Carbon-Dioxide Gas Molding

This process was widely used in Europe for rapid hardening the molds and
cores made up of green sand. The mold making process is similar to
conventional molding
procedure accept the mould material which comprises of pure dry silica sand
free from
clay, 3-5% sodium silicate as binder and moisture content generally less than
3%. A
small amount of starch may be added to improve the green compression
strength and a
very small quantity of coal dust, sea coal, dextrin, wood floor, pitch, graphite
and sugar
can also be added to improve the collapsibility of the molding sand. Kaolin
clay is added
to promote mold stability. The prepared molding sand is rammed around the
pattern in
the mould box and mould is prepared by any conventional technique. After
packing,
carbon dioxide gas at about 1.3-1.5 kg/cm2 pressure is then forced all round
the mold
surface to about 20 to 30 seconds using CO head or probe or curtain as
shown in Fig.
12.14. The special pattern can also be used to force the carbon dioxide gas
all round
the mold surfaces. Cores can be baked this way. The sodium silicate
presented in the
mold reacts with CO2 and produce a very hard constituents or substance
commonly
called as silica gel.
This hard substance is like cement and helps in binding the sand grains.
Molds and
cores thus prepared can be used for pouring molten metal for production of
both ferrous
and nonferrous casting. The operation is quick, simple require semi-skilled
worker. The
evolution of gases is drastically reduced after pouring the thus prepared
mould. This
process eliminates mold and core baking oven. Reclamation of used sand is
difficult for
this process.

Machine Molding
For mass production of the casting, the general hand molding technique
proves un economical
and in efficient. The main advantage of machine molding, besides the saving of
labor and
working time, is the accuracy and uniformity of the castings which can otherwise
be only
obtained with much time and labor. Or even the cost of machining on the casting
can be
reduced drastically because it is possible to maintain the tolerances within
narrow limits on
 casting using machine molding method. Molding machines thus prepare the
moulds at a
faster rate and also eliminate the need of employing skilled molders. The main
operations
performed by molding machines are ramming of the molding sand, roll over the
mold, form
gate, rapping the pattern and its withdrawal. Most of the mold making operations
are performed
using molding machines