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Green Sand Metalcasting Foundry News

Blow-hole Defect Analysis of Cylinder Block-A Case Study

Posted by Hill and Griffith Company on Dec 22, 2020 10:18:43 PM

Excerpt from the January 2017 article in International Journal of Engineering Research and Technology by M.R. Latte and P.D. Chougule. 

Abstract

In this research paper, the blow-hole defect analysis of MH1-VST 4-cylinder block fitted on tractors is presented as a case study. An MHI-VST 4-cylinder block is the central component of a tractor or any vehicle. It plays an important role in lubrication, temperature control and stability of the engine. It must be of the highest quality so there is no room for shortcuts. In this case study, parts pre- and post-analysis is done by using quality control (QC) tools such as Pareto charts and cause/effect diagrams. A DMAIC approach is followed and proper actions are taken to reduce the defect and rejection rate at the factory end. The work is done under two phases:

Phase 1: identifying drastic effects of blow holes in production; 
Phase 2: sorting out the issues by using various QC tools and expert opinion.

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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

Different Types of Casting Processes Used in Manufacturing

Posted by Hill and Griffith Company on Dec 15, 2020 5:05:39 PM

This article focuses the application of green sand in large scale infrastructure projects.

Excerpt from the Thomas Register article defining the different casting processes. 

Casting manufacturing is a process in which liquefied material, such as molten metal, is poured into the cavity of a specially designed mold and allowed to harden. After solidification, the workpiece is removed from the mold to undergo various finishing treatments or for use as a final product. Casting methods are typically used to create intricate solid and hollow shapes, and cast products are found in a wide range of applications, including automotive components, aerospace parts, etc.

 

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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

User Guidelines for Foundry Sand in Green Infrastructure Construction

Posted by Hill and Griffith Company on Dec 8, 2020 4:49:01 PM

This article focuses the application of green sand in large scale infrastructure projects.

Excerpt from the December 2011 principle investigation by Craig H. Benson and Sabrina Bradshaw from University of Wisconsin-Madison's Recycled Materials Resource Center. 

Introduction

Foundry sand is high-quality uniform silica sand used to make molds and cores for ferrous and nonferrous metal castings. The metal casting industry annually uses an estimated 100 million tons of foundry sand for production. Over time, foundry sands physically degrade until they are no longer suitable for molds. Consequently, 9 to 10 million tons of sand are discarded each year. However, the discarded foundry sands have remarkably consistent composition and are typically considered a higher quality material than typical bank run or natural sands used in construction. Currently, an estimated 28% of discarded sand is reused in primarily construction related applications, while the remaining sand is discarded in landfills (American Foundry Society 2007). Recycling of foundry sand can:

  • save energy
  • reduce the need to mine virgin materials
  • may reduce costs for both producers and end users
Use of foundry sand as a fine aggregate in construction applications offers project managers the ability to enhance green sustainable construction by reducing their carbon footprint, while also qualifying for LEED credits. The USEPA recently estimated that at the current recycling level 20,000 tons of CO 2 emissions are prevented while 200 billion BTUs of energy are saved. Support for increased reuse of foundry sand has brought together the USEPA, the Federal Highway Administration, the US Department of Agriculture, the Recycled Materials Resource Center (RMRC), state environmental agencies, the foundry industry and end users to develop the tools and resources needed to increase foundry sand recycling to 50% by 2015.

 

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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

Nobake Basics (Including Mold Coatings)

Posted by Hill and Griffith Company on Dec 2, 2020 3:44:38 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

Aluminum Foundry Green Sand Metal Casting Video

Posted by Hill and Griffith Company on Nov 18, 2020 2:16:18 PM

 (This week's post is from Alcast Technologies's video of the aluminum green sand foundry metalcasting process.)

"Alcast Technologies uses only the best automated molding technologies available to produce the industry's highest quality green sand molds while maintaining unparalleled productivity standards. Two state of the art Roberts Sinto FBO series Flaskless Molding Machines are used to produce molds within a 16" x 20" frame and a 20" x 24" frame. These investments have significantly improved mold design flexibility and give Alcast a distinct advantage over more rigid and antiquated automated technologies."

