DOCSLIB.ORG

Type Title of Paper Here

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Type Title of Paper Here 2020 AFS Proceedings of the 124th Metalcasting Congress Paper 2020-076 (10 pages) A Casting Trial to Evaluate Various Chemically Bonded Sand Disc-Shaped Specimens for Surface Finish and Erosion Defects M. Raval Altair Engineering Inc., Troy, MI S. Ramrattan Western Michigan University, Kalamazoo, MI Copyright 2020 American Foundry Society ABSTRACT greatest proportion of sand/metal defects associated with thin and tiny sections in the casting occurs with the Casting issues on thin wall surfaces and in complex chemically bonded sand process. AFS Research geometry interface is not negligible and can result in Committees are studying the troublesome and energy costly defects. Foundries prefer chemically bonded sand intensive issues related to sand defects with a plan to mold over green sand when it comes to castings with thin- minimize or eliminate the concern. This study examines wall sections and complex internal dimensions. Still, various chemically bonded silica sand systems for sand interfacial defects defects in chemically bonded sand erosion and surface finish in cast iron and aluminum process are an issue. This paper addresses chemically castings at different head heights. bonded sand erosion and surface finish issues for aluminum and cast iron castings. Erosion in chemically Erosion defects are major concerns with any casting bonded sand can occur when molten alloy dislodges process involving bonded sand. Erosion usually occurs grains of sand, resulting in a rough as-cast finish. within the gating system and/or at a mold-metal interface of the pattern cavity. Sand erosion is caused when molten Based on a casting trial used to study the erosion in alloy dislodges grains of sand resulting in a rough as-cast alternative green sand specimens; a new trial was finish. This defect is associated with turbulent metal fill. developed to teste to evaluate erosion on multiple This phenomenon of high velocity pouring can cause chemically bonded sand specimens simultaneously. Gray surface defects on casting. The reasons for erosion defects cast iron and an aluminum alloy were delivered from are due to one or a combination of the following: design, controlled head pressures and temperatures to achieve a raw materials (sand, binder and additives), molding and turbulent flow across chemically bonded sand specimens filling technology. Poor sand characteristics such as prior to solidification of the castings. Flow and reactive contaminants, weak sand properties, turbulent solidification simulation of the casting trial model was metal flow, head pressure, cross-sectional area of the conducted. The simulated predictions were evaluated gating system and molding technology are some examples along with results of aluminum and gray cast iron casting that can lead to erosion defects. trials at two different head heights. Results show that in both alloys there are surface differences among the Erosion phenomenon is the relation between a stationary various chemically bonded sand systems studied. entity and fluid flow. In other words, it is the defect caused by the kinetic energy of fluid flow. A sand mold Keywords: casting surface finish, remains stationary while molten metal flows inside the chemically bonded sand, disc-shaped specimens, sand cavity with some definite momentum. This impetus can erosion dislodge sand particles. When the bond between two particles breaks, because of flow momentum a lift occurs, INTRODUCTION and it removes these particles from the surface. This progression causes cavities on the mold surface that leads In the foundry industry, there can be many types and to surface roughness. causes of metal casting defects. These casting defects can be related to the alloy and/or the mold/metal interfacial Solidification simulation is a valuable tool in the foundry issues. There are several publications dedicated to industry. They can be used to predict casting defects. imagining and identifying causes for these defects. Simulations are mainly used for design and sometimes for However, the processing parameters related to such manufacturing problem solving. Nowadays the metal defects are lacking.1,2 Casting issues at the sand/metal casting industry is using a solidification simulation interface result in defects such as inclusions, veining, software to predict casting quality. The rational for using penetration, scabs, scars, erosion, etc.3 Moreover, the this approach would be to identify casting design issues Page 1 of 10 2020 AFS Proceedings of the 124th Metalcasting Congress Paper 2020-076 (10 pages) and detect metallurgical concerns prior to actual materials and processes, testing will be performed over production. various sand binder systems. The disc-shaped specimens used in this study is identified in Table 1. Current solidification simulation tools contain superior alloy property data but property data for granular media is PUCB Specimens lacking. Real time information such as temperature, The PUCB