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Green Sand Metalcasting Foundry News

Foundry Leadership Conference Insights, Guest Post by Doug Kurkul, AFS CEO

Posted by Doug Kurkul on Oct 2, 2018 12:12:04 PM

Metalcasters around the world face many of the same challenges. That point was articulated at the recent Foundry Leadership Conference in Amelia Island, Florida, presented by the American Foundry Society.

Moderated by AFS Vice President Peter Reich, LaempeReich, a panel on the Condition of the Global Foundry Industry also included Brad Muller, Charlotte Pipe and Foundry; Atsushi Nagai, SintoKogio; Carsten Kuhlgatz, HA International; and Denny Dotson, representing the World Foundry Organization.

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The Metal Casting Foundry Holiday Gift Giving Season is Right Around The Corner

Posted by Hill and Griffith Company on Sep 26, 2018 10:52:42 AM

Here are the top ten metal casting books available in the American Foundry Society (AFS) bookstore

The AFS has compiled a list of the top 10 books purchased in the 2018 fiscal year. If you've purchased a book from AFS, thank you! If you haven't, check out what your friends in the industry are reading.

The top 10 bestsellers of 2018

1.Casting Defects Handbook: Iron & Steel

The first edition of the AFS Casting Defects Handbook was considered the go-to pocket reference for metalcasting personnel worldwide for more than 35 years. This edition has been rewritten by George Goodrich in conjunction with the American Foundry Society (AFS) Cast Iron Division and the Steel Division to provide the metalcasting industry with updates to reflect the changes in foundry technology.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Green Sand Additive Products, Green Sand Foundry Supplies, Metal Casting Books

"W, X, Y, Z" - Glossary of Foundry Additives (Including core oils)

Posted by Hill and Griffith Company on Sep 4, 2018 9:24:48 PM

W, X, Y, Z - Foundry Additives Glossary

WAD ORE (See: MANGANESE DIOXIDE) 

WATER GLASS (See: SODIUM SILICATE) 
"Sodium silicate," "soluble glass," and "silicate of soda" are all called "water glass." Water glass is a composition of various ratios of Na, O to SiO, in dry crystalline or hydrated form. It is used as a binder in mold and core sand mixtures. The Carbon Dioxide (C02)-Sodium Silicate Process is used by the foundry industry. When 2% to 4% sodium silicate (Water Glass) is added to a clean silica sand or a refractory sand and carbon dioxide gas is passed through this formed mold or core, it hardens into a refractory mass, making excellent cores and molds for certain castings. Sodium silicate dissolves in hot water. Sodium silicate (water glass) is made by melting sodium carbonate with silica or by applying heat and melting sodium carbonate together with sand, charcoal and soda. This product, fused sodium silicate, is then ground and dissolved in boiling water for use as a foundry binder. Sodium and potassium carbonate can also be made into a double soluble water glass. 

WATERLESS BINDERS (See: NEO-BOND)
Neo-Bond is a waterless binder which is very popular in the foundries where waterless binders are required. No temper water is necessary. Five percent (5%) by weight Neo-Bond, plus less than 2% of a high viscous coastal oil is all that is required when mulled together to form a waterless molding sand mixture. Waterless binder mixtures have produced, and are producing castings, with better detail than more expensive processes such as shell molding. Such waterless mixtures are molded "green" and are generally a low cost repetitive operation. Waterless binders, such as Neo-Bond, are used with fine silica sands, olivine, zircon, or Hevi-Sand mixtures.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies, Core Oil

Article Review: "How Properties Vary Throughout a Casting" from Modern Casting Magazine

Posted by Hill and Griffith Company on Aug 28, 2018 9:32:49 PM

A study set out to show how properties can vary throughout a casting and why that’s ok. 

(Introduction)

The bulk of A356 castings are poured in permanent molds with solidification times generally less than 10 minutes. This process normally provides the best metallurgical properties when compared to the other common casting processes such as high pressure die casting (traditional or vacuum), sand casting, plaster molding and investment casting. Because of these properties, the tilt poured permanent mold process is used often for high integrity parts.

