Tips for auditing your green sand system.

(guidelines
for metalcasters)(Cover Story)
Modern Casting - March 1, 1999
Kevin C. Pickrell

Word count: 3197.

citation details

Following are guidelines that metalcasters can follow to systematically self-examine

their green sand systems in search of a more controlled operation.

Many variables exist in a green sand system, which by its nature is in a constant state
of change. Problems can occur when one or more key control properties fall outside of
the control range. When an effective system is in place to monitor these key control
properties and correct the variances, green sand systems can be more effectively
controlled.

Following is the AFS Green Sand Molding Committee's (4-M) procedure for auditing
green sand systems, which was developed out of numerous plant visits. This article
identifies the main areas of the sand system that foundry personnel should self-audit for
process improvement and scrap reduction.

Because operations and equipment are so different, absolute rules for control do not
exist. However, foundries are advised to examine and question their methods of green
sand control - and recognize that yesterday's process may not necessarily still be the
best one for today.

Controlling your green sand system requires breaking the process down into key areas
and then working to reduce the variability of those key areas. To properly focus the
audit, it is recommended that foundrymen examine three key areas - return sand,
prepared sand and sand properties.

RETURN SAND

Proper control of the percentage of clay, sand, moisture and temperature in the return
sand will greatly enhance the ability to hit target properties coming out of the muller. The
following areas are critical and should be given priority during the return sand system
audit.

* Contamination. The audit should verify that core butts, trash, metal and other
contaminants are being purged from the system sand.
* Size Distribution. Much about the state of the return sand can be learned from the
prepared sand screen analysis and AFS clay or 25 micron test. While some may think
this is a prepared sand issue, the fact is that with the exception of the new sand
additions at the muller, most changes to the size distribution of the sand occur outside
the muller.

The washed 140 screen in the prepared sand should be maintained between 10-15% to
reduce penetration and increase the number of grain-to-grain contacts for reduced
friability and mold erosion. This has a positive effect on all strength readings (green, dry
and wet tensile).

The (200+270+PAN) should be kept as low as possible because these materials

contribute only minimally to penetration resistance, while causing higher moisture levels
and lower permeability. A level of 4% or less is recommended.

* Moisture Sponges. The moisture sponge percentage (defined by the committee as

AFS Clay minus methylene blue clay) should be generally maintained between 2-5%
(varies with foundry and metal poured). This dead, light, moisture-absorbing material
competes with the clay for water, thereby increasing the moisture needed to hit the
compactability target.

Excess moisture sponges can lead to pinholes, rough surfaces, scabs and erosion.
Insufficient moisture sponges, meanwhile, make compactability more difficult to control
because the sponges "even out" errors in moisture addition. They also reduce
compactability loss on the belt as the sand travels from the muller to the molding line.
The moisture sponge percentage is affected by:

* dust collector location and flow rates. These light, powdery materials are easily pulled
off, especially in areas where the sand is churned or free-falls;

* dryness of the return sand, which allows higher amounts of light material to be drawn
off;

* changes in the rate at which fines or blackwater are added back in to the system.
Addition rates and percentages must be consistent;

* the rate that new sand and core sand is added to the system. Adding sand dilutes the
percentage of moisture sponges in the return sand. If the system is not purged with
enough sand, sponges will build up. On the other hand, too much new sand can create
green sand that is too "clean" (moisture-sensitive) and friable, since new sand requires
more energy to coat it than system sand.

* Return Sand Moisture & Temperature. Because clay won't adhere to sand over 130F
(54C), temperature is one of the most critical elements of return sand. The lower the
sand-to-metal ratio is, the quicker the temperature of the sand rises (see chart at right).
Long cooling lines and high pouring temperatures also drive sand temperature up. Many
foundries straggle to control the temperature of their sand and look for ways to cool it.
Adding water before the sand hits the muller cools the sand and starts the rehydration
process. Because time in the muller is generally limited, water often is applied to the
sand before it enters the storage bin so that rehydration can begin.

Most foundries check the moisture of their prepared sand, but the moisture levels of the
return sand should not be overlooked. If the sand is too wet, it can plug equipment. If it's
too dry, the complete rehydration of the sand will be difficult. The tighter the return
sand's moisture, temperature and moisture sponges are held, the easier it is to
consistently maintain compactability in prepared sand.

GREEN SAND PREPARATION

The goal of green sand preparation is to homogenize, moisturize and effectively smear
clay onto the sand grains to create a sand that has the optimum properties for the
molding machines.

