2012

QUALITY CONTROL

SEKHAR 111263 GREENTECH INDUSTRIES

Tests at quality control (QC)

AUTOMATIC

MANUAL

GREEN SAND

MOISTURE COMPACTIBILITY SAND TEMPERATURE PERMEABILITY GREEN COMPRESS STRENGTH

MOISTURE LOSS ON IGNITION ACTIVE CLAY TOTAL CLAY A.F.S BEFORE WASH A.F.S AFTER WASH

BENTONITE

MOISTURE LOSS ON IGNITION GRAIN SIZE SWELLING CAPACITY M.B VALUE TESTING

SEA COAL

MOISTURE GRAIN SIZE ASH TESTING VOLATILE TESTING

GREEN SAND: The sand temp, moisture, compactibility, permeability, green compress strength are tested in automatic green sand property tester. Whereas, moisture, grain size, active clay, total clay, A.F.S after wash, A.F.S before wash are tested manually. Moisture is tested by taking the green sand sample of 100gms each in two baker pans. Put these baker pans into infrared drier and on the timer knob for 15 min after 15min just mix the sample and keep it in infrared drier for more 15 min. after that weight those samples and record the values and average is calculated. Note: you will observe the reduction in weight The moisture is calculated by the formula: X = Q1-Q2/Q1 * 100 Loss on ignition is tested by taking the moisture tested sample of 25gms each in two crucibles and then placing it into the muffle furnace at a constant temp of 10000c and burn for 2 hours and allows it to cool in room temperature. Loss on ignition is calculated by the formula: LOI = G-G1/G*100 Active clay is tested by taking 5gms of sample in a filter paper and then into the conical flask. Measure 50ml of 2% sodium pyrophosphate solution into the volumetric conical flask and heat it with the help of electric heater for 5min from the time of formation of bubbles. Take 50ml of methylene blue solution in a burette and do dot test a light blue halo should be formed thats the M.B point. Active clay is calculated by the formula: M.B VALUE/5.7 Total clay is tested by taking 50gms of moisture tested sample in a washing cup and add 25ml of 2% sodium pyro phosphate solution , 375ml hot water and place it on the electric heater for 5min from the time of formation of bubbles and then place it in a SXW-II vortex sand washer for 15min as it mixes the contents and then take this into the SXX-B auto siphon sand washer for a period of 4 hours and then with the filter paper separate the water content and sand and then place the sample in infrared drier as same as moisture and then record the weight. Total clay is calculated by the formula: X = Q-Q1/Q*100 A.F.S after wash is tested for the total clay sample the sample is put on sieves and sieved for 15min in vibrating sieve shaker and grain size is calculated. A.F.S before wash is tested by taking 50gms of moisture tested sample into the sieves and these sieves are sieved by the vibrating sieve shaker for a time of 15 min and then these sieves are taken and weighed and note down each of its values .

BENTONITE: It is used to improve the bonding strength of the green sand. The following tests are conducted for the bentonite. Moisture is tested by taking 20gms in a petri dish. First the empty dish is weighed and heated in electric thermal drier and then 20gms sample is taken and kept into electric thermal drier for 2-2.5 hours and then the sample is taken and weighed. Moisture is calculated by the formula: G-G1/G*100 Loss on ignition is calculated by taking 8gms from the moisture tested sample in a crucible which has been burned stable at 980100c. Put crucible into 1000100c and burn for 2 hours. Take out the crucible and weight it after cooling at room temperature. Loss on ignition is calculated by the formula: LOI = G-G1/G*100 Grain size testing is calculated by taking 20gms bentonite at room temperature into 200 mesh sieve. Shake the sieve until no bentonite pass through the sieve. Weight the sample on base pan. Grain size is calculated by L = Q1/Q*100 Swelling capacity is tested by taking 100ml distilled water in a measuring cylinder. Weigh baked bentonite 2gms and put into cylinder for several times nearly 10-20 times. Observe volume of sediment in cylinder after all bentonite put into cylinder. Put cylinder at stable place wait for 24 hours record the volume of sediment which is bentonite swelling capacity. M.B value testing is same as active clay test done for green sand. Measure 50ml 2% sodium pyrophosphate solution and weigh baked bentonite 0.3gms into the flask. Heat the flask for 5 min after the formation of bubbles and then with the methylene blue solution do the dot test. Record the no.of.millimeters of M.B solution Formula for the calculation of M.B value is: (A*B/C)*100 Where A = Methylene in 1ml solution B = Quantity of millimeters of M.B solution C = Sample weight.

SEA COAL: It is used to produce the reduction gases and to prevent the oxidation of molten iron. It fills the gap between the sand grains and improves the bonding strength and also helps in obtaining smooth surface of the casting. MOISTURE is tested by taking 1gm of sample at a temp of 105+/-50c. Weigh it after half an hour and place it again in the drier for more half an hour and weigh it repeat this process until no weight is decreased. Calculate the moisture by using the formula: G-G1/G*100.

