Experimental Investigation on the Properties of Sand Moulding Using Aluminium Dross

International Journal of Scientific Research and Review ISSN NO: 2279-543X

EXPERIMENTAL INVESTIGATION ON THE PROPERTIES OF SAND MOULDING USING ALUMINIUM DROSS

JEYAPRIYA.B Department Of Mechanical Engineering, Mr.N.S.MOHAN,ME (Assistant Professor) Erode Sengunthar Engineering College, Department Of Mechanical Engineering, Erode, India, Erode Sengunthar Engineering College, [email protected] Erode, India.

Mr.J.DINESH,ME (Assistant Professor) Mr.M.NAVEENKUMAR,ME (Assistant Professor) Department Of Mechanical Engineering, Department Of Mechanical Engineering, Erode Sengunthar Engineering College, Erode Sengunthar Engineering College, Erode, India. Erode, India.

Castings are used to make engine blocks, cylinder blocks of ABSTRACT automobile and airplane engines, machine tool beds and frames, pistons and piston rings, mill rolls, wheels and housings of steam and In moulding process Green sand Moulding is ancient and hydraulic turbines, aircraft jet engine blades and turbine vanes, pipes, common in practice for manufacturing complex shaped products. In sanitary fittings, etc. recent days efforts are taken to replace industrial waste in the place of silica sand. 1.1 SAND MOULD CASTINGS Here, the alternative is made from aluminium dross Sand mould castings produce about 80% of the total output powder extracted from aluminium industry for economical cost of cast products (Aramide et al 2012). After a single use, the casting saving and also effective usage of industrial waste. Number of mould is usually smashed for taking out the component after the cylindrical samples in different compositions of waste powder, solidification of metal in the mould cavity. The materials used for bentonite and oil were prepared based on AFS standards and tested. making mould casting are silica sand mixed with certain binder The waste material extracted is subjected to various tests like materials, additives and water. Natural silica sand is generally the permeability, green compression and dry compression strength. preferred foundry sand to prepare mould and core. These properties were measured in the samples for checking the suitability of the waste powder. The mould cavity is prepared with 1.2 NATURAL SILICA SAND the most appropriate compositions of waste powder with bentonite The natural silica sand (Lujan 1992) collected from river binder and additives. Molten aluminium, gun metal and cast iron are bed or sea shore are put into myriad uses, including preparation of then poured into the cavity prepared in the mould box. mould and core in foundry, as well as for construction (Trivedi et al The castings obtained were investigated and the result 2013), ceramic industries, chemical industries, glass, paint (Scanning Electron Microscopy analysis, Hardness test-Rockwell, industries, etc. The natural availability of silica sand has been fast Brinell, Vicker’s) reveals that the addition of waste powder with depleting due to the ever growing demand. bentonite sand increases the surface finish and thereby providing better mechanical properties and also reduces the cost of production compared to green sand specimens made using silica sand. Another growing concern due to the continuous removal of the natural silica sand from the river bed and sea shore is the severe threat that it poses to the environment. The present work is aimed to Keywords: Aluminium dross powder, Casting, Bentonite, address the environmental concerns as well as proposes ways to Mould, Binders, Specimen, AFS- American Foundry Society recycle the used sand (Danko 2011) thereby to decrease the extraction of this resource.

INTRODUCTION 1.3 PROBLEM STATEMENT Several legal resolutions and government policies are in Casting is one of the oldest methods of manufacturing metallic and place to control the extraction of precious natural resources and to nonmetallic components. When molten metal is poured into a mould manage the waste generated from the use of such resources. cavity, a preferred shape of the component is obtained on However, very less significant work has been done to safeguard the solidification of the metal in the mould cavity. The component is environment and protect the planet from its slow destruction. removed from the mould and used after further treatment. Moreover, the growing industrial world has found minimum success in finding alternative materials so as to reduce its reliance on natural

