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M. DAWSON TECHNICAL MANAGER, FOUNDRY SAND SYSTEMS & CASTING METHODS CAST METAL SERVICES PTY. LTD. PH # 0732666266 FAX#073266366 ABSTRACT
Silica Sand is the most essential raw material and its importance is sometimes forgotten amongst Foundry personnel. Silica Sand as used by Foundries is desired for its thermal resistance and availability. In Queensland Australia it falls under the minerals act as it is processed and sold for its chemical properties. Whilst Silica Sand is abundant throughout Australia the technical requirements of Foundries allow only a few deposits to be mined and processed for their use. This paper will cover some of the processing routes along with grading and physical/chemical attributes of Silica Sand.
When referring to Silica Sand for Foundry use we define it as the mineral quartz; its sizing, chemical purity, shape and physical durability will be discussed along with the thermal properties.
To introduce the sizes most commonly used the Red Spheres denote 0.425 mm, Green 0.212mm, Yellow 0.3mm, Salmon 0.15mm and an undesirable black sphere at 0.075mm or 75 microns. Ideally the sand grains should be spread across four sieve sizes in a Bell type distribution. The Older Silica Sand deposits are subjected to a greater degree of weathering hence a rounder grain evolves. This explains photo 2 where this material was laid down a mere 12,000 Years ago!
Photo 4: 300,000 Tonne /annum Wet Plant Photo 5: Aerial View of an Open Pit Mine A Modern Wet Plant, Beachmere QLD photos courtesy of Southern Pacific Sands, QLD.
The washing process can involve as many as three to four cycles to ensure that the sand has an exceptionally low turbidity, free from clay and fines, low in unwanted salts and an acceptable pH value. The Industry Standard in Australia is a hybrid system using Metric sized sieves that match the old Mesh Numbers of the US Standard (ASTM E11-61) and allow an AFS Grain Fineness Number to be calculated. A Table displays the way in which this is calculated and a simple spreadsheet can be devised and used. Sieves of known size are assembled and placed in a vibratory jig. The grains fall through square mesh sizes that are placed coarse on top usually 0.60mm or 30 mesh through to 300 mesh or 53 microns at the bottom above a collector tray. The sand that is retained on each sieve is weighed and tabulated, that weight is multiplied by a factor dependent upon the sieve size it was recorded against and an AFS GFN Number is calculated. The Table Below demonstrates a typical Sieve Analysis for the Mine above and the Bell Curve obtained is nearly ideal!
IMPURITIES CONTAMINATES AND TESTING PROCEDURES The Acid Demand Value test:
The acid demand value is important because it displays the amount of alkaline materials that should not be present in washed and classified foundry silica sand. Minerals such as limestone and shell, (CaCO3), dolomite Ca/Mg CO3, Lime CaO. The importance of the Acid Demand in testing should not be overlooked as it reveals various carbonates and salts that may be missed with a standard pH test. A high ADV will significantly shorten bench life in the cold box system and lead to pinhole defects in castings due to the production of CO2 gas evolution. Typical Values for Queensland silica Sands are: FSD 710M 0-4ml, Rouse Channel Sand 15-40ml. The Best Value is 0 and a usable maximum value is 15. The acid demand test can be obtained by the use of hydrochloric acid or Sulphuric Acid as per the BCIRA Broadsheet 210-4 (1983)
Moisture:
Moisture contents of 0.2% and above are detrimental to the overall quality of the Cold Box, Phenolic Urethane process, the water reacts with the hydroscopic poly-isocyanate part 2. The Bench life is considerably shortened, core strength is lowered and Flowability is reduced. Other key indicators are lower scratch hardness and core rigidity. In general terms there is a 30% loss of tensile strength for every 0.1% moisture increase!
Moisture versus Tensile Strength
250
150
100
50
This impellor core made from the Cold Box process and has 6% of a proprietary CMS Anti- Veining additive.
Conclusion:
Whilst we have an abundance of high purity silica within Australia, without the correct understanding of its properties, ideal sizing for a given application and the available resins systems at the disposal of todays Casting engineer the true benefits will only be partially realized.