disc-specimens were prepared by blowing the pressure and fill velocities derived from simulation specimens with a laboratory core blower into a core box. software is useful in understanding erosion phenomena. Researchers can make a reasonable argument that either Materials: metal flow or the sand binder properties are responsible The sand was a washed and dried Wisconsin round grain for erosion defects by studying the properties of the silica sand 65 GFN, 3 screen, roundness/sphericity chemically bonded sand and simulation results. (Krumbein) 0.8/0.8, pH 7.1, acid demand 0.8 and the total Polyurethane binder level was 0.9% B.O.S. This chemically bonded sand erosion study uses a casting trial model developed at Western Michigan University Procedure: (WMU) and involves acquired related data from both 1) Add weighed sample of sand to DeLonghi Mixer. casting simulation and laboratory sand testing. The 2) Make two pockets in the sand. purpose of this study was to determine if there are 3) Add Part 1 component into one pocket and Part II to different erosion tendencies among various chemically the other pocket. bonded sands with respect to iron and aluminum castings. 4) Mix for 1 minute. 5) “Flip” mixture and mix for 1 additional minute. OBJECTIVES 6) Using laboratory core blower set at 0.379 MPa (55 1. To measure the surface roughness of a cast psi) for 0.5 seconds and blow the mixed sand into the alloy/chemically bonded sand specimen interface at four cavities of the core box. different head pressures. 7) Cure by gassing with TEA using a Luber gas 2. To measure the volumetric changes occurring at a generator. Gassing parameters: 1 second gassing with cast alloy/chemically bonded sand specimen TEA, followed by an air purge for 6 seconds (gas interfaces at different head pressures. pressure at 0.172 MPa (25 psi) and air purge pressure at 0.103 MPa (15 psi)). METHODOLOGY Refractory Coated PUCB: Some of the PUCB disc-specimens were refractory An experimental model was designed to perform a casting coated. The coating used in this study were ceramic- trial on chemically bonded sand specimens. The graphite coatings similar to those used by iron sand chemically bonded sand specimens will be used as the casting foundries. A LabWave IV microwave solids mold/metal interfaces during casting. The methodology analyzer was used to determine the solids content and was divided into three areas: deionized water was used to dilute the coating to 38% 1. Preparation of disc-shaped chemically bonded solids. Disc-shaped specimens were manually dipped into sand specimens. the mixed coating to the same depth for two seconds. 2. Gray cast iron and aluminum casting trials. 3. Data gathering, observation and analysis. SHLHB Specimens SHLHB specimens were prepared using a hot-box core Note: All chemically bonded sand systems used in the making technique used in industry when employing resin experiment were tested in controlled laboratory coated sand systems. conditions: the ambient temperature at 70 ± 2˚F (20 ± 1˚C) and relative humidity at 50±2%. Materials: The sand was an Illinois round grain silica sand 60 GFN, DISC SHAPED SPECIMENS 3 screen, roundness/sphericity (Krumbein) 0.7/0.7, pH In the present work, specimens of phenolic urethane 7.1, acid demand 0.8 and the total Phenolic-Novolac amine cold box (PUCB), hot-box shell (SHLHB) and 3D binder level was 1.3% B.O.S. printed furan (FUR3D) were fabricated. Procedure: Specimens (50 mm in diameter by 8 mm thick) were The hot-box cure temperature used for producing provided by three different manufacturers. The specimens was 250°C for 40 seconds. manufacturers all used dissimilar specimen fabrication techniques, sands, binder levels, and chemistries. The FUR3D Specimens chemical sand binder systems used were not optimized for These disc-specimens were 3D printed. the casting alloy, fill temperature, or head-pressure. To ensure the proposed approach is valid across numerous Page 2 of 10 2020 AFS Proceedings of the 124th Metalcasting Congress Paper 2020-076 (10 pages) Materials: the final casting. This prediction will allow the The sand was a washed and dried round grain silica sand comparison of actual castings to obtain information for 80 GFN, 2 screen, roundness/sphericity (Krumbein) improving the design. Table 1 shows values obtained 0.8/0.8, pH 7.0, acid demand 0.8 and the total Furan from simulation results. binder level was 1.4% B.O.S. Procedure: The FUR3D specimen were printed on an ExOne S Max #8. FUR3D printed disc-shaped specimens were produced within the same build-box. Processing parameters such as binder level, recoater angle, and print speed were controlled. Table 1. Disc-Shaped Specimens Types Specimens Fabrication Method PUCB Phenolic urethane amine cold box Refractory coated phenolic urethane Coat-PUCB amine cold box Figure 1. CAD image of erosion model. SHLHB hot-box shell Table 2. Simulation Predictions FUR3D 3D printed furan No. Temperature Velocity (m/s) CASTING TRIALS Aluminum 6” 730 1.4 The casting trial consisted of the following steps: Gray Cast Iron 6” 1511 (℃) 1.37 i.
