Green Sand Metalcasting Foundry News

Glossary of Metalcasting Terms, Encore Publication

Posted by Hill and Griffith Company on May 22, 2018 11:07:49 PM

(From the American Foundry Society site)

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"N" - Glossary of Foundry Additives (including Core Binders)

Posted by Hill and Griffith Company on May 15, 2018 3:26:40 PM

N - Foundry Additives Glossary

NAPHTHALENE
Is also known as "NAPHTHALIN"-"WHITE TAR" or "TAR CAMPHOR." Its chemical composition is [C10H8J. Its molecular weight is 128.2. It has the odor of mothballs and is derived from coal tar where it is the most abundant single constituent. It is crystallized from the middle or "carbolic oil" fraction of the distilled tar. It is con­tained in a few liquid sprays used in the foundry, such as certain liquid partings.

NATURAL ROSIN (See: BINDERS-BONDS-PINE RESIN-RES­INS-ROSIN-TRULINE BINDER)
A hard resin left after distilling-off the volatile oil of turpentine. It generally has a higher melting point than other resins. The natural resins are used as supporting sand core binders in making heavy cores or molds which require baking. Resins work best with higher temper water levels in a foundry sand mixture. They also work best where clay is used in the sand mixture. Rosin is blended into core oil and enhances core mixtures which contain cereal, dextrin, lignin sulphite and other water soluble additives.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, metal casting supplies, foundry supplies, green sand casting, Green Sand Metal Casting, Green Sand System, green sand metalcasting, core binders, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies

"M" - Glossary of Foundry Additives (including Core Oils)

Posted by Hill and Griffith Company on May 9, 2018 3:43:18 PM

M - Foundry Additives Glossary

MAGNESITE
Is a refractory mineral called magnesium carbonate (MgCO3). It has some contaminants present, such as iron carbonate (FeCO3) and ferric oxide (Fe2O3) present. Its specific gravity is 3.1 and it is fused at 3929°F. (2165° C.). For foundry preparation and use it is a very valuable refractory aggregate particularly where basic refractories are required. Magnesite, when finely ground, is added to chrome sand mixtures as (MgO). MgO is also used as a foundry sand in certain mixtures. Where basic lined furnaces are in operation, dead burned magnesite is used. It is a hard, dense, granular material obtained by calcining magnesite rock at a temperature high enough to form a product inert to atmospheric moisture and carbon dioxide. It is chiefly magnesia (MgO) and is a basic refractory. In the casting of manganese steel, olivine sand or chromite Hevi-Sand containing 10% to 15% MgO addition is an excellent core sand base.

MANGANESE DIOXIDE
An oxidizing agent, MnO2, can be made synthetically or may be found as an ore, known as "bog manganese" or "wad." It has many uses in the foundry, one use being in core sand mixtures for oxidizing purposes. Small amounts are used, such as 0.25 percent.

MENHADEN OIL (See: CORE OIL-OILS)
An oil obtained by steaming or boiling fish caught along the U.S.A. Atlantic coast line. It is also called, "Porgy Oil," "Whitefish Oil," and in the South it is called, "Fatback" and "Moss Bunker." The oil contains 27% oleic acid, stearic acid and a few fats, so that it polymerizes as easily as vegetable oil used in core oils.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, metal casting supplies, foundry supplies, green sand casting, Green Sand Metal Casting, Green Sand System, green sand metalcasting, Foundry Additives Glossary, Green Sand Additive Products, Green Sand Foundry Supplies, Core Oils

Improving Parting Compound Odor and Reducing Flammability

Posted by Hill and Griffith Company on May 1, 2018 9:30:09 PM

Hill & Griffith has developed and patented a unique water-based liquid parting compound which provides improved odor characteristics and reduced flammability for foundry molding applications.  Flammability has long been a concern in automatic molding operations and with the water-based formula, this concern can be minimized or eliminated.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, foundry supplies, green sand casting, Green Sand Partings

"L" - Glossary of Foundry Additives (including Lignin "Goulac" core binder)

Posted by Hill and Griffith Company on Apr 24, 2018 11:41:09 PM

L - Foundry Additives Glossary

LAC (See: RESIN-SHELLAC)

LAKE SAND (See: SAND, LAKE)
Sand occurring in, or near, lake areas which may contain some impurities is called "Lake Sand." It is used in many Midwestern foun­dry core and molding compositions. It is an economical foundry base sand.