* Muller Maintenance & Adjustment. A written record of preventive maintenance on the

muller is a must. Nothing should be assumed - records should be verified. Checks
should include:

* plow and wheel spacing - this affects the smearing of the clay;

* lining condition - poor conditions cause a drag effect, thus increasing the muller's
amperage needed to turn the sand mix. If the doors are of the type that open when high
amperage is reached, the door may open before sufficient mulling is achieved;

* dust collection - air flow rates, especially over the muller, can cool the sand. Vigorous
dust collection can also draw off bond before it has had a chance to be mulled in;

* compactability controller - the compactability controller must be maintained and

calibrated periodically. Keep in mind that the controller performs much better when the
moisture sponges and other characteristics of the return sand are controlled well;

* aerator - this is an important piece of auxiliary equipment for the muller. It fluffs the
prepared sand prior to molding, and the longer the transport distance from the muller to
the machine (more precompaction), the more important fluffing becomes.

* equipment for bond and water addition - this can offer the biggest challenge when it
comes to maintaining reliability and consistency. Verify that both bond and water are
being fed consistently. Is there an alarm that provides an alert if either stops feeding?

* Materials Addition. The first thing to examine is how, when and where each of the
additions are made. For new sand additions, a common rule of thumb is that 300 lb of
sand should be added per ton of iron poured. In reality, however, there is no "one size
fits all" formula for new sand additions. Each foundry must take into account its
equipment, core sand addition rate and level of moisture sponges. The core sand
addition rate becomes important when considering adverse effects of partially burned
core sand that is coated with carbon. Clay does not adhere well to carbon-coated sand
grains.

The rate of clay addition required to maintain target methylene blue clay levels in the
prepared sand depends on the amount of live clay in the return sand and the amount of
new sand being added. Return sand clay levels are dictated mainly by the burnout rate
of clay due to the molten metal, the amount of clay removed from the system by the
dust collectors and the amount of clay removed from the system in dump sand. Clay
burnout rates are dictated by the sand-to-metal ratio-heavier parts expose the sand to
higher temperatures for a longer period of time, burning out more clay.

For batch mullers, are additions made in the most favorable sequence? If dry materials
are added first, foundries must consider that no tempering can begin until the water is
added. Many foundries find the best results by adding water first. This cleans off the
plows and begins the hydration of the sand as soon as possible.

Where possible, it can be beneficial to add clay to return sand to create mixing and
tempering (prehydration) of the clay before it reaches the muller. Many foundries
hydrate the return sand and clay as much as possible without causing silo plugging so
that water added in the muller is only trim.

In the batch muller, any changes that increase the amount of time the water is in contact
with the return sand and bond will increase muller efficiency (less water to achieve
desired properties). The total time the water is in contact with the premix and sand is
called the "true mulling time." How long does it take to add premix and water? As the
time to make the addition increases, the time available to mull the water and premix into
the sand is reduced.

Continuous mullers use "retention time" instead of "true mulling time" when discussing
how long the premix and water are being mixed. Retention time equals average mass of
sand in the muller divided by the feed rate into the muller (assuming feed rate in equals
feed rate out). The retention time must be long enough to achieve consistently good
properties. Some foundries speed up the input rates in continuous mullers because of
higher sand demands. These foundries must judge the cost/benefit of scrap vs.
production rates.

What are the components of the premix and why is each being used? Examine whether
each additive is still necessary and actually achieving the characteristics originally
intended. Should the percentage be changed or should an additive be eliminated? Over
the years, premix requirements often change as equipment changes or casting
requirements change.
GREEN SAND PROPERTIES

The three critical areas for examination of green sand properties are material
percentages, sand properties and test equipment/methods.

* Material Percentages

Material percentages in green sand (methylene blue clay, moisture, grain size
distribution, volatiles and combustibles) are all independent of mulling. Each foundry
establishes target levels based on the molding equipment in their plant. Once the
targets have been set, a system must be in place to keep them there.

For example, the methylene blue clay must be set at an appropriate level for your
molding equipment and the defects seen. (Higher pressure molding machines generally
run better with more clay, as do foundries that run parts prone to scabbing defects.)
Does the methylene blue clay show sharp swings?

Moisture Levels - Tight moisture control is critical for controlling compactability. High
moisture levels can cause can metal penetration, pinholes and scabbing. Low moisture
allows friability, erosion and sand inclusion problems.

