SAND CASTING

MOLD AND MOLD MAKING

Schematic of foundry sand processes and material flows

The Foundry Sand

Most common sand to used Silica (SiO2) or silica mixed with other minerals

Important features of foundry sands: Good refractory properties - capacity to endure high temperatures without melting Grain size - small better surface finish on the cast part - large more permeable, allowing gases to escape during pouring Distribution of grain size in the mixture Shape of the individual grains irregular shapes is stronger because of interlocking, compared to round grains Disadvantage: interlocking tends to reduce permeability

Selection of Sands
Smaller grain size results in a good surface finish

Irregular grain shapes produce stronger mould

Larger grain size ensures better permeability - Allow gases and steam escape

Ingredients of Moulding Sands

Mold material The grains of sand are held together by a mixture of water and bonding clay
Control of the moisture content of the molding sand Coats the clay flakes surface, help in bonding develop strength

Water 3% Clay 7%

Bonding agent Source of the strength and plasticity, with suitable water content e.g. of clay minerals: bentonites

Sand (SiO2) 90%

Differ in: Average grain size, grain distribution, and grain shape Chemical composition Refractoriness and thermal stability

Properties required in moulding material

used to determine the quality of the sand mould

Moulding Sand Properties

The properties depends on several factors:

The sand ingredients The methods of preparing the sand for molding The method of molding employed in using the sand Variables related to the casting e.g. weight, shape, kind of casting alloy, and gating design

Effect of the Ingredients:

Each of the ingredients can have important effects in the properties Principal ingredient Silica Sand Grains

Effects of the Sand Grains:

Casting surface finish, mold permeability, and strength, refractoriness, and expansion characteristics are all influenced by the sand grain portion of the mixture Sand-grain contour of the mold cavity Fine grains smooth wall at the metal interface

Moulding Sand Properties

Sand Grains and Permeability:
Coarser sand greater permeability Finer sand lower permeability The grain size distribution has a pronounced effect on permeability Narrowest distribution range and minimum of fine materials such as silt or clay present most permeable Permeability is also promoted by the rounded type of sand grain

Sand Grains and Strength:

Strength surface area of sand grains available for binding Fine sands present more surface area and can develop high strength, but of course more clay is required Size distribution wide size distributions favour strength, while narrow distributions reduce strength Angular sand grains More strength

Sand Grains and Refractoriness:

Refractoriness - ability of the molding material to resist temperature of the liquid metal so it not get merged with the metal High refractoriness sand grains of maximum purity and size Impurity which discolour silica lower its fusion point Finer grains appear to be more easily merged than coarser ones

Moulding Sand Properties

Sand Grains and Expansion:
Wide size distribution dense packing of the grains cause expansion problems Fine sands also expands more

Clay and Sand Strength:

For a given clay type and content, there is an optimum water content The effects of the clay on dry and hot strengths are quite important Too low and dry strength permits washing of the sand by the metal, and dirt in the castings Too low or too high a hot strength is also undesirable Aluminium castings only green and dry strength have appreciable importance since casting are poured at low temperatures

Clay Content and Permeability:

Permeability are reduced by fine material in the sand Increasing clay content lowers permeability Higher clay content also require more tempering water, and hence more steam is formed when the metal is poured

Moulding Sand Properties

Clay Content & Bulk Density:
Clay content also influence the bulk density achieved by the sand during ramming A sand having minimum bulk density has much void space and will have a good permeability adequate with its sand grain characteristics

Clay Content & Expansion:

Clay content of 10 to 14 % in the sand mixture are accompanied by minimum confined-expansion value, 0.03 to 0.04 in. per in. as measured 2500 F High clay contents together with the proper amount of water and ramming if the sand thus favour thermal stability

Clay Content and Other Properties:

High hot and dry strengths are developed by bentonite and bentonitefire clay mixtures less collapsibility Combustible materials may be added to promote collapsibility Excess clay clay balls Good mixing is required

Green sand mold

- Mixture of sand, clay, and water - green sand in the mold is moist - Least expensive method of making molds Advantages: - Sufficient strength for most applications - Good collapsibility - Good permeability - Good reusability Drawbacks: - Moisture in the sand can cause defects in some casting