LAMPBLACK (See: CARBON -CARBON BLACK
Lampblack is actually soot formed by the smudge process of burning oils, resins, tars, or other carbonaceous material where there is an insufficient supply of air. The soot is allowed to settle on the metallic, cooler walls or areas before it is collected. Lampblack is practically pure carbon. It is used in the foundry as a coloring agent and in a few commercial facing mixtures. Chemically it resembles carbon black which is made by burning gas. Lampblack is very fine and colloidal in form. One pound may occupy over 200 cubic inches in volume.

LARD Oil (See: LIQUID PARTINGS-OILS-PARTINGS)
Lard oil is a fluid oil which contains oleic, stearic and palmatic acids. It is widely used in foundry lubricating oils, but it is also used in many liquid partings of the foundry. It is usually blended with kerosene and other compatible liquids. It has a specific gravity of 0.92. Lard has been used in the past as an additive for certain core oils, as a pattern or core box release.

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New AFS Website Provides Enhanced Green Sand Foundry Education

Posted by Hill and Griffith Company on Apr 17, 2018 3:35:37 PM

The American Foundry Society has launched a new website that serves the needs and advances the interests for green sand foundry education 

In aligning with the association’s strategic direction, the new afsinc.org now has a greater focus on several key elements: much-improved navigation for users, streamlined information about careers in metalcasting, a clear presentation of the economic importance of the industry to our modern quality of life, and one-stop access to information for casting designers and buyers.

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"K" - Glossary of Foundry Additives (Green Sand Foundry Supplies) 

Posted by Hill and Griffith Company on Apr 10, 2018 12:18:02 PM

K - Foundry Additives Glossary

KAOLIN (See: BONDING CLAY-CLAYS-FIRECLAY)
Kaolin is commonly called "kaolinite" as well as "China clay" in the ceramic industry. It is a hydrous aluminum silicate. It is a clay that has the composition of (2SiO2 • Al203 • 2H20). It is used through­out the foundry industry from refractories to bonding purposes, as well as in many foundry compounds and commercial foundry mixtures.
The fireclays used in the foundry are commonly called "kaolinites" but the fireclays contain impurities such as feldspar, fine quartz sand, mica and iron oxide. A true kaolinite clay generally has a specific gravity of 2.6 to 2.63 and a Moh's hardness of 2.0 to 2.5. When wetted, kaolin can be made into shapes and will retain these shapes after they are baked or fired. Most commercial "Kaolin" grades of clay are used by the ceramic industry and the whiter burning "Kaolins" are washed and shipped from the South for use as Green Sand Foundry Supplies. 

KAOLINITE (See: CLAYS -KAOLIN)

KELP (See: SODIUM ALGINATE)

KEROSENE (See: CORE OILS-FUEL OIL-OILS-PETROLEUM)
Kerosene is known in some localities as "Coal Oil." It is a light, oily, liquid prepared from the distillation of petroleum oils. It distills­ off after the gasoline. It is a hydrocarbon having the composition (C10H22 to C16H31). Its specific gravity is between 0.75 and 0.78. It burns freely but it is not so volatile as to be explosive, therefore, it is used in the foundry to prevent molding sands from drying-out. It is, and has been, used to replace some percentage of seacoal. Many liquid partings contain kerosene. Core oils contain kerosene, as a low tem­perature and faster baking ingredient, or a similar light oil.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, metal casting supplies, foundry supplies, green sand casting, Green Sand Metal Casting, Green Sand System, green sand metalcasting, Foundry Additives Glossary, Core And Mold Coatings, Green Sand Additive Products, Green Sand Foundry Supplies

Nobake: The Basics (Including Mold Coatings)

Posted by Hill and Griffith Company on Apr 4, 2018 3:37:11 PM

This article focuses on the nobake process and when it would be appropriate for use.