Load more

Recommended publications
  • Casting High Quality C12A
    Casting High Quality C12A Valve Manufacturers Association of America March 2012 BRADKEN ENERGY PRODUCTS March 2012 Elaine Thomas, Director of Metallurgy Bradken Tacoma ASTM A217 C12A and ASME Code case 2197-7 Chemistry Element wt% C 0.08 – 0.12 Mn 0.30 – 0.60 Si 0.20 – 0.50 P 0.020 S 0.010 Mo 0.85 – 1.05 Cr 8.0 – 9.5 Nb 0.060 – 0.10 V 0.18 – 0.25 N 0.030 – 0.070 Al .02 Ti .01 Zr .01 2 © 2011 BRADKEN® QUALITY SYSTEM MANUAL 3 © 2011 BRADKEN® CERTIFICATES • ASME • ISO 9002:2002 • Det Norske Veritas • Nuclear Industry Assessment Committee (Audit) • American Bureau of Shipbuilding • LLOYDS Registrar • Boeing D6-56202 4 © 2011 BRADKEN® EMPLOYEE TRAINING • • TrainingTraining Manuals Manuals for Skilled for Skilled Positions Positions • • ContinuingContinuing Education Education From ProfessionalFrom Professional Society Participation Society Participation ––AmericanAmerican SocietySociety for forTesting Testing and Materials and Materials ––SteelSteel FoundersFounders Society Society of America of America ––AmericanAmerican FoundryFoundry Society Society ––AmericanAmerican WeldingWelding Society Society ––AmericanAmerican SocietySociety for forNon Non-destructive-destructive Testing Testing • • ContinuingContinuing Education Education From NationalFrom NationalConferences Conferences – Offshore Technical Conference – Offshore Technical Conference – Submarine Industrial Base ––SubmarineMarine Machinery Industrial Association Base Conference ––MarineHydro Vision Machinery Association ––HydroPower -VisionGen – Power-Gen 5 © 2011 BRADKEN® THE CASTING
    [Show full text]
  • Implementation of Metal Casting Best Practices
    Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof.
    [Show full text]
  • Mahimkar, C., Richards, V., Lekakh, S., Metal-Ceramic Shell Interactions During Investment Casting, Transactions Of
    Paper 11-077.pdf, Page 1 of 11 AFS Proceedings 2011 © American Foundry Society, Schaumburg, IL USA Metal-Ceramic Shell Interactions during Investment Casting C. Mahimkar, V. L. Richards, and S. N. Lekakh Missouri University of Science and Technology, Rolla, Missouri Copyright 2011 American Foundry Society When steel is poured into preheated ceramic shells, the ABSTRACT prime coat of the shells comes in contact with the melt and its oxides. Thus, there is the possibility of melting Interactions of liquid steel with preheated ceramic shell and/or chemical reactions at the mold-metal interface. molds can adversely affect the surface quality of Metal-mold interactions have been studied for decades in investment castings and increase casting cleaning and the casting industry but most of the work was dedicated to finishing expenses. This phenomenon was studied using a study the specific burn-in/burn-on surface defect special cube-shaped specimen with a deep pocket. The formation when using green sand and no-bake sand temperature field in the specimen and shell during the molds. Gilliland found the mold material at or near mold- casting process was simulated with MAGMAsoft. A metal surface often becomes a burnt sand layer, which has foam pattern was used to form investment casting shells experienced temperatures equal to or very close to solidus prepared in the Missouri S&T Laboratory with three point of metal being cast1. He conducted experiments by different prime coats: silica, zircon and alumina. For pouring gray iron, ductile iron and steel into sand molds comparison, shells prepared around the same specimen and observed interface reactions in hot and cold regions.
    [Show full text]
  • Foundry Industry SOQ
    STATEMENT OF QUALIFICATIONS Foundry Industry SOQ TRCcompanies.com Foundry Industry SOQ About TRC The world is advancing. We’re advancing how it gets planned and engineered. TRC is a global consulting firm providing environmentally advanced and technology‐powered solutions for industry and government. From solid waste, pipelines to power plants, roadways to reservoirs, schoolyards to security solutions, clients look to TRC for breakthrough thinking backed by the innovative follow‐ through of a 50‐year industry leader. The demands and challenges in industry and government are growing every day. TRC is your partner in providing breakthrough solutions that navigate the evolving market and regulatory environment, while providing dependable, safe service to our customers. We provide end‐to‐end solutions for environmental management. Throughout the decades, the company has been a leader in setting industry standards and establishing innovative program models. TRC was the first company to conduct a major indoor air study related to outdoor air quality standards. We also developed innovative measurements standards for fugitive emissions and ventilation standards for schools and hospitals in the 1960s; managed the monitoring program and sampled for pollutants at EPA’s Love Canal Project in the 1970s; developed the basis for many EPA air and hazardous waste regulations in the 1980s; pioneered guaranteed fixed‐price remediation in the 1990s; and earned an ENERGY STAR Partner of the Year Award for outstanding energy efficiency program services provided to the New York State Energy Research and Development Authority in the 2000s. We are proud to have developed scientific and engineering methodologies that are used in the environmental business today—helping to balance environmental challenges with economic growth.