Volume 7, Issue 3, 2018 23 http://dynamicpublisher.org/ International Journal of Scientific Research and Review ISSN NO: 2279-543X resources. Expectations on the possibilities of recycling or reusability The idea of the utilization of industrial waste (such as (Lucarz2006) of resources have attracted much academic curiosity. aluminium dross) is less well explored. The growing accumulation of The present work is placed in this direction. such wastes in and around industrial units has attracted much Industrial wastes like aluminium dross are dumped at sites adjoining criticism from both environmental advocates and administrators and the plants. Thus, many vast regions around the globe that host is a problem which requires urgent solutions. numerous manufacturing and production plants are defenseless to A proposal is described here to convert waste from environmental pollution (Spirutova et al 2012). Industries incur huge aluminium industry for a partial replacement of natural silica in the costs towards storage and disposal of wastes, thereby a heavy burden making of sand mould castings. This study has promising outcomes on industrial overheads. Thus, effective disposal of waste is one of that will substantially reduce the accumulation of industrial waste and the most pressing problems to the industry. reduce the present colossal extraction of natural silica. This study has utilized aluminium industry waste in the foundry to make high- One industry’s waste is another’s raw material is a theory quality castings. that is well regarded (Ilyushechkin et al 2012). The present work proposes and presents evidence that wastes generated in aluminium The objectives of the study are: industries such as aluminium dross can serve as additive materials to make sand mould in the foundry. Table 1.1 presents the waste  To study the characteristics of aluminium dross sand materials generated by some industries that the present study has molding using different binders. identified as having reusable value (Sobczak & Purgert 2002).  To analyze industrial waste such as aluminium dross waste Table 1.1 Industrial wastes for their usability and partial replacement for natural sand. Industries Waste materials  To generate different sand moulds using different Aluminium Industries Aluminium dross proportions of natural silica sand, industrial waste and

binders.

 To study the permeability, green compression strength and 1.4 PRESENT WORK dry The present work proposes an effective way of disposal of compression strength of moulds produced using waste from aluminium industries. Such waste can make an alternative various compositions. to natural silica sand in the making of sand mould castings. Silica  To find ways to reduce casting defects such as blow holes, sand, water, industrial waste powders were mixed with different porosity, gas holes, etc. binders in various proportions to obtain American Foundry Society (AFS) standard specimens. Tests of permeability, green compression 1.6 OUTLINE OF THE REPORT strength, dry compression strength were performed with the Chapter 1 presents a brief introduction to sand moulding specimens. and the relevance of the present study. It also explains the problem statement and objectives of the present work. 1.4.1 Permeability Chapter 2 discusses the characterization of silica sand and The permeability of a sand mould is the ability to permit waste powders. Samples of aluminium were sourced from aluminium unwanted gases from the mould cavity to leave through the gap industry for analysis and inclusion in the present work. Binder between sand particles. Thus, the molding sand should be permeable materials considered were bentonite, urea formaldehyde, phenol or porous. Sands which are coarse or have rounded grains exhibit formaldehyde, synthetic resin and sodium silicate with carbon more permeability. Soft ramming, water and clay addition in lesser dioxide gas. Characterization techniques such as XRD, TGA, amounts also improves permeability. In the absence of adequate microvolt endo-down, derivative weight, EDS, SEM and sieve test permeability, defects like surface blows, gas holes, mould blast, etc. were considered. may be experienced. Permeability of the specimens was measured Chapter 3 discuses the preparation of AFS sample, using a permeability meter. The permeability of dry sand moulds are permeability of sand, green and dry compression strength of sand, higher than the green sand moulds due to the less in moisture content. mould preparation and inspection of sample castings such as hardness 1.4.2 Green Compression Strength test and surface inspection. Green compression strength is the strength of the sand CHAPTER 2 mould and core in moist conditions. A mould without adequate green strength will lose its shape and dimensional stability. Green strength MATERIAL CHARACTERIZATION helps in making as well as handling the moulds and cores. Green This chapter discusses the use of materials and their compression of the specimens was measured using a Universal physicochemical characterization. Using a collection of samples of Strength Machine (USM). silica sand and different industrial waste powders, several analytical tests were performed, including X-ray diffraction (XRD), 1.4.3 Dry Compression Strength thermogravimetric analysis (TGA), microvolt endo-down, derivative Dry compression strength is the strength of the sand mould weight, energy-dispersive x-ray spectroscopy (EDS), scanning and core in the dry state which are measured using a Universal electron microscopy (SEM) and sieve analysis tests. The results of Strength Machine (USM). Dry compression strength is greater than these tests were used to decide the suitability of waste powders for the green compression strength due to the low moisture content. the partial replacement of silica sand in the making of sand mould in When in contact with molten metal being poured, sand mould must foundry. have strength to bear up erosive forces, withstand pressure and retain its shape. 1.5 SCOPE OF THE STUDY 2.1 MATERIALS