GRAIN SIZE is tested by taking 10gms of sample in a 140 mesh sieve and sieve it until no sample pass through the mesh. Weigh the sample on base pan and grain size is calculated by the formula: Q1/Q*100

ASH is tested by taking 1gm of sample in an ashing crucible which is being weighed stable at 980+/-100c. Keep the sample into muffle at a temperature below 1000c and then increase the temperature to 5000c . the temperature should raise in 30 minutes and hold the temperature at 5000c for half an hour and then increase the temperature to 8150c and hold the temperature for 1 hour and then cool the crucible and weigh it and ash is calculated by the formula G1/G*100

VOLATILE is tested by taking 1gm sample and keep it in muffle at a temperature of 920 c. When the muffle opened the temperature decreases and when it closed the temperature should raise to 9000c in just 3 minutes otherwise the test is failed. The sample is burned for 7 minutes and allows it to cool to room temperature and weighed and it is calculated by the formula G-G1/G*100-W
0

Where W = moisture content

- STARCH: This is used to improve the surface finish of the casting. Various tests conducted for starch are: Moisture is tested by taking 10gms in a petri dish. First the empty dish is weighed and heated in electric thermal drier and then 20gms sample is taken and kept into electric thermal drier for 2-2.5 hours and then the sample is taken and weighed. Moisture is calculated by the formula: G-G1/G*100

ASH is calculated by taking 4gms from the moisture tested sample in a crucible which has been burned stable at 980100c. Put crucible into 1000100c and burn for 2 hours. Take out the crucible and weight it after cooling at room temperature. Loss on ignition is calculated by the formula: LOI = G1/G*100

GRAIN SIZE is tested by taking 20gms of sample in a 70 mesh sieve and sieve it until no sample pass through the mesh. Weigh the sample on base pan. Grain size is calculated by the formula: Q1/Q*100

Silica sand testing: Moisture is tested by taking the green sand sample of 100gms in a baker pan. Put this baker pan into infrared drier and on the timer knob for 15 min after 15min just mix the sample and keep it in infrared drier for more 15 min, after that weight those samples and record the values and average is calculated. Note: you will observe the reduction in weight The moisture is calculated by the formula: X = Q1-Q2/Q1 * 100 Loss on ignition is tested by taking the moisture tested sample of 10gms each in two crucibles and then placing it into the muffle furnace at a constant temp of 10000c and burn for 2 hours and allows it to cool in room temperature. Loss on ignition is calculated by the formula: LOI = G-G1/G*100 Total clay is tested by taking 50gms of moisture tested sample in a washing cup and add 25ml of 2% sodium pyro phosphate solution , 375ml hot water and place it on the electric heater for 5min from the time of formation of bubbles and then place it in a SXW-II vortex sand washer for 15min as it mixes the contents and then take this into the SXX-B auto siphon sand washer for a period of 1.5 hours and then with the filter paper separate the water content and sand and then place the sample in infrared drier as same as moisture and then record the weight. Total clay is calculated by the formula: X = Q-Q1/Q*100 Grain size is tested by taking 100gms of room temperature sample into the sieves and these sieves are sieved by the vibrating sieve shaker for a time of 15 min and then these sieves are taken and weighed and note down each of its value Ph is tested by taking 50 gms of heated sample in a 100ml cup with 100ml water in it and then keep it undisturbed for 1 hour and then check the Ph using Ph meter until got a constant value. Acid consumption test is tested by taking 50gms of heated silica sand in a 200ml cup with 50ml water in it. Take another 200ml cup with only 50ml water in it. Now mix 50ml HCl in both silica sand and water, titrate it for a span of 5 minutes and then keep it undisturbed for 1 hour. Now separate sand and water using filter paper and conical flask and again mix 50 ml water slowly and separate using filter paper. Add 10 drops of bromothymol blue solution in both the sand separated water and pure water. Take 50ml NaOH in burette and titrate it until it changes it colour i.e.; from yellow to blue. Acid consumption value is calculated by the formula: Volume of NaOH (water sample) - Volume of NaOH (silica sand sample)

Various solution preparations: 2% sodium pyrophosphate solution: Weight 20 gms of sodium pyrophosphate by electric balance , put into 1000ml chemical bottle. Measure 1000ml distilled water and pour into the bottle, stir the solution until sodium pyrophosphate fully dissolved in water. It can be used for 2 months from the date of preparation. 0.01 mol/l methylene blue solution: Weight 3.739gms of methylene blue solution and put into 1000ml brown chemical bottle, measure 1000ml distilled water pour into bottle now stir it until methylene blue fully dissolved in water. It can be used for 1 month from the date of preparation. Bromothymol blue(1gm/L): Weight 1gm of methylene yellow and 1000ml of ethyl alcohol in a brown chemical bottle, titrate for few minutes. It can be used for 6 months from the date of preparation. Dilution of HCl: measure 8.33ml of concentrated HCl and 1000ml distilled water in a 1000ml chemical bottle and titrate it for few minutes and place a tag on it with the date of expiry. It can be used for 6 months from the date of preparation NaOH Solution preparation: weight 4 gms of NaOH and mix it with 1000ml water in 1000ml chemical bottle and titrate it until fully NaOH dissolved in water. It can be used for 6 months from the date of preparation