    [Show full text]
  • Quantifying Casting Quality Through Filling Conditions
    2020 AFS Proceedings of the 124th Metalcasting Congress Paper 2020-051 (14 pages) Quantifying Casting Quality Through Filling Conditions Daniel Hoefert,1 David Weiss,1 Randy Oehrlein,2 Cory Sents,2 Travis Bodick,2 Chris Hastings,3 Jerry Thiel,4 Travis Frush,4 Leah Dunlay,4 Kip Woods,4 Robin Foley,5 John Griffin,5 Kyle Metzloff,6 Henry Frear6 1Eck Industries Inc., Manitowoc, WI; 2Carley Foundry Inc., Blaine, MN; 3Morris Bean & Co., Yellow Springs, OH, 4University of Northern Iowa, Waterloo, IA, 5University of Alabama/Birmingham, Birmingham, AL; 6University of Wisconsin/Platteville, Platteville, WI, Copyright 2020 American Foundry Society ABSTRACT This leaves us to wonder, is this also happening below the surface? Focused concern and education related to filling damage and oxide inclusions has been widely promoted among If entrained into the metal stream, even a thin oxide film the foundry industry in the past three decades; with may present a threat to the quality of a casting. Alumina special regards to aluminum.1 However, predicting the skin is insoluble to the melt and has a melting point more quantifiable damage that oxide film may cause to the than double that of molten aluminum.2 The interface of quality of aluminum castings during the filling process the folded skin (bifilm) will not bind to itself; essentially remains largely theoretical, due to a lack of supporting forming a crack. The density of alumina is nearly the data. The purpose of this experiment was to turn on and same as aluminum,3 making them difficult to observe turn off turbulent filling conditions consistent with bifilm with radiography.
    [Show full text]
  • Transmission Case
    Title Page --Aluminum MMC Transmission Case A Design Study in Metal Matrix Composite Castings Transmission Case for the Advanced Amphibious Assault Vehicle Design Study Outline Introduction Designing for Performance Alloy Selection Designing for Castability Orientation in the Mold Metal Flow and Thin-Wall Fill Gating/Rigging Design Tooling Machining Lessons Learned and Summary Start the Design Study ! Next Acknowledgment -- The metalcasting design studies are a joint effort of the American Foundry Society and the Steel Founders' Society of America. Project funding was provided by the American Metalcasting Consortium Project, which is sponsored by the Defense Logistics Agency, Attn: DLSC-T, Ft. Belvoir, VA, 22060-6221 Copyright 2001 by the American Foundry Society In cooperation with All rights reserved. Address comments to: [email protected] Eck Industries Return to AFS Last Modified:September, 2001 by STG Home Page file:///C|/Documents%20and%20Settings/Administrator.ROB3/Desktop/dev/tutorials/aaavtrans/default.htm [2/6/2002 12:25:34 PM] Application A Design Study in Metal Matrix Composite Castings - AAAV Transmission Case Transmission Case - Application The Application -- This component is the transmission case for the Advanced Amphibious Assault Vehicle (AAAV) being developed for the U.S. Marine Corps. The AAAV is a high water-speed amphibious armored personnel carrier designed to replace the current family of Marine Corps assault amphibians. The AAAV will weigh about 37 The AAAV provides a tactical assault capability for Marines on amphibious ships standing well tons, be able to carry 17 combat offshore—even over the horizon—from the equipped Marines and a crew of 3 objective. The vehicle will rapidly transport the landing force over the beachhead to an objective over 3 ft.
