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15/11/2017 Hobby Aluminum Casting | Sand Casting Aluminum | Green Sand Casting Process | Mechanical Engineering

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HOBBY ALUMINUM CASTING | SAND


CASTING ALUMINUM | GREEN SAND
CASTING PROCESS
September 25, 2017 admin Leave a comment

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CO2 Sand Casting process

CO2 sand casting or Hobby Aluminum casting is


suitable for urgent and heavy orders with high
accuracy and good surface finish on castings
required. Hobby mould casters used this method
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15/11/2017 Hobby Aluminum Casting | Sand Casting Aluminum | Green Sand Casting Process | Mechanical Engineering

because in this method elimination of core drying


machine, but it is not an economical process. The
only expense hobby mould caster encounters are
the cost of the CO2 cylinder, regulator, and hoses
and hand held applicator gun or nozzle. The
operation is fast and the possibility of rejections is
less. CO2 is a sand molding technique and it uses
grain sand which is mixed with a solution of sodium
silicate that acts as binding agent. CO2 gas is used to
harden the mass of sand after the mould has been
made. The chemical reaction takes place is
explained below:

H2O + Na2SiO3 + CO2 Na2CO3 + SiO2 (Silica Gel in


Colloidal state)

In this process, CO2 gas is passed through sand mix


(0.25% moisture content Sodium Silicate), then the
sodium silicate sand becomes stiff gel which gives
enough strength for the mould. Additives used are
Coal powder, Wood Flour, Sea coal, Dextrin, Kaolin
clay, Aluminium oxide and Invert Sugar.

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15/11/2017 Hobby Aluminum Casting | Sand Casting Aluminum | Green Sand Casting Process | Mechanical Engineering

Properties of Additives:
1. Kaolin clay is used for mould stability
2. Aluminium oxide is used for hot strength of
bonded sand
3. Invert Sugar is used after pouring to reduce
the retained strength of the mould or core
which removes from the mould with less
shaking.

READ Pressure Thermite


Welding | Thermite Welding
Process

Steps involved
1. Mould material is pure Silica, 3-5% of liquid
base binder of sodium silicate, mulled for 3 to 4
minutes
2. Now rammed around pattern in moulding
box
3. CO2 gas forced into mould at about 1.4 to 1.5
kg/cm2 for a predetermined time (15 to 30
seconds)
4. Apply refractory coating, system ready for
pouring
5. Use either wood or metal pattern
6. Suitable pressure reducing valves are used to
reduce pressure of gas
7. Pattern rubbed with graphite before
ramming to overcome removal of pattern from
mould

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15/11/2017 Hobby Aluminum Casting | Sand Casting Aluminum | Green Sand Casting Process | Mechanical Engineering

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Advantages:
1. Low raw material cost
2. Fast production rate
3. No core or mould baking equipments
4. Semi skilled workers enough
5. Hollow moulds can be easily made
6. Easily mechanized

Disadvantages:
1. Difficult to reclaim the used sand
2. Poor collapsibility due to inorganic nature of
bond
3. Moisture susceptibility
4. Less suitable for non ferrous casting

Applications:
1. For larger cores preparation
2. Heavy or thick walled castings
3. Producing cores of Fe, Al, Cu base alloys

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