Tensile strength and ductility are closely tied to metallurgical properties such as secondary dendrite spacing, the level of microporosity, and the metal cleanliness which impacts the level of inclusions.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies

"V" - Glossary of Foundry Additives (Including Vegetable Core Oils)

Posted by Hill and Griffith Company on Aug 21, 2018 3:51:12 PM

V - Foundry Additives Glossary

VEGETABLE OILS (See: CORE OIL-COTTONSEED OIL-LIN­SEED OIL-OILS-TUNG OIL)
These are oils obtained from plants. They are used in the foundry as drying oils, as lubricants, and for other purposes. Examples of vegetable oils are linseed oil, cottonseed oil, olive oil, palm oil, and castor oil. The chief distinction between vegetable oils and fats is physical. Oils are fluid at ordinary temperatures. Vegetable oils can be thickened by oxidation, or more simply by blowing air through them. They may be hydrogenated by passing hydrogen gas through them. in the presence of a catalyst. Foundry oils contain a large quantity of the vegetable oils sold.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Core Binders, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies, Core Oil

"U" - Glossary of Foundry Additives (Including Core Binders)

Posted by Hill and Griffith Company on Aug 14, 2018 12:59:00 PM

U - Foundry Additives Glossary

UFFA TYPE RESINS (See: HOT BOX RESINS-RESINS)
Are resins of a special type commonly used as binders having different setting times, cold-set strengths, hot cured strengths and setting properties.

UNMODIFIED UREA FORMALDEHYDE (See: RESINS-UREA) 
Unmodified UF resins, catalyzed, are difficult to control in setting time when used as cold-set resins. Their cold-set strength is medium, but they have a high hot-cured strength. They have poor setting properties and are sensitive to mold-metal reactions, unless a proper coating is given the sand surface.

UREA BINDER (See: LIQUID UREA BINDER)

UREA FORMALDEHYDE CATALYZED (See: UREA RESIN) 
When urea resins are catalyzed, they start to cure immediately when used. This can be a bench life problem. The higher the temperature, the faster the curing process.

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"T" - Glossary of Foundry Additives (Including Core Oils)

Posted by Hill and Griffith Company on Aug 7, 2018 4:21:00 PM

T - Foundry Additives Glossary

TALC (See: SOAPSTONE)
Talc is a hydrated magnesium silicate with the composition [4SiO2 3MgO • H2O]. It is a soft, friable mineral having an oily touch. It has a Moh's hardness of 1 and a specific gravity of 2.8. It is referred to as "soapstone." It is used as a parting compound when impregnated with wax and ground. It has been used in nonferrous mold coatings, ladle refractory coatings, and when blended with clay, bentonite, cereal or dextrin, it is used as a core paste. It is used as an additive in various core compounds and core fillers.

TANNIC ACID (See: BINDERS-CORE BINDERS)
Is prepared from extraction of the liquid squeezed from wetted oak bark. It is rarely, but sometimes used as an auxiliary binder in core sand mixtures where clay is present.  

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"S" - Glossary of Foundry Additives (Including Southern (calcium) Bentonite)

Posted by Hill and Griffith Company on Jul 25, 2018 3:32:50 PM

S - Foundry Additives Glossary

SAFFLOWER OIL (See: CORE OIL - OILS)
This oil is not as popular as other plant oils used in core oil formulas. Safflower is a plant native to the East Indies, Asia, and Egypt. The oil is pressed from the seeds of the plant. It is used sparingly in foundry core oils.

SAL SODA (See: SODA ASH) SALT
The common name for sodium chloride is "salt." The mineral name is "halite." Its chemical formula is (NaCl). It is used in the foundry to harden core and mold coatings so as to give a glaze to mold and core surfaces. Salt is used to glaze refractories such as ladles, linings, and as an addition to clays and other clay-like minerals to lessen their viscosity when used with water slurries. The Moh's hardness of salt is very low, only 2.5. Its specific gravity is 2.1 to 2.6. It has a melting point of 1472° F. (800 ° C.). Expendable cores are made from salt brines for use as cores in casting light metal, such as aluminum. Wonderful results have been obtained with the use of salt cores. Salt brines are used in the quenching of metals. Salt has a world-wide use, but it is not commonly used in sand mixtures of the foundry.