An MCDP Staff Report
Click here to see this story as it appears in the January/February 2018 edition of Metal Casting Design & Purchasing

Dozens of chemically bonded sand molding methods exist, but they can be divided into three main categories: coldbox, heat-activated and nobake. The basic principle is that a binder and catalyst are mixed with the sand to help form the mold into a “brick-like” product when cured. The differences in the process focus on the sand resin binder and catalyst used and how the mold or core is cured.

Coldbox—with this method, sand is coated with one of several binders, such as liquid sodium silicate or phenolic urethane, and catalyzed by a gas (such as carbon dioxide or sulfur dioxide) passing through the sand. This causes the resin binder to harden (cure) and lock the sand grains in place to maintain a solid mold wall.

Heat-Activated/Shell (also called hotbox and warmbox)—heat is used as the curing means in shell molding. Plastic resin-coated sand is compacted around a pattern and allowed to rest until a “shell” forms. The mold then is heated to temperatures higher than 500F (260C) to cure the mold.    

Nobake (also called airset, dry sand and precision sand)—like coldbox, several binders are optional. However, a liquid catalyst is used. The sand is processed in a continuous mixer and then formed around the pattern until it is fully cured.

Mold coatings are applied to more than 75% of noble molds. The coatings help prevent defects and improve surface finish.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, metal casting supplies, foundry supplies, Green Sand Metal Casting, green sand metalcasting, Core And Mold Coatings, mold coatings

"I" - Glossary of Foundry Additives (Green Sand Additive Products)

Posted by Hill and Griffith Company on Mar 27, 2018 2:56:47 PM

I - Foundry Additives Glossary

ILLITE (See: CLAYS-SHALE)

INDUSTRIAL ALCOHOL (See: ETHYL ALCOHOL)

INHIBITORS
Are agents which prevent decomposition, or retard decomposition rates to acceptable levels. They are widely used in magnesium molding sands to diminish oxidation rates which can cause severe fire conditions or explosions. Materials such as boric acid, sulphur or a fluoride are used to prevent the burning of molten magnesium alloys when poured in foundry molds, and are called inhibitors. These inhibitors restrain an undesirable mold-metal chemical reaction generally due to the oxygen reaction in the mold cavity when the hot metal enters the mold.

INORGANIC BINDERS
Binders such as clay, bentonite, cement, sodium silicate, silicon esters, and others are classified as inorganic binders. Some metallic salts are so classified in the foundry. Usually, foundry binders of this type are more refractory than the organic type. They do not decom­pose as fast and have more durability.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, metal casting supplies, foundry supplies, green sand casting, Green Sand Metal Casting, Green Sand System, green sand metalcasting, Foundry Additives Glossary, Core And Mold Coatings, Green Sand Additive Products

Apprentice Nation? The American Foundry Society Institute has the courses.

Posted by Hill and Griffith Company on Mar 20, 2018 2:58:42 PM

 

A goal of 5 million apprenticeships in the next five years is very lofty considering last year 505,000 people held apprenticeships.

A lofty goal was set in March of 2017 when Marc Benioff, Salesforce CEO, asked President Trump to up the ante and create 5 million apprenticeships in the next five years.

Trump took the bait and included it in his workforce agenda.

While the U.S. might be on the right path, there is a long way to go from the 505,000 people that held apprenticeships last year. (Only 35% of those apprenticeships were in manufacturing.)

But hope springs eternal in the U.S. psyche and so there are studies that predict if only we could reach the same share of its workforce as Australia, Canada and England, the number of apprenticeships would reach 4 million. This is the belief held by Robert I. Lerman, an institute fellow at Urban Institute.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, foundry supply, foundry supplies, green sand casting, Green Sand Metal Casting, Green Sand System, green sand metalcasting, American Foundry Society Institute

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