Investigation of the Foundry Properties of the Locally Available Sands for Metal Casting
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ORIGINAL PAPER
Investigation of the Foundry Properties of the Locally Available Sands for Metal Casting Prafulla Kumar Sahoo 1 & Sarojrani Pattnaik 1 & Mihir Kumar Sutar 1 Received: 1 May 2020 / Revised: 25 August 2020 / Accepted: 27 August 2020 # Springer Nature B.V. 2020
Abstract Utilization of locally available sands for building moulds for sand casting will reduce the production cost and time as compared to procured sands. In the present study, the foundry properties of the locally available sands namely, mined silica river and beach sands have been investigated to check their suitability for metal casting. Different physical and mechanical tests were conducted on the chosen sand samples. Aluminium alloy was cast in all mould types and its cast properties such as volumetric porosity and surface roughness (SR) i.e. Ra value were determined for comparison. The foundry test results showed that the beach sand was the finest possessing highest grain fineness number (GFN) of 64 and the mined silica sand was the roughest, possessing lowest GFN of 44 among all sand samples. The pH value of all the sands was more than 7 which represents their good bonding ability with the binder. The mould’s permeability and strengths was found to decrease and increase with rise of 5–30% clay content in all cases. The mined silica sand mould demonstrated highest permeability in contrast to other sand moulds. The Al-Si alloy castings obtained from the mined sand mould exhibited minimum porosity with acceptable surface roughness. Keywords Sand . Moisture content . Permeability . Green compression strength
1 Introduction Sand is the main moulding material utilized for casting different metals in foundries. As a result, it plays an important role in foundry due to its refractory nature. This nature of sand enables the mould to withstand its shape at high temperatures of molten metal without being fused with the melt. Due to its chemical resistivity, it does not react chemically or combine with molten metal and for this nature, it can be used frequently. The silica sand mould should possess substantial amount of permeability without affecting the strength so as to eradicate hot air and gases out of it. Foundry sand should possess characteristics like cleanliness, uniformity in size with an adequate amount of silica and good bonding nature. It must be free from dirt that can result in producing scabs on the surface of the casting [1]. Clay produce good bonding between the sand grains and it gives strength to the moulding sand so that the shape of the * Sarojrani Pattnaik [email protected] 1
Department of Mechanical Engineering, VSSUT, Odisha Burla, India
mould cavity can be retained. There should be an optimal addition of binder in the sand mixture because it adversely affects the mould’s permeability, though it favours the green compression strength (GCS) of the mould [2]. Bentonite clay is used in many industries like foundry, cosmetics, ceramics, polymer nanocomposites. The foundry industries require several raw materials to prepa
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