Free Water - For this discussion, free water is defined as the water held by the moisture
sponges in the green sand. This means dead clay, coked seacoal, wood flour and any
other nonclay, moisture-absorbing materials in the sand. Some free water is good
because it helps "even out" the moisture in the sand and helps combat compactability
drop, offs due to moisture losses. Too much of this water, however, can interfere with
flowability and cause sticking. Pay attention to the clay/water ratio. Is it consistent?
Many things can throw the ratio off. If mulling is not adequate, the system may be using
excess water to reach the target compactability. If dust collector fines are staying in the
system, more water is needed due to moisture sponges.

Carbon Levels - The volatiles test is an index of low-temperature carbons and the
combustibles are an index of the high-temperature carbons. Are the volatiles and
combustibles levels appropriate for the molding equipment and castings being
produced? Seacoal swells to fill the gaps between sand grains when heated, and
prevents scabbing by relieving the stress of expanding sand grains. Generally, as the
machine's ability to produce harder molds increases, the level of combustibles that are
needed is reduced.

Sudden increases in core sand input can cause volatiles to surge. Fines levels usually
index combustibles since the size distribution of seacoal is usually highly peaked on the
below-270 screen. The level of fines can change when dust collector flow rates or return
sand moisture changes. Also look at blackwater - has the rate of re-addition or removal
changed?
Besides scabbing, low carbon levels can cause pinholes and poor peel. When carbon
levels surge, there may be increased erosion, blows, or sand inclusions.

* Sand Properties Reported

The most common sand tests performed are compactability, green compression
strength, specimen weight, methylene blue clay, permeability and moisture.

Methylene blue clay is affected by the ratio of western (sodium) to southern (calcium)
bentonite, moisture, level of moisture sponges, mulling quality and time.

Compactability is a function of the % methylene blue clay, moisture, mulling quality and
time, moisture sponge level, and the western/southern bentonite ratio. After your
foundry has decided on its target compactability, a plan should be developed to keep it
there. If you're having problems with stickers, not getting flowability into mold pockets or
losing mold details, the sand may be too wet from attempts to achieve a high
compactability.

Green compression strength is a function of the same variables as compactability plus

grain size distribution, core sand/new sand ratio and quantities being added to the
system and other special strength-altering materials in the premix (like wood flour).

Specimen weight is mainly a function of grain size distribution and the moisture sponge
level. Specimen weight is a good indication of moisture sponge problems. For instance,
if an iron foundry's specimen weight falls below 148, it will expect to find a moisture
sponge value exceeding 4% (the system choked with fine, dead material) and a
clay/water ratio below 2. This can culminate in moisture-related defects previously
mentioned. If the specimen weight for an iron foundry is above 162, the foundry may
well find moisture sponge levels below 1.5% (too clean) and difficult to control
compactability levels also previously mentioned. Know where your foundry typically runs
well and how much it varies from day to day.

* Test Equipment and Methods

Before you make any decisions based on the results of sand tests, you must consider
how confident you are with the testing equipment and methods. Are you sure the data is
reliable? Are samples representative of the sand in the system?

The more variation that exists in the sand, the more frequently it should be tested. Also
take into account the size of the system and the turns of sand per shift. Although
automatic controllers can reduce the frequency of testing, most foundries test their sand
at least once per turn.

Audit the test lab on sample preparation and test procedures. Check all shifts and
operators. Are they consistent?
Equipment and procedures affect reliability. For example, compactability testing using 3
rams is affected by the rigidity of the rammer base, how freely the weight falls along the
shaft and the balance of the arm.

Methylene blue solution should be calibrated against a clay standard stored in airtight
container. Due to the accuracy required to prepare the solution, purchasing the solution
may be worth the extra cost. Do all technicians have the same judgment as far as the
methylene blue clay halo end point? Note that because methylene blue clay solution
calibration standards vary, methylene blue clay test results between labs do not always
compare well.

Different crucible sizes are thought to affect volatile readings. Larger crucibles have
more oxygen to react with the carbon to produce CO2.

Keep in mind that the choice of oven temperatures affects the volatiles test. The higher
the temperature, the more carbonaceous material is burned off. Temperature control
should be verified and the thermostat should be scheduled for replacement at a set
interval of 6-12 months. Besides ensuring accuracy, replacing the thermostat is less
expensive than a burnt-out heating element.

Is test equipment calibrated on a regular basis? Verify, through records, that calibration
is performed regularly.

