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AFS Transactions 2006 American Foundry Society, Schaumburg, IL USA
LOI. These tests relate to the control of the five basic variables in green sand: water, bonding agent, sand, sand additives,
and carbonaceous materials. In addition, LOI test are run on chemically bonded sands (Krysiak, 1990 & 1994).
There is not total agreement between green sand experts on how often to run the basic tests. These basic tests can be
broken down into two classifications: daily tests and weekly tests. The sand technician in the foundry may find it necessary
to run certain tests more or less frequently to produce quality sand systems. The carbonaceous material is an important
constituent of the sand, particularly in iron sands. Many foundries determine the carbonaceous material on a daily or weekly
basis using the combustibles test (Roshan, 1989). In many other foundries LOI is considered a weekly test only because it is
a time consuming procedure.
LOI testing can be an effective quality check of chemical binder additions to sand mixes and has often been discussed as a
control tool for the sand reclamation process. But unlike tests for compactibility or compressive strength, which take little
time and can be done on-line for immediate control, conventional LOI testing results are too slow to be used as an effective
tool in on-line process quality control. An LOI test that is both fast and accurate provides a much needed process control tool
for monitoring carbonaceous materials in the foundry.
PROBLEM TO BE INVESTIGATED
This study examines a new and faster LOI test when compared to the more laborious and time-consuming LOI tests currently
available. This research project focused on quantifying LOI data from the new technique and comparing it to that obtained
from the AFS-defined LOI test. The equipment used for the new LOI test was a redesigned induction power supply. Graphs
showing change in mass as a function of time and temperature are provided for sand systems studied. Real-time plot of those
graphs are generated on a computer screen for monitoring of the test; in addition, the measured data is saved for further
analyses and comparison.
OBJECTIVES
Three key issues required proving:
1.
confirm that the new test is faster,
2.
determine the real time rate of mass change as a function of temperature, and
3.
confirm that the new system can accurately measure LOI.
METHODOLOGY
TESTING APPROACH
In the experiments the same lake sand system was use for all samples. Table 1 provides the raw lake sand properties. Sand
was coated with a chemically bonded shell resin at three different levels (1%, L1; 3%, L2; and
5%, L5) and used as samples for LOI testing. In addition, clay bonded (8% pre-mix) green sand used in a working foundry
was sampled and dried for LOI testing.
An induction power supply is redesigned for heating a metallic crucible within its coils in ambient conditions. Induction
heating provides rapid heating to the metallic crucible and its sand contents. Using a computer data acquisition system, a
non-contact infrared pyrometer is used to constantly monitor and control the temperature of the crucible (Figure 1 and 2).
The induction field within the coil heats the crucible that transfers the heat onto the sand sample. The temperature is
achieved whereby organic materials in the sample decompose and certain components volatilize. The resulting loss in weight
from the sample is the LOI measurement.
Table 1. Raw Sand Properties
Type
Source
459L
(Lake)
MI
AFS/gfn
Shape
62
Rounded
Screens
4
Roundness/Sphericity
(Krumbein)
pH
0.6/0.6
Neutral
Acid
demand
(pH-7)
<1
1
2
7
T
g
F
t,s
on
1.
2.
3.
4.
5.
6.
7.
DAC
57.68g
Figure 2. Crucible within coils being heated (left) and non-contact pyrometer (right)
To operate the induction LOI tester (Figure 1), the electrical power was switched on, and the temperature control was set to
2,000 F (1093 C) and controlled by a data acquisition system. In addition, the computer and data acquisition system
provide monitoring and plotting graphs of temperature/time versus distortion in real time.
The crucible is positioned within the induction coils and simultaneously engages the data acquisition system that
automatically logged and plotted the sample mass versus time/temperature curve.
The length of the test for these experiments is set for five minutes; however, this can be varied. The test can be automatically
stopped when the LOI curve starts to flat line. A predetermined test temperature can be set or some heat history chosen to
represent a molten metal solidification simulation can be programmed into the test.
Note that all samples were tested in laboratory conditions at Western Michigan University. Ambient conditions were
controlled: temperature at 75F 3F (24 1C) and relative humidity at 50 2%.
INDUCTION LOI TEST PROCEDURE
In performing the induction LOI test, the following procedure was followed:
1.
2.
3.
4.
5.
6.
7.
While there have been attempts to cut testing time for chemically bonded and green sand by using smaller samples and
shorter furnace times, accuracy may be lost with a less than representative sample size and incomplete combustion. With the
combination of higher precision in analytic balance measurements and the ability to achieve the combustion temperature
rapidly with induction heating, those shortcomings are resolved. Further, the test is conducted in ambient conditions so
oxygen can get to the sample for rapid oxidation. This plays a role in cutting test time, compared to the relatively static
combination conditions in closed chamber furnaces.