SAND (See: FOUNDRY SAND - MOLDING SAND)
Sand is a specific particle size of grains, rocks, or minerals. Sand is a size, not a mineral. It is formed in nature by winds, water action, and other elements of the weather. Sand composes much of the earth's surface. The most useful and commercial sand found for use in the foundry is silica, but other materials such as zircon, chromite, olivine, silicon carbide, or ceramic materials may be called "sand," if they are of that "size." There are more sand foundries in the United States than those casting by any other process. Metal cast into sand molds comprises 96% of the total foundry industry. Die casting into metal molds represents about 3%. All other methods account for the balance of 1%. Silica sand is perhaps the best known sand used in the foundry for making molds, cores and refractories, but there are many minerals used as "foundry sand." (Also See: CHAMOTTE-CHROMITE-FOUNDRY SAND-HEVI-SAND­MOLDING SAND-NATURALLY BONDED SAND-OLIVINE -SILICA-SILICA SAND-SILICON CARBIDE-SYNTHETIC SAND-TENNESSEE SAND-ZIRCON SAND.)

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"R" - Glossary of Foundry Additives

Posted by Hill and Griffith Company on Jul 3, 2018 9:58:52 AM

R - Foundry Additives Glossary

RED OIL (See: OLEIC ACID)

REFRACTORIES
Any substance which resists high temperatures is called a refrac­tory. They are generally used for lining melting furnaces, pouring ladles and metal pots. Clay minerals are the oldest and most commonly used refractories. Natural refractories are ceramic materials such as fire clay, bauxite, ball clay, kaolin, zircon, silica, chromite-spinel, olivine, magnesite, and hundreds of others. Refractories are usually classified as being acid, basic, or neutral. The silica refractories are called "acid," the "basic" refractories are magnesite, dolomite and a few others. The "neutral" refractories are chromites, graphite and alumina. A product is not considered "refractory" unless it withstands at least 2806°F (1541°C). High grade refractory materials should withstand at least 3100°F. (1700°C.) and should resist slag, metallic oxide and chemical attacks. Refractories are prominently used in the foundry industry in every operation where heat is applied.

RELEASE AGENTS (See: PARTING COMPOUNDS-POWDER RELEASE AGENT)
Kerosene and light oils containing waxes are used as release agents with most green sand mixtures. Silicone type release agents appear to be very effective for use with furan no-bake binder mixtures, hot box and shell applications. There are many commercial types and grades. 

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"Q" - Glossary of Foundry Additives

Posted by Hill and Griffith Company on Jun 26, 2018 4:34:38 PM

Q - Foundry Additives Glossary

QUARTZ (See: MOLDING SAND-QUARTZITE-SAND-SILICA FLOUR-SILICA SAND)
Is widely deposited and is the most common variety of the min­eral, silica ( SiO2). Most quartz deposits contain impurities. It usually crystallizes in hexagonal prisms, or hexagonal pyramids. Its specific gravity is 2.65. It has a Moh's hardness of 7. Quartz is so widely used in the foundry that it is a basic aggregate.

QUARTZITE (See: GANISTER-QUARTZ-SAND-SILICA)
Is a massive group of quartz grains cemented together by water, silica gel, and pressure. Most quartzites contain angular grains of silica. Quartzite is said to have been derived from sandstones under intense metamorphism. It is a refractory, as it has a melting point of 3092°F. (1700°C.) when it is in the pure state. Foreign contaminants lower its refractory value and its commercial foundry value. It is widely used in the foundry industry, not only for the base sand in molding and core making, but for various refractory purposes in lining furnaces, ladles and other uses. 

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies

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