Periodically send samples to an outside lab for testing. Many foundries consider this
practice valuable, as it can alert managers if equipment is going awry and help evaluate
lab performance. Results from two labs may not match, but they should track each
other. Foundries do this anywhere from once a week to once a month. The outside lab
also may perform additional tests that your lab doesn't have equipment for.

SYSTEM EQUILIBRIUM

As long as every variable in the system is held constant, the system will be in
equilibrium. However, one of the many absolutes for foundries is that every variable
always is changing to some extent.

There are, however, some key equilibrium concepts worth understanding. The clay level
in the system is a balance between what is added at the muller, burned out at pouring,
removed through dump sand or sucked out through the air ducts. When dust collector or
blackwater fines are added back in, the equilibrium shifts toward higher clay so that the
clay addition must be reduced.When the maintenance department "fixes" the dust
collectors, the clay addition rate must again be reviewed. Core sand plus new sand
additions dictate the dump rate of sand from the system and therefore also affect
equilibrium. Western/southern bentonite ratios also affect the equilibrium, since the
southern clay bums out at a lower temperature than western.
Similarly, moisture sponges have their own equilibrium factors. "Generated" during
pouring, they are affected by the same factors noted in the previous paragraph, but also
the target methylene blue clay level since the higher the clay percentage in the mold,
the more will be burned out.

The auditor should be aware of these key equilibriums so not only can the "out of
bounds" property be identified, but also the reason it is out of bounds - and what the
best route is for getting it back in control.

A systematic audit of the green sand system through return sand, sand preparation and
property verification, followed by corrective action to maintain target properties of the
green sand, will lead to a reduction of scrap and a more consistent quality performance.

This article was adapted from a panel presentation at the 1998 AFS Casting Congress.

Citation Details

Title: Tips for auditing your green sand system.(guidelines for metalcasters)(Cover

Story)
Author: Kevin C. Pickrell
Publication: Modern Casting (Magazine/Journal) 
Date: March 1, 1999
Publisher: American Foundrymen's Society, Inc.
Volume: 89    Issue: 3    Page: 30(4)
Its about hacking WhatsApp verification p1rocess and decrypting .crypt7,8 files.
So basically if You have a .crypt7 file, and you need to decrypt it. there is a way to decrypt without KEY .

First You have to Register Whatsapp by same number . that is the number .crypt file belong to

Use Whatsapp With Someone Else’sNumber !!! This hack works by tricking the WhatsApp Verification
Servers by receiving sms by spoofer app.

1) Delete Your Whatsapp account

2) Go to sdcard/WhatsApp/Databases/
3) Copy a backup of your Database (crypt file) and delete everything in that.
4) Paste the file you want to decrypt.
5) If the file name is such as msgstore-2015-01-23.1.db.crypt8 or msgstore-2015-01-23.1.db.crypt7 then
rename it to msgstore.db.crypt8 .
6) Download & Install WhatsApp on your device .
7) Enable Airplane mode.
8) Download google play app for sms spoofing . there are many on play store.

https://play.google.com/store/apps/detai…id.fakesms
https://play.google.com/store/apps/detai…p.fakecall ( I used this one)
https://play.google.com/store/apps/detai…smsfakepro

9) Enter the number you want to register (the number of .crypt7-8 you want to decrypt).

10) Press Register or whatever is there

11) Whatsapp will wait for you to enter code but if you receive message they automatically register

10) Use the App and Recieve fake sms:

” To: +(Country code)

(victims mobile
number)
From: ”

11) If the Above didn’t work try vice versa

To: 
From: +(Country code)
(victims mobile
number) ”837478
Make sure you are in Airplane mode with wifi on.

You will successfully register in to their whatsapp . Remember – by this method the Previous whatsapp
(victim’s) account will be disabled. Try doing this at night time or whenever the victim is asleep or away
from his mobile. I will make another tutorial in which their whatsapp will not get affected.)

12) It will ask There is a backup found do you want to restore. Click on RESTORE.
13) Will take time. If it didnt . just dont click continue. close whatsapp and restart. might come some error

but just keep retrying and you will be IN 

www.extremehacking.org
CEHv8 CHFIv8 ECSAv8 CAST ENSA CCNA CCNA SECURITY MCITP RHCE CHECKPOINT ASA
FIREWALL VMWARE CLOUD ANDROID IPHONE NETWORKING HARDWARE TRAINING
INSTITUTE IN PUNE,Certified Ethical Hacking, Center For Advanced Security Training in India,IT
Security Training Information Security Traning Courses in Pune, ceh certification in pune, Ethical
Hacking Course in Pune