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Core Pastes, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Pattern Release Agent

Green Sand Publications from the American Foundry Society

Posted by Hill and Griffith Company on Nov 10, 2020 9:12:14 PM

The 2019 AFS Publications Catalog just came out and there are many titles that can help you with Green Sand and Permanent Mold metalcasting applications.

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Tags: AFS, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, American Foundry Society e-Learning

Reclaiming Clay and Carbon from Green-Sand Dust

Posted by Hill and Griffith Company on Mar 10, 2020 8:00:00 AM

Considering process solutions or beneficial reuse options to resolve where all the spent foundry sand will go.

Article excerpt from the Foundry Management & Technology February 2020 issue by Rob Steele.

For years, foundries have been asking, “Where will all the sand go?” They have looked for ideas or innovations to deal with over 10 million tons of spent green sand from molding and core making operations annually — and particularly for sustainable treatment processes. Specifically, they have been looking for process solutions or options for beneficial reuse of all that sand.

Let’s focus on the green-sand dust collector fines, usually rich in active clay and carbon. The ideal treatment technique would:
1) reclaim active clay and lustrous carbon from the dust collector material
2) use a water-based reclamation process to separate sand, clay, and carbon
3) implement no chemicals or unusual by-products
4) result in a clay slurry that has excellent performance characteristics

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Metal Casting Design & Purchasing

Case Studies in Green Sand Casting

Posted by Hill and Griffith Company on Mar 3, 2020 5:11:22 PM

Article excerpt from the September/October 2018 issue of Metal Casting Design & Purchasing.

The common practice allows designers the freedom to achieve many different parts via an evolving method of production.

The green sand casting process is the most widely-used process for casting ferrous and nonferrous metals. The process has evolved from a manually intensive operation to a highly mechanized and fully automated process.

In terms of weight, complexity and alloy composition, a wide range of castings can be produced via green sand casting. In terms of shape, the process can be used to cast parts as simple as ingots and as complex as engine blocks. It is commonly used for ferrous alloys; however, it can be used for almost any alloy, including those of aluminum, copper, magnesium and nickel.

One of the major advantages of green sand casting is its low cost, especially when mass-producing castings on highly automated molding and coremaking equipment. Another major advantage of green sand is its versatility with respect to production. The process can be economically applied to small and large production runs. In addition, the production rate can be increased by making multiple mold cavities in a single mold.

 

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Green Sand Foundry Supplies, Metal Casting Design & Purchasing Magazine

Life Cycle Assessment in Foundry Sand Reclamation – Comparison of Secondary Reclamation Processes

Posted by Hill and Griffith Company on Feb 25, 2020 6:58:51 PM

Excerpt from Samuel Keith Ghormley's University of Nebraska Graduate Thesis from December 2017.

Foundries represent a significant part of the base of the world’s economy and as a sector are one of the largest consumers of energy and producers of solid waste in the United States. Sand casting foundries use approximately 5-10% of their total energy on sand handling processes. By adding a secondary sand reclamation process, foundries can expect to become more energy efficient as well as reducing solid waste from the foundry. To measure the broader environmental impacts, life cycle assessment (LCA) can be used. The goal of the current research was to examine a medium-sized foundry in the United States that sources its sand from a long distance away by using LCA techniques.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Green Sand Foundry Supplies

Intro to Green Sand Casting Foundries

Posted by Hill and Griffith Company on Feb 18, 2020 8:00:00 AM

Article excerpt from the TheMetalCasting.com.

Foundry sand is used for making castings, and is primarily generated by the automotive industry and its part suppliers. It consists of clean silica sand, which is of high quality; or lake sand, which is bonded to make molds for ferrous (iron and steel) and non-ferrous (copper, aluminum, brass) metal castings. The following types of sands are used for making molds in the foundry industry: Green Sand, Resin Coated Sand, Molasses, Cold Box Sand, Hot Box Sand, and CO2 Sand.

These types of sand can be obtained directly from the foundries located in the Midwest states such as Illinois, Wisconsin, Michigan, Ohio, and Pennsylvania.
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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Green Sand Foundry Supplies, TheMetalCasting.com

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