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For this study, waste material from aluminium industry and sodium silicate are generally used as binders in making sand were considered, such as aluminium dross waste. In addition, mould. different binders such as Bentonite, urea formaldehyde, phenol formaldehyde, synthetic resin and sodium silicate were analyzed (Ji 2.1.3.1 Water et al 2001). The characterization of each will be explained hereunder. Water activates the bonding action of clay in the sand and increases plasticity and strength of the mould. The part of water absorbed by the clay is responsible for the green strength of mould 2.1.1 Silica Sand cavity. The remaining water, called free water, acts as a lubricant and Silica sand or quartz, chemically called silicon dioxide increases plasticity and moldability of the sand mixture. (SiO2), is one of the most commonly found minerals on earth’s surface. The natural silica sand is widely used to make mould and core in the foundry for making metal castings. The used silica sand in 2.1.3.2 Bentonite found appears black (Figure 3.1). Natural availability, high melting Natural clay and bentonites are commonly used binders in point and refractoriness are the main advantages of silica sand for sand moulding (Ayoola et al 2010). Natural sodium bentonites have making moulds and cores. higher dry strength and fusion temperatures and are more durable. The selection of bentonite type is based on the type of casting. The characteristics of bentonite (Cholewa & Kozakiewicz 2012) such as swelling ability and filtration loss greatly influence the properties of the mould such as permeability, strength, moldability and compactibility. It has been widely used in casting, metallurgy, machinery, petroleum, chemical industry, environmental protection and in other areas, so it is known as “universal soil” (Wei et al 2009).

CHAPTER 3

METHODOLOGY OF EXPERIMENTAL STUDY Figure 3.1 Used silica sand A variety of industrial waste powder such as aluminium

industry aluminium dross waste were studied for their potential to

partially replace natural silica in making moulds and core for metal 2.1.2 Industrial Waste Powders castings. After making mould specimens using different compositions Aluminium dross waste powder is considered for analyses in this of silica sand, waste powders and binders, permeability, compression study. strengths were conducted on them. Finally, specimens of castings It is discussed as below. were prepared and their behaviors tested. Accordingly, the aim of this To produce pure aluminum ingots , aluminium scrap has study was to identify the best industrial waste powder having the to be heated up to 2000°C using coal (Yildirim & Prezzi 2011). Upon maximum potential to partially replace natural sand for making adding salt to this substance, aluminium dross waste will get moulds and cores in foundry. Also, the maximum percentage of the separated from it in the form of powder. The aluminium dross waste waste powder for optimal working of the mould was found. The powder usually appears color like grey (Figure 3.2). Huge quantity of study has also identified an ideal binder that works for the aluminium dross is wasted in the aluminium industry and it is stored combination. nearby the industry after the aluminium extraction. Storage, maintenance, transportation and handling the waste 3.1 EXPERIMENTAL WORK without affecting the environment is a big task to the manufacturer. Permeability, green compression strength, dry compression

strength of the moulds produced using silica sand and industrial waste powder mixtures in different proportions were tested. Finally,

the assessment of aluminium, gun metal and cast iron castings

obtained was performed via surface, microscopic, hardness and x-ray

testing.

3.2 METHODOLOGY

Collection of Raw Materials

Addition of aluminium

dross and binders Figure 3.2 Aluminium dross waste powder Mixing of aluminium dross .

 Permeability test

 Green 2.1.3 Binders for Sand Molding Testing of aluminium dross Binders are generally additives that increase strength of the compression test mixture mould and core, as well as bonding between particles. Water, clay,  Dry compression bentonite, urea formaldehyde, phenol formaldehyde, synthetic resin Preparation of mold

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Melting of metal 3.2.3.1 SIEVE TEST The test of determining the AFS grain finesses number is performed on a dried sand sample from which all clay substances Formation of casting have been removed. A set of standard testing sieve is used to screen the sand. These sieves are stacked in sequence with the coarsest sieve  Hardness test at the top and placed in a sieve shaker(Figure 3.4). About 500 grams  Impact test sand is placed at the top sieve and, after 15 minutes of vibration, the Testing of casting  SEM Analysis weight of the sand retained in each sieve is obtained. The AFS grain fineness number of the sand tested can then be determined by taking the percentage of sand retained on each screen, multiplying each by a multiplier (which is simply the next available sieve old mesh number 3.2.1 COLLECTION OF RAW MATERIALS greater than the one being weighed out), adding the total, and then The materials needed for the experiment are aluminium dividing by the total percentage of sand retained on the sieves. dross, silica sand, bentonite which is used as binder and metals such as aluminium, gun metal, gunmetal are used to produce castings. The aluminium dross is got from I-Tech Metal Industries which is located in SIPCOT, Perundurai. Bentonite binder and metals such as aluminium, gun metal, cast iron are purchased in Erode. 3.2.2 MIXING OF SAND The green sand is mixed in proportion with the aluminium dross (Figure 3.3). Then the green sand and aluminium dross is mixed with water and bentonite which is used as binder.

