Molding sand and its properties

Properties of the molding sand:

A good molding sand must have the following properties:

1) Porosity or Permeability:
It is the property of molding sand by which the sand allows steam and
gases to pass through it. When molten metal is poured into the mould, steam and gases will be
formed. If the gases are not removed, casting defects such as blow holes will occur. This
property by which molding sand allows the gases to go outside is called porosity or permeability.

2) Plasticity:
This is the property by which the molding sand gets the shape of the pattern and
retains the shape of the pattern. Only due to this property, the molding sand gets the shape of
the pattern in the mould.

3) Adhesiveness:
This the property by which the sand particles stick or adhere to another body. The
molding sticks to the side of the molding boxes by this property. The molding sand does not fall
out of the box because of adhesiveness.

4) Cohesiveness:
It is the property by which sand particles stick together. It is also called
crumbleness. This property is the main reason for the strength. Because of this property mould
remains strong and does not break when molten metal is poured.

5) Refractoriness:
This is the property of molding sand to resist high temperature during pouring
without fusing or major physical change.

6) Flowability:
It is the ability of molding sand with which it flows freely like a fluid around the
pattern and (fill cavity) all part of the flask when being rammed. The flowability of the molding
sand should be such as to attain a uniform density and strength all over the volume of mould
with least effort in ramming. It depends on the nature, quantity of binders and clay, the
moisture content, the size and shape of grains.
 7) Yieldability:
It is the ability of molding sand to decrease in volume so as not obstruct the
contraction of solidifying casting. Poor yieldability leads to internal stresses and cracks can
appear in castings. More porous and more plastic molding sand possess a higher yieldability.

8) Survivability or Serviceability:
It is the ability of molding sand to retain its initial properties for a
specified period of time.

9) Collapsibility:
It is the property of molding sand that permits it to be knocked out from cooled
castings. Good collapsibility is usually associated with loss of strength of binder completion of
formation of a casting.

Testing of molding sand:

The molding sand is required to undergo certain tests before mould making.
This is done to obtain the sand in conditions most suitable for flawless casting. The tests are:

1) Moisture content test:

The test for moisture content is very important, since excess moisture
means less permeability and less moisture means less strength.

Method-1:
A 50 grams sample is taken in a test plan, weighed and heated at around 225 .F. then
it is cooled in room temperature and re-weighed.
The difference is the weight of the moisture evaporated. The moisture content is
expressed in percent by weight.

Method-2:
The moisture content can be determined by chemical reaction also. A 10 gram
sample is placed with a known quantity of power calcium in a special container. The chemical
reaction produces acetylene gas, which is proportional to the moisture through a calibrated
scale then percentage evaluated.
2) Clay Content Test:
A sample of 50 gram of the molding sand is dried and placed in a wash bottle.
Then to the bottle is added about 500 c.c of distilled water, 25 c.c of NaoH solution. It is stirred
for about 5 minutes. The wash bottle is then filled with water upto a mark on the bottle. The
mixture is allowed to settle for about 10 minutes and then liquid is siphoned off. The filling of
wash bottle and siphoning are continued till the water above the sand in the bottle looks quite
clean. Then the residue is dried out completely over and weighed. The difference between the
initial and final weight gives the amount of clay. Since the clay has been washed away by water
and removed by siphoning action, the percentage can be calculated.

3) Grain Fineness and Distribution Test:

The grain fineness can be tested with the help of an
equipment called sieve shaker. This consists of a set of standard sieves. The sieves have
apertures (holes) through which the sand particles may pass. The size of apertures is denoted by
mesh and have the value 6,12,20,30,40,50,70,100,140,200 and 270 respectively. The sieve with
minimum mesh number has largest apertures (or openings) and so on. The whole set of the
sieves are stacked over each other with lowest mesh number at the top and highest mush
number sieve at the bottom.
The sample of sand is first washed out to remove the clay it. Then
it is dried. A weighed quantity of this sand is now placed in the sieve at the topmost position and
the whole unit is shaked for a definite period with the help of an electric motor. The sand falls
through the apertures; the sands of smallest size come to the bottom passing through all the
sieves and get collected in the pan kept at the bottom of the scale. The sand on each sieve is
collected and weighed separately. The grain fineness number is then calculated.
The sieve set used to determine the AFS grain fineness number consists of parallel
sieves.

S.no Sieve no. (or) Mesh Multiplying AFS GFN Class of Grain Size
factor
1. 6 3 10-15 10
2. 12 5 15-20 9
3. 20 10 2 8
4. 30 20 2 7

AFS fineness is calculated from the table given above. The table is used for measuring GFN. The
residue of the molding sand left after the clay content test is used for this test.

GFN= (Total product) ÷ (% Sand substance)

4) Refractoriness Test:
The refractoriness is determined by its sintering temperature, i.e the
temperature at which the sand grains start cutting. For this, a furnace which has automatic
temperatures could be used. The sand specimen in a porcelain crucible is inserted in the furnace
through a tube where the temperature is around 1000° C. The tube mouth is sealed and
temperature is varied in steps of 50° C. Each temperature is maintained for about 5 minutes, the
sample taken out and inspected. This is continued till the sintering temperature is reached.

5) Strength Test:
The molding sand are tested for compression test, shear strength, tensile strength
and bending strength. Different shapes of specimen are required for different test, such as
cylindrical specimen for tensile test. Square prism 172 mm in height, 5sq.cm cross sectional are for
bending test.

6) Core Hardness Test:

For testing green core hardness the mold hardness test with a large intender
loaded having a light spring is used. Because strength of core stand is lower than that of the
mould sand.
For testing baked core hardness, the tester uses a knife-edge intender, which is
spring loaded and scratches the surface of the core. By drawing the tester slowly over a flat baked
core surface hardness can be read directly from the tester dial.