Dry sand mold

- Also called cold box mould - Made using organic binders rather than clay - The mold is strengthen by baking it in an oven Advantages - High dimensional accuracy Drawbacks - More expensive - Lower production rate because of drying time

Types of Sand Mould

- The mold begins like a green sand mold, but additional bonding materials are added - Mold cavity surfaces are dried by torch or heating lamp to increase mold strength - Used for large castings - Better dimensional accuracy and surface finish Drawbacks: - Distortion to the mold is greater - Castings susceptible to hot tearing - Slower production rate - Synthetic liquid resin is mixed into the sand - Hardens at room temperature - Good dimensional accuracy control in high production

Skin-dried mold

No-bake mold

Open Molds and Closed Molds

Two forms of mold: (a) open mold, simply a container in the shape of the desired part; and (b) closed mold, in which the mold geometry is more complex and requires a gating system (passageway) leading into the cavity.

The Sand Casting Mold

Elements of a Gating System:

POURING CUP: This is where the metal is poured into the mold. SPRUE: The vertical channel from the top of the mold to the gating and riser system. Also, a generic term used to cover all gates, runners and risers. RUNNER: The portion of the gate assembly that connects the sprue to the casting in gate or riser. GATE: The end of the runner in a mold where molten metal enters the mold cavity. RISER: A reservoir of molten metal provided to compensate for the contraction of the metal as it solidifies. BLIND RISERS: Risers that are completely contained within the mold. OPEN RISERS: Risers that are open at the top to the outside environment. MOLD CAVITY: The impression in a mold produced by the removal of the pattern. When filled with molten metal it forms a casting.

COPE: Upper or top most section of a flask, mold or pattern.

PARTING LINE: A line on a pattern or casting corresponding to the separation between the parts of a mold. DRAG: Lower or bottom section of a flask, mold or pattern. VENTS: Vents help to assist in the escape of gases that are expelled from the molten metal during the solidification phase of the metal casting process. INGATE/CHOKE AREA: Once at the sprue base the molten material must pass through the ingate in order to enter the inner area of the mold. The ingate is very important in flow regulation during the casting operation.

Gating System
The pouring cup, downsprue, runners, etc., are known as the mold gating system, which serves to deliver the molten metal to all sections of the mold cavity. The aims are to providing defect-free casting by: 1. Rapid mold filling 2. Minimizing turbulence 3. Avoiding erosion 4. Removing inclusions 5. Controlled flow and thermal conditions 6. Minimizing scrap and secondary

operations

Elements of a Gating System

Pouring Cup
-As a reservoir from which the molten metal will moves smoothly into the sprue - Main function: -To reduce momentum of the liquid flowing into the mold by settling first into it - To minimize splash and turbulence as the metal flows into downsprue - Main requirements for pouring cup design: -One of the wall should inclined about 45 - to absorb metal momentum and avoid vortex formation - Deep enough to avoid turbulence - During pouring, the pouring cup should be kept full to avoid vortex formation

Proportion of pouring cup dimension

Sprue
- A channel through which the molten metal is brought into the parting plane where it enters the runners and gates to ultimately reach the mould cavity - Require smaller area of cross section at the bottom to gain velocity to flow - Tapered to gradually reduce the cross section to eliminate problem of air aspiration

Proportion of sprue height

Sprue Base Well

- A reservoir for metal at the bottom of the sprue - To reduce momentum of the molten metal and flow through the runner in a uniform way prevent splashing - Dimension- general guideline : -Well area = 5 X sprue choke area -Well depth = runner depth - well diameter (for a narrow and deep runner) = 2.5 X runner width (in two runner system) = 2 X runner width (in one runner system)

Runner
- Connect to sprue allowing molten metal to enter mold cavity - Design consideration: - sharp corners or sudden change of section should be reduced to avoid turbulence and gas entrapment - circular cross section is preferable to avoid heat loss - width ~ 2 X runner depth - the entry into runners from sprue base well should be made as smooth as possible

Runner Extension
- The runner is extended a little further after it encounters the in-gate - To trap contaminants in the molten metal