The fast organic removal rate allows quick and accurate LOI testing. The new induction LOI testing system provides
automatic temperature control with sufficient power to achieve and maintain steady state test temperatures. In addition
heating of the crucible provides adequate heat transfer to the sample. Apart from providing an ease of temperature control
during testing the data acquisition system (Figure 4) allows real-time analysis of sample mass change as a function of time
and temperature that can be graphically represented; this provides some additional information when compared to just a
percent LOI obtained in conventional testing. Additionally, the computer data acquisition system can be programmed to
reproduce heat history profiles from previous simulation studies. This allows LOI to be used in shakeout analysis of
chemically bonded sands used to heat treat castings and cores used in semi permanent molds. Further, the acquired data can
be saved for further analysis, comparison, and record keeping. The foundry application of the new LOI test can provide
technicians with technology to get an early handle on quality problems that might just be creeping into the sand system.
In lieu of a cost comparison among the muffle furnace technique, the microwave furnace technique, and the new induction
technique, the authors offer another consideration. Many foundries have chosen to replace the older technology of
carbon/sulfur determination with a spectrometer. The old equipment possesses an induction power supply that can be
modified to become an induction LOI tester. Within two weeks the system was designed, parts procured, the test system
installed, and tests performed. By making such a modification the induction LOI tester saves on energy costs and there are
no consumables required in testing.
These findings bear out a good correlation between the muffle furnace method and the new induction LOI testing (Table 2
and Figure 5). From an evaluation of the test machines performance and an analysis of LOI test data, a proof-of-principle is
shown. The results from LOI testing show that the new method is faster and just as accurate as the conventional test. The
authors identified a process whereby the total combustibles can be separated from silica sand at a faster rate than the
conventional AFS LOI tests. The test is simple to run, and the required equipment is easily obtained.
Table 2. Properties of the Chemically Bonded Sand
Chemically
Bonded
Sand (Shell)
L1
L3
L5
Green Sand
Hot
Tensile (#)
Cold
Tensile (#)
Density
(g/cm3)
110
400
570
NA
135
460
645
NA
1.74
1.71
1.55
1.50
Muffle
Furnace
LOI (%)
1.3
3.7
6.1
3.5
Induction
LOI (%)
1.5
3.5
6.5
3.2
LIMITATIONS
Only systems with silica sand have been studied. The work in this paper represents three chemically bonded lake sands
(shell) and green sand as examples of an application for LOI tests. Specialty sand, alternative molding media, and reclaimed
sands were not considered in this study. There are numerous other materials from which additional data can be gathered to
learn more about the LOI properties.
LS 1%
3.05
0.00
2.95
1.67
2.9
3.33
2.85
5.00
2.8
6.67
LS 5%
GS
LOI [%]
Weignht [g]
LS 3%
3
2.75
0
50
100
150
200
250
300
(78)
(999)
(1015)
(1019)
(1006)
(1064)
(1046)
350
CONCLUSIONS
The new LOI tests were run and the following are key findings:
The induction LOI test provides a quick method for removing organic material and water of hydration in clay from
silica sand. The induction LOI method provides testing results in less than five minutes.
The induction LOI technique has a data acquisition that allows real time analysis of sample mass change as a
function of time and temperature that is shown on a graph. The acquired data can be saved for further analysis or
record keeping. Further, this allows the LOI test to be an effective process control tool in the foundry industry.
Tests show that there is a strong correlation between the new induction LOI method and the AFS muffle furnace
LOI method when using silica sand.
RECOMMENDATION FOR FUTURE WORK
A complete gage R&R study involving correlation among the three LOI testing techniques needs to be carried out for
validity. Also, the design of the crucible shape needs to be optimized to increase the surface area contact of the sample to
achieve the best heat transfer.
ACKNOWLEDGMENTS
The authors gratefully acknowledge the technical support of G. Hall, J. Fiala, A. Poot, and P. Thannhauser, all from Western
Michigan University.
REFERENCES
Krysiak. M.B., Reducing Casting Defects--A Basic Green Sand Control Program, Georg Fischer DISA Inc., Holly, MI
(Jan. 1994).
Krysiak, M.B., Pedicini, L.J., Sand Testing Design, 3 parts, Modern Casting, (Feb., Mar., Apr. 1990).
Laitar, R. A., Cavanaugh, J E., Rapid Method For Loss-0n-Ignition Testing, AFS Transactions, vol 103 Paper 95-101 pp.
693-698, (1995).
Laitar, R. A., Cavanaugh, J E., Microwave Technology Brings LOI Testing Up To Speed, Modern Casting, V 86 N 2 P 4041, (Feb. 1996).
Mold & Core Test Handbook, 3rd. Edition, AFS (2000)
Roshan, H. Md., Quality Control of Molding Materials, Foundry Engineering Handbook, Utility Publications Ltd, India
Chapter 13, pp.110-144, (1989).
Schleg, F. P., Technology of Metalcasting, AFS, pp. 49-76, (2003)