Evaluating a Ceramic Resin-Coated Sand for Aluminum and Iron Castings

• Published in: International journal of metalcasting Vol. 13; no. 3; pp. 519 - 527
• Main Author: Ramrattan, S.
• Format: Journal Article
• Language: English
• Published: Cham Springer International Publishing 15.07.2019
• Subjects: Characterization and Evaluation of Materials; Chemistry and Materials Science; Materials Science; Metallic Materials; Structural Materials; core binder system; disc-shaped specimen; thermal distortion; chemically bonded sand; hot-box shell
• ISSN: 1939-5981; 2163-3193
• DOI: 10.1007/s40962-018-0269-5

Shell molding technology remains an important part of metal casting technology because it permits precision sand castings. However, there is a lack of information available on shell resin-coated sand (RCS) produced with ceramics. This paper relates the physical, mechanical, and thermo-mechanical properties of disc-shaped shell core specimens made from either silica or ceramic sands. Gravity-filled disc-shaped shell core specimens were fabricated with silica and ceramic sands. Specimens were laboratory tested and evaluated in aluminum and iron casting trials. Testing included density, abrasion, thermal distortion, hot permeability, impact and retained strength. All tests were accomplished according to newly adopted American Foundry Society standards. With a ceramic RCS, it is possible to produce cores and molds having superior abrasion resistance, strength, and thermal stability when compared to a silica RCS. Ceramic RCS shell core specimens showed fewer casting surface issues when compared to silica RCS shell core specimens in aluminum and iron casting trials.