sand structure has the comprehensive advantages that it improves retractability while maintaining strength relatively well, reduces the residual stress, and avoids cracks in castings and itself.

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Section: Introductionmentioning

confidence: 99%

Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures

Xu,

Kang,

et al. 2024

Materials

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“…National Steel Policy estimates 200 million tonnes of steel production in India by the year 2025 with more than 500 million tonnes of Iron ore requirement to be met by that time period [4]. Iron and steel production in India also accounts for more than 10 million tonnes of slag production per year [5]. This slag has the potential to serve as raw material for foundry and cement industries as a replacement for costly silica sand (SiO 2, Al 2 O 3 , Fe 2 O 3 ) [5].…”

Section: Introductionmentioning

confidence: 99%

“…Iron and steel production in India also accounts for more than 10 million tonnes of slag production per year [5]. This slag has the potential to serve as raw material for foundry and cement industries as a replacement for costly silica sand (SiO 2, Al 2 O 3 , Fe 2 O 3 ) [5]. Proper utilization of slag produced along with the optimization of production techniques in a fast and efficient manner is, therefore, the key to scaling up future production [6].…”

Section: Introductionmentioning

confidence: 99%

Optimization of high alumina slag practice in blast furnace ironmaking: an industrial approach (PART 1: fundamental aspects)

Hazra,

Pal,

Biswajeet

et al. 2023

Ironmaking & Steelmaking

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The productivity of the blast furnace Ironmaking process is significantly dependent on the slag chemistry. The presence of compounds like Al 2 O 3 in high quantities can make the hearth slag highly viscous and difficult to tap. The objective of part-1 of this study is to provide a comprehensive analysis of the role of high alumina (Al 2 O 3 > 15%) compositions in the blast furnace slags. Slag viscosity, liquidus temperature, activation energy, etc., are critically reviewed with respective solutions to operate under the desired conditions. Flow parameters of the slag are examined to understand the melting-softening phenomena which directly affect the slag tap-totap time. The addition of certain additives to the slag system has also been studied with the aim to improve the target properties of the slag. A range of slag compositions and their optimization techniques are discussed in this part to provide greater insight into the topic.

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“…The new sources not only reduce the cost of casting products but also meet the scarcity of silica sand. Researchers and scientists are investigating the feasibility of industrial waste such as fly ash [4][5][6][7][8], ferrochrome slag [9,10], blast furnace slag [11][12][13][14], riverbed sand [15], and red mud [16] as an alternative to silica sand for sand mold casting process. On the other hand, some of the foundry industries are far away from the location where the silica sand having high SiO 2 content is available and they pay higher transportation costs, leading to an increase in the price of sand-casting products.…”

Section: Introductionmentioning

confidence: 99%

A Study on the Suitability of Mahanadi Riverbed Sand as an Alternative to Silica Sand for Indian Foundry Industries

Nayak

Sadarang

2022

Trans Indian Inst Met

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The availability of silica sand is diminishing and as a result, the price of silica sand increasing. Therefore, there is a need to evaluate the suitability of local riverbed sand for nonferrous alloy casting in Indian foundries. The present investigation focuses on the suitability of Mahanadi Riverbed Sand (MRS) for nonferrous alloy casting. The sand particle size, chemical composition, density, and fusion point, are evaluated and found suitable for nonferrous alloy casting. The mold ingredients are designed and optimized through the design of the experiment and response surface methodology, respectively. It is found that 11.5 wt.% of bentonite clay, 5 wt.% of moisture, and 3.5 wt.% of coal dust is suitable to achieve the desire sand mold properties. The fusion point of MRS shows that it is not suitable for ferrous casting. Therefore, aluminum alloy (A356) casting is performed using MRS and silica sand mold. The as-cast surface roughness (R a ), hardness, and microstructures of A356 alloy casting are evaluated and compared between MRS and silica sand mold castings. It is observed that the mechanical properties of MRS mold casting are better than silica sand mold casting and may be used as an alternative to silica sand for aluminum alloy casting in Indian foundry industries.

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Challenges and Future Prospective of Alternative Materials to Silica Sand for Green Sand Mould Casting: A Review

Cited by 6 publications

References 115 publications

Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures

Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures

Optimization of high alumina slag practice in blast furnace ironmaking: an industrial approach (PART 1: fundamental aspects)

A Study on the Suitability of Mahanadi Riverbed Sand as an Alternative to Silica Sand for Indian Foundry Industries

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