Fig 3.4 Sieve Shaker

Fig 3.3 Mixing of aluminium dross 3.2.3.2 PERMEABILITY TEST Permeability is defined as that physical property of the 3.2.3 TESTING OF ALUMINIUM DROSS MIXTURE molded mass of sand mixture which allows gas to pass through it. It The following tests are conducted on the mixture of is determined by measuring the quantity of air that passes through a aluminium dross and silica sand. The tests are conducted to find the given sample of sand in a prescribed time and under standard properties of the mixture. The results of the tests are then studied to condition. Permeability of molding sand depends on several factors compatibility of the mixture being used as molds. including shape of sand grains, fineness, and degree of packing,  Sieve analysis test moisture content and amount of binder present. Hence coarse grained  Permeability test sand is more permeable than finer ones. To determine permeability  Green compression test the AFS Standard sand specimen of 5.08 cm (2 inches) diameter and  Dry compression test 5.08 cm in height is prepared by ramming the required quantity of

Volume 7, Issue 3, 2018 26 http://dynamicpublisher.org/ International Journal of Scientific Research and Review ISSN NO: 2279-543X sand in a smooth surface tube with three blows of standard rammer. Reading scale This sand specimen is placed in the mercury cup of the permeability meter. The air drum is raised to take 2000 cm3 of air in to the air drum which will be indicated by the graduation on it. The whole air is then allowed to escape through the sand specimen with a pressure of about 10g/cm3 and the time is recorded. Hand wheel Fig 3.6 Universal strength machine

3.2.4 PREPARATION OF MOLD The mixture of green sand and aluminium dross in the suitable proportion is mixed with the bentonite binder and water.

Once the mold is prepared using this proportionate mixture, the CO2 process is carried out. Carbon dioxide molding is sand casting process Manometer that employs reading a molding mixture of sand and bentonite binder. The molding mixture is then hardened by blowing carbon dioxide gas through it. The mold making process is similar to conventionalOrifice molding procedure except the mold material which Fig 3.5 Permeability Meter comprises of pure dry silica sand free from clay, 5-10% bentonite as binder and moisture content generally less than 3%. A small amount 3.2.3.3 SAND STRENGTH TEST of starch may be added to improve the green compression strength Sand strength test is the measure of holding power of and a very small quantity of coal dust, sea coal, dextrin, wood floor, various bonding materials in green and dry sand. It determines the pitch, graphite and sugar can also be added to improve the cohesiveness or natural binding capacity of the sand grains. There are collapsibility of the molding sand. After packing, carbon dioxide gas four types of test for sand strength: (1) compression, (2) shear,(3) at about 1.3-1.5 kg/cm2 pressure is then forced all-round the mold tensile, and (4) over-hang bar test of this test, the compression test is surface to about 20 to 30 seconds using CO2 head or probe or curtain. by far most widely used and is very convenient for routine testing of Molds and cores thus prepared can be used for pouring molten metal all types of national bonded and synthetic molding sand. For green for production of both ferrous and non-ferrous casting. compression strength test, the AFS Standard sand specimen is prepared. The test is performed on the sand specimen by using universal sand strength machine. This machine consists of a pusher arm and weight arm, both hanging from a pivot bearing at the top of the machine. The weight arm applies load on the specimen while pusher arm pushes the specimen against the weight. As the weight arm is pushed up higher, the load increases until the specimen breaks. Then the compression strength in gm/cm2 may be read at the magnetic marker whose left side shows the maximum upward travel of the weight arm. For dry compression strength test, the AFS Standard specimen is cooled and tested it on the same day they are made. The specimen is placed in the upper position of the sand strength and broken the specimen as in the case of green strength test. The dry strength values are read in gm/cm2 off the dry strength scale.

Fig 3.7 CO2 Molding process

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Hardness is a measure of how resistant solid matter is to various 3.2.5 MELTING OF METAL kinds of permanent shape change when a compressive force is The aluminium, cast iron, gun metal which have to be poured in the applied. Some materials, such as metal, are harder than others. mould for obtaining the castings are melted in muffle furnace at a Macroscopic hardness is generally characterized by strong temperature of 9100C, 9500C, 10100C respectively. intermolecular bonds, but the behavior of solid materials under force is complex; therefore, there are different measurements of hardness: scratch hardness, indentation hardness, and rebound hardness. Hardness is dependent on ductility, elastic stiffness, plasticity, strain, strength, toughness, viscoelasticity, and viscosity. Reading sca 1/16th ball indent Sample material 3.2.7.2 IMPACT TEST Impact testing reveals how tough a material is. Toughness Fig 3.8 Melting of metal can be defined as the ability of a material to absorb energy without

