Investigation of the Foundry Properties of the Locally Available Sands for Metal Casting

Sahoo, Prafulla Kumar; Pattnaik, Sarojrani; Sutar, Mihir Kumar

doi:10.1007/s12633-020-00677-x

Cited by 9 publications

(5 citation statements)

References 7 publications

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“…The volumetric porosity and surface roughness (SR), measured in terms of the Ra value of cast aluminium alloys from various moulds, were compared. The volumetric porosity (mean value in %) is found to be 3.84, 4.56, 4.12 and surface roughness (R a in µm) is found to be 3.8, 2.2, 2.7 for mined silica sand, beach sand and river sand respectively (Sahoo et al, 2021).…”

Section: Introductionmentioning

confidence: 90%

Effective Utilization of Industrial and Constructional Solid Waste Materials in Foundry Mould Making to Prevent Environment Pollution and Conserve Natural Silica Sand

2023

Global NEST: The International Journal

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<p>Green sand moulding uses silica sand for metal casting. Silica sand mining and delivery to foundries destroy the ecosystem, making metal casting unsustainable. Due to increased sand-casting output and massive civil buildings in India, the silica sand supply is declining. The depletion and shortage of silica sand necessitate the search for viable replacements. Industrial solid waste from large-scale industrialization pollutes land, air, and water. In order to use industrial waste in large amounts, an attempt is made to use it as a replacement for natural resources. The main objective of this research is to reduce the consumption of silica sand in the foundry mould-making process. Silica sand is replaced with industrial solid waste, cupola slag, and construction solid waste sources like spent fire bricks and quarry dust, up to a considerable amount, to save the natural resources. Utilization of solid waste material in the mould-making process will reduce production costs and environmental pollution, like dumping solid waste materials on land. Sand tests like permeability, green compression strength, dry compression strength, and compactability were conducted to assess the moulding properties of these alternative moulding materials. The process parameters considered for this investigation were the percentage of bentonite binder and the percentage addition of alternative mould materials with silica sand. The various sand tests showed that 40%, 30%, and 20% of quarry dust, spent fire bricks, and cupola slag, respectively, will adequately replace silica sand for mould making. A bentonite binder of 8% is suitable for quarry dust mould, and a 10% bentonite binder is required for spent fire brick particles and cupola slag to yield better results. Aluminium castings were produced at the optimal mixture of these solid waste particles and silica sand. The results of mechanical tests such as hardness, tensile, and impact tests are comparable to those of silica sand castings.</p>

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Section: Introductionmentioning

confidence: 90%

Effective Utilization of Industrial and Constructional Solid Waste Materials in Foundry Mould Making to Prevent Environment Pollution and Conserve Natural Silica Sand

2023

Global NEST: The International Journal

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“…Therefore, local river sand can be used in the sand mould casting [139]. The chemical composition of local river sand, beach sand, and mined sand is reported in Table 6 [9]. The green compressive, shear and dry compressive, and shear strength of river, beach, and mined sand mould increases with the increase in binder concentration as shown in Fig.…”

Section: Other Waste Materialsmentioning

confidence: 99%

“…However, mould permeability decreases due to less particle size of the binder. The Al-Si alloy casting produced by mined sand mould has less porosity [9]. As the demand for silica sand increases, river sand mining and cost also increase.…”

Section: Other Waste Materialsmentioning

confidence: 99%

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

Sadarang

Nayak

Panigrahi

2021

Trans Indian Inst Met

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Near-net shape casting having complex geometry is manufactured through the sand casting process. However, day by day, the availability of natural or synthetic silica sand has been decreasing and increasing the production cost of sand casting components. Therefore, there is a need to look into low-cost and readily available alternative materials to substitute the commercial-grade silica sand for the sand mould casting process. The constituent of silica sand is primarily silica (SiO 2 ), Al 2 O 3 , and Fe 2 O 3 . The major constituents of industrial wastes such as fly ash, blast furnace slag, ferrochrome slag, stone dust, and red mud have SiO 2 , Al 2 O 3 , and Fe 2 O 3 . Therefore, industrial wastes may be used individually or combined with silica sand at a different ratio to substitute the commercialgrade silica sand in green mould castings. Researchers and scientists have evaluated the suitability of industrial wastes and local riverbed sand as an alternative material for green sand mould castings. The present review summarizes the advantages and constraints of using industrial wastes and local riverbed sand as an alternative to green sand mould casting process.

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“…The authors showed how the peak pressure varies for samples with varying grain size distributions. Sahoo et al [ 13 ] investigated the foundry properties of locally available sand. In their work, they emphasized the importance of the grain fineness number (GFN) as a critical foundry sand property and its effect on the permeability of prepared cores.…”

Section: Introductionmentioning

confidence: 99%

On the Relation between the Gas-Permeability and the Pore Characteristics of Furan Sand

Sundaram

Svidró

et al. 2021

Materials

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Furan sand is one of the most commonly used chemically bonded molding materials in foundries across the world. It consists of a furfuryl alcohol-based resin and an acid-based liquid catalyst. When the molding material comes in contact with the molten metal, it undergoes a thermal shock accompanied by a certain release of volatile gases. In order to evacuate these gases, molds and cores should have optimal gas permeability values and proper venting by design. If the volatile compounds are not appropriately evacuated, they are prone to enter the melt before the first layer of solidified metal is formed which can lead to the formation of gas-related casting defects. Standard gas permeability measurements are commercially available tools used in the industry to compare and to quality control different sands, however, they only provide reference numbers without actual units. Permeability in a standard unit, m2, provides uniformity and helps the comparison of results from difference sources. In this paper, a new method using Darcy’s law (prevalent in earth sciences), was adapted to measure the gas-permeability of furan samples made of silica sand with various grain size distributions. The effect of grain size distribution on the gas-permeability of furan sand samples was studied. Gas-permeability values in m2 were then correlated with mercury-porosity measurement results to bring new light on the relation between pore size, pore volume and the permeability of molding materials.

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Investigation of the Foundry Properties of the Locally Available Sands for Metal Casting

Cited by 9 publications

References 7 publications

Effective Utilization of Industrial and Constructional Solid Waste Materials in Foundry Mould Making to Prevent Environment Pollution and Conserve Natural Silica Sand

Effective Utilization of Industrial and Constructional Solid Waste Materials in Foundry Mould Making to Prevent Environment Pollution and Conserve Natural Silica Sand

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

On the Relation between the Gas-Permeability and the Pore Characteristics of Furan Sand

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