Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique

Prabhakar, Arun; Salonitis, Konstantinos; Jolly, Mark

doi:10.1007/978-3-030-06034-3_27

Cited by 5 publications

(6 citation statements)

References 6 publications

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“…Hence, the effect of these parameters on the formation of defects on the surface was investigated. Moreover, the use of pure lead does not result in the mottled appearance on the top sheet surface, which is one of the most characteristic and desired properties of cast lead sheet [8]; thus, most foundries use a mix of pure (refined) and scrap lead. This factor was also included in the study as defects could also be caused due to the melt quality or interaction between the melt and the mould.…”

Section: Df Ss Msmentioning

confidence: 99%

“…There are three main methods for manufacturing lead sheet, namely: (a) rolling (also referred to as milling), (b) continuous casting and (c) sand casting [4, 7,8]. Amongst the aforementioned methods, rolling and continuous casting are often preferred due to their low cost and thickness consistency.…”

Section: Introductionmentioning

confidence: 99%

“…Despite being the oldest and most traditional method, sand casting is still being used nowadays for the production of sheets for roofing, flashing and plumbing applications in the heritage industry as well as the renovation of old churches, cathedrals, castles and state homes. Sand cast sheets have a more attractive sheen compared to the ones manufactured via rolling or continuous casting methods; the top side (exposed to the atmosphere during casting) has a shiny mottled appearance while the bottom side (surface in contact with the sand bed) retains the texture of the sand [8].…”

Section: Introductionmentioning

confidence: 99%

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Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Prabhakar

Papanikolaou

Salonitis

et al. 2020

Metals

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Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

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Section: Df Ss Msmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Prabhakar

Papanikolaou

Salonitis

et al. 2020

Metals

Self Cite

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“…The lead sheet sandcasting process essentially consists of two main stages, namely: (a) pouring molten lead on a sand bed and (b) smearing of the melt surface using a strickle [10]. The process starts with preparing the rectangular sand mould, usually 3 -7 m long and 0.75 -1.3 m wide.…”

Section: Introductionmentioning

confidence: 99%

“…After pouring, the strickle which is guided by a screed rail is used to smear the flowing melt along the mould ( Figure 2) and seconds later, the melt solidifies into a sheet. Although both continuous casting and rolling of lead sheet have been investigated using both numerical and experimental studies ( [11][12][13][14][15][16]), the lead sheet sandcasting technique has not been thoroughly investigated yet, with the exception of a recent study [10], focused on characterising the mechanical properties of sand cast lead sheet. It is evident that there is still limited knowledge in this area with respect to the effects of process parameters, such as the pouring temperature and strickle velocity, on the quality of the final cast product.…”

Section: Introductionmentioning

confidence: 99%

Sand casting of sheet lead: numerical simulation of metal flow and solidification

Prabhakar

Papanikolaou

Salonitis

et al. 2019

Int J Adv Manuf Technol

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Sandcast lead sheets are characterised by their superior aesthetic performance and mottled surface. Lead sheet casting is widely used in the construction industry for roofing and flashing applications, while the roots of this process can be tracked back to the Roman times. In this study, two-dimensional Computational Fluid Dynamics (CFD) simulations have been performed to simulate the melt flow and solidification stages of the lead sandcasting process. The effects of process parameters such as pouring temperature, screed velocity and clearance between the screed and the sandbed on the final quality of the lead sheet are investigated. Lead sheet quality has been quantified by measuring the variance and the average value of the final sheet thickness over the sandbed length. The developed CFD model has been validated against experimental results by comparing the time evolution of the lead-sandbed interface temperature against data collected by thermocouples during the real-time process. The numerical results show that all of the aforementioned parameters affect the final quality of the cast product and suggest that superior quality lead sheets can be produced for a range of relatively low values of the pouring temperature and slow strickle motion.

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Ancient Lead, Mercury, and Tin

Colás

2021

Reverse Engineering of Ancient Metals

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Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique

Cited by 5 publications

References 6 publications

Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Sand casting of sheet lead: numerical simulation of metal flow and solidification

Ancient Lead, Mercury, and Tin

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