breaking. Impact testing is commonly done with pendulum impact

tests. The two most common pendulum impact tests are Charpy and

Izod. In both methods the tested piece is notched. Izod impact testing 3.2.6 FORMATION OF CASTING was initially developed by a metallurgist (whom the test is named Once the metal is melted , the molten metal is poured into the mold. after) for testing metals used for cutting tools; subsequently it was The mold setup is kept undisturbed for some time to allow the molten adopted for use by the plastics industry for testing plastics. The piece metal to solidify inside the mold. to be tested is held vertically and the impact contacts the piece on the

notched side in a cantilever beam fashion. The unnotched Izod test occurs with the sample simply turned around so the notch is opposite the impact side. The test is then labeled "unnotched". Charpy impact testing (Fig. B) also utilizes a pendulum to impact the piece. Yet, the orientation of the piece is horizontal and the impact is opposite the notch side. This test simulates a high speed flexural test (three point bend) of the material. Charpy impact is particularly valuable in measuring the effect of micro cracking, flow and weld lines on the parts toughness. Fig 3.9 Formation of casting

RESULTS AND DISCUSSION The results and discussion sections present the research findings and analysis of those findings. It also contains a conclusion section, which focuses on practical application or provides a short summary of the research.

4.1 SIEVE ANALYSIS TEST FOR NATURAL SAND

Sieve analysis test is help for find the grain size of the sand Fig 3.10 Machined castings and weight of sand in each microns.

3.2.7 TESTING OF CASTING Table4.1 Sieve analysis test result for natural silica sand 3.2.7.1 HARDNESS TEST

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SI.No. Sieve size Weight of Weight of the natural sand in % (in microns) natural sand S.No Sieve Weight of Weight of (in grams) size (in aluminium the microns) dross (in aluminium 1 2057 78.2 0.78 grams) dross in % 2 1680 49.52 0.495 1 2057 69 0.69

3 1003 245.20 2.45 4 710 45.26 0.45 2 1680 77 0.77 5 500 198.32 1.98

6 355 26.14 0.261 3 1003 70 0.70 7 150 225.34 2.25 8 103 20.69 0.20 4 710 47 0.47

9 75 10.48 0.10

10 53 6.45 0.06 5 500 65 0.65

6 355 13 0.13

7 150 309 0.309

8 103 10 0.10

9 75 11.76 0.117

In this graph, sieve size of the natural silica sand is taken in X-axis 10 53 11.92 0.119 and percentage of the sand retained is taken in Y-axis. From this graph, it is clearly that 150, 500 and 1003 microns size has more amounts of sand present in natural silica sand, so we took 150 4.3 PERMEABILITY TEST microns as our sample silica grain size. Permeability of the sand specimen prepared was determined by The sieve size of the silica sand plays a major role in preparing the passing a given volume of air through the sand. This test was taken mould because the size decides that the permeability where it is a in the permeability meter. How much air passing through the major source in casting that is during the time of casting the gases specimen was to be showed by manometer reading. The formed due to its hot nature of molten metal reacted with the mould permeability number should neither low nor high. The entire tests that we prepared. The size will give the good mould and permeability choose 4% water which is optimum value for good binding. also having good strength of mould when comparing with various moulds with different grain size of the natural silica sand.

4.2 SIEVE ANALYSIS TEST FOR ALUMINIUM DROSS 4.3.1 Permeability test of aluminium dross with 5% of bentonite Sieve analysis is used to find the grain size of the sand. binder Table 4.2 Sieve analysis test result for aluminium dross Table 4.3 Permeability test of aluminium dross with 5% of

bentonite binder

S.No Aluminium dross (%) Permeability Number

1 10 205

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Rockwell Hardness Number for Cast iron

2 20 185 Load applied = 100 kgf th Type of indenter = 1/16 ball indenter Rockwell Hardness Number (RHN) is B97 3 30 243 Rockwell Hardness Number for Gun metal

Load applied = 100 kgf 4 40 178 Type of indenter = 1/8th ball indenter

Rockwell Hardness Number (RHN) is B13 5 50 173 4.7.2 BRINELL HARDNESS TEST

Brinell Hardness Number for Aluminium 6 60 264 Load applied = 180 kgf Type of indenter = 1/16th ball indenter 7 70 341 Formula = 2P/{3.14*D(D-[D2-d2]1/2)} Brinell Hardness number (BHN) is 23.16 8 80 440 Brinell Hardness Number for Cast iron

Load applied = 180 kgf th 9 90 550 Type of indenter = 1/16 ball indenter 2 2 1/2 Formula = 2P/{3.14*D(D-[D -d ] )}

Brinell Hardness number (BHN) is 65.71

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