Comparative Study on Different Sand/Binder Mixtures for Suitability in Metal Casting Operations
Morouj Omar Rajab, Houssien Mannaa Masoud, Ahmed Mohammed Asaleh Salem
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Sand casting refers to an object produced using the sand casting process. Sand castings are produced in specialized factories called foundries. It is known that over 70% of all metal castings are produced via sand casting process. Molds that are made of sand are relatively cheap, and sufficiently refractory for high temperature use. In addition to the sand, a suitable binder is mixed with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop the strength and plasticity of the clay and to make the aggregate suitable for molding . This research offers a comparative study on the usability and suitability of different local sands and binders for metal casting operations. The aim was to examine three different properties that are necessary for sand casting. Four different types of sands and three binders were combined successfully in different design mixtures. The sands under study were Red sand (Ashkeda), white well sand, red well sand and silica sand (Zallaf). The binders used in the new mixtures were sugar solution, dates extract and local clay . To achieve the research aim, certain properties concerning sand casting were investigated which are; the mixture strength, thermal collapse temperature and sand texture analysis so that all results can be linked together to support the findings . The overall conclusion is that each type of our local sand require certain binder to give the best combination of properties required for metal casting operations. The best recommendation for sand/binder mixture for casting is (silica + clay) since this type tolerates a temperature of about 1100 ºc and compression strength of 700 N. The reason for this is that silica contain quartz element that has high melting point of about 1670 cº. The new second best mixtures was the sample with mixture of (the white well sand + dates extract). This type of sand/binder mixture can endure a temperature as high as 870 cº, and has a strength of 800 N. The third best choice for metal casting operation will be (Ashkida + dates extract). This type can withstand about 870 ºc and has failure strength of 750 N.
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