Compressive Strength

(kN/m2)
Surface
Sand Composition
Process Roughness Remark
(by weight %)
Green Dry (RMS value)
strength Strength

Green Sand Sand • Most common process.

+ 5% Bentonite (Calcium base) • May give permeability in
the range of 170.
+ 0.75 to 1% Starch 30 – 50 30 – 70 600 to 2500
+ 2% Coal dust ( In case of CI)
+ 3 to 5 % water

Dry Sand Sand 50-80 150-250 600 to 2500 • Drying of mould at 200-
+ 8-10% clay (Sodium base) 240℃
+ 0.5 to 1% dextrin • May give permeability
+ 6 to 8 % water index about 100.

Oil Base Sand 9-14 500-700 600 to 2500 • Baking of sand

Sand Process + 1.5-3% (Blended oil) mould/core at 200-240
+ 0.2 – 1.5% Starch ℃ for about 1 to 3 hrs.
+ 2 to 2.5 % Water (1 hr per sq. inch c/s)
 Compressive Strength
(kN/m2) Surface
Sand Composition
Process Roughness Remark
(by weight %)
Green (RMS value)
Dry Strength
strength
CO2 Process Sand • CO2 will be used 0.75 kg / kg
+3-5% Sodium silicate of sodium silicate
(Silica soda ratio=1.5 to 3: 1) (theoretically)
+Alumina – 1.5 to 2 % (for • Practically, due to loss to the
1.4 140 to 280 600-2500 atmosphere used more than
Hot Strength) 1 kg / kg of sodium
+In case of iron used a coal • Pressure – 1.4 to 4 kg / cm2
dust – 2%

NIZHIYHMHA Sodium silicate → Binder • Pulverised FeSi when added

Process Ferro silicate → Accelerator with sodium silicate
(Self setting ,exothermic reaction take
Process) Sand Compressive strength place which sets sand into
+3-6% Sodium silicate after complete setting is ___ hard mass.
(Silica soda ratio=1.5 to 3: 1) 60 kN/m2 • But Hydrogen pickup is the
+Pulverised FeSi = 0.5-2% problem in this process.
 Surface
Sand Composition Compressive
Process Roughness Remark
(by weight %) Strength
(RMS value)
(kN/m2)

Fluid Sand Sand • Setting time is about an hour &

Process + 6% sodium silicate fluidity of sand is achieved by
(Self setting + 4% dicalcium silicate 140 to 175 600-2500 foaming agent
Process) + 1% Water • Foaming agent → 1% of sand

Investment Sand • Mould cooling time is

Casting + 3-4% Ethyl silicate considerably longer and hence
/Sodium silicate it is difficult to make large
+ 5% Alumina ___ 25-180 castings
+ 30% Water

‘C’- Process Sand Resin + Hardener + Heat →Hard

(Or) + 4-6% Phenol mass
Croning Process formaldehyde as a binder
(Or) + 14-16% Hexamethaylene
Shell Process of binder weight >700 250-1250
(also called tetramine &
commercially called ‘Hexa’.)
 Compressive Surface
Sand Composition
Process Strength Roughness Remark
(by weight %)
(kN/m2) (RMS value)

Hot Box Process Sand • Resin + Catalyst + Heat →

+ Resin Binder Water + Solid mass
(1.5 to 2% Phenolic or Furan Resin) • Catalyst will act only when
+ Catalyst >700 250-1250 provide heat
(Metallic chloride or nitride = 20- • Core made in core metallic box
30% of resin weight) and then heated upto 170-
240℃

Warm Box Sand • Resin + Catalyst + Heat →

Process + Binder Water + Solid mass
(0.8-1.8 % furfuryl alocohol-type • Curing action taking place at
resin) 65-96℃
(Furfuryl alcohol content ~ 70%)
+ Catalyst >700 250-1250
Copper salt derived from aromatic
sulphonic acid in water or alcohol
solution (20-35 % of resin weight)
 Sand Composition
Process Remark
(by weight %)

Cold Box Process Sand • Sand temperature effect bench life

+ Binder • Above than recommended temperature
(Phenolic Resin- Phenol formaldehyde: 1 to 1.5%) of sand decreases the bench life
+ Hardner • Below than recommended temperature
(Isocynide: 1to 1.5%) of sand increases the bench life
+ Catalyst
(Triethyl amine gas)

ABC (or) Sand • High strength and best collapsibility

3-Part sand system (or) +Part A :- Alkyd type resin • Low bench life
3-part binder system (1-2 % of sand weight) • 8-10 hrs of setting time
• High cost
+Part B :- Metalic catalyst
(2 to 10 % of part A)
+Part C :- Hardner
(Isocynide-18 to 20% of part A)