    [Show full text]
  • The AIST Foundation: Raising Awareness for the Steel Industry of Tomorrow
    Foundation President’s Message The AIST Foundation: Raising Awareness for the Steel Industry of Tomorrow Dear members, The success of the AIST Foundation is due largely to financial support from the steel industry in addition to the dedicated efforts of the Board of Trustees . We thank Fred Harnack, retired from United States Steel Corporation, for his two years of leadership as president of the Foundation . As I begin my two-year tenure as president, I look forward to continuing the good work of the AIST Foundation . Since 2005, the AIST Foundation has awarded more than US$5 3. million in scholarships and grants to over 500 university students and teaching profes- sionals at more than 50 different universities . During this time, more than 55 steel plants have provided internship opportunities as part of the scholarship program . In addition to various scholarships administered by our 22 Member Chapters, the Foundation offers three levels of scholarships, all of which are for one year: • US$3,000 for steel scholarships . • US$6,000 for steel scholarships, which include a paid summer internship . • US$12,000 to our top-scoring applicant . Almost 60% of all AIST Foundation interns have secured employment in our industry, so the success rate is quite high for these particular scholarships . The Foundation also offers several grants aimed at increasing the number of students choosing steel as a career path, including our Kent D . Peaslee Junior Faculty Award (US$35,000 per year for 3 years) . While this is still a new program, industry awareness has greatly increased because of the recipients’ efforts to organize plant tours and university “steel days ”.
    [Show full text]
  • GRAY IRON CASTINGS SDS SC-000-041 Rev
    SAFETY DATA SHEET (SDS) GRAY IRON CASTINGS SDS SC-000-041 Rev. 13 DATE ISSUED Meets the Requirements of OSHA Standard 29 CFR 1910.1200 Hazard Communication and EPA Supplier Notification Requirements under Section 313 of the Emergency Planning and Community Right-to-Know Act. 04/19 SECTION 1—PRODUCT IDENTIFICATION & COMPANY INFORMATION PRODUCT NAME GRAY IRON CASTINGS OTHER DESIGNATIONS: ASTM (American Society for Testing & Materials) Specification No’s., (ACI (Alloy Casting Institute) Alloy Designations— Grades) ASTM: A48, A74, A126, A159, A278, A319, A667, A748, A823, A942 PRODUCT IDENTIFICATION (Label Identifier) MANUFACTURER’S NAME STREET ADDRESS EMERGENCY TELEPHONE NO. MAILING ADDRESS TELEPHONE NO. CITY, STATE, ZIP CODE, COUNTRY FAX NO. E-MAIL ADDRESS/WEBSITE RECOMMENDED USE OF CHEMICAL AND RESTRICTIONS ON USE Solid casting; no restrictions on use SECTION 2—HAZARD IDENTIFICATION CLASSIFICATION Castings are metal articles that do not present hazards in their original form. Grinding castings that have not been cleaned or that contain embedded sand may generate significant amounts of dust containing crystalline silica. Dust or fumes generated by machining, grinding, drilling, melting, casting, sawing, blasting, polishing, buffing, brazing, soldering, welding or thermal cutting of the casting may produce airborne contaminants. The following proposed classification and label elements are for the hazardous substances that could be released or generated from these processes. CLASSIFICATION Respiratory Sensitizer, Category 1A (hexavalent chromium)
    [Show full text]
  • Lost Foam Casting
    Emerging Technology and Successful Partnerships: Lost Foam Casting Harvey Wong, U.S. Department ofEnergy Kenneth M Green, BCS, Incorporated ABSTRACT In 1989, a consortium offoundries, suppliers, and academiajoined the U~So Department ofEnergy (DOE) .. in a research program to improve c'ontrol over the lost foam casting process thereby reducing defects and producing high quality precision castings. Lost foam casting is a process that offers many energy and environmental advantages and enables the production of complex parts. The government side,ofthis partnership is led by the u.s. DepartmentofEnergy (DOE), Office ofEnergy Efficiency and Renewable Energy, Office ofIndustrial Technologies (OIT), Metal Casting Industry ofthe Future. Research is conducted through the Lost Foam Technology Center at the University of Alabama em Birmingham. The Consortium has been credited as the driving force behind technical improvements in the lost foam casting process.. Ithas improved knowledge andcontrol inall stages oflostfoam casting.. The LostFoam Casting research was recently profiled by the International Energy Agency, Centre for the Analysis and DisselninationofDemonstrated Energy Technologies (CADDET). Lostfoam casting isjustone of many metal casting techniques. The Metal Casting Industry of the Future partnership is conducting research to improve productivity and energy efficiency innearly all areas ofcasting.. Usingthe ongoing Metal Casting Industry ofthe Future lostfoam research as anexample, paper discusses the be ts ofindustry-government consortia advancing R&D for critical U"S .. industries such as metal casting.. It describes how such partnerships can be pivotal in helping to move emerging technologies from concept to implementation~ Introduction metalcasting industry is vital to the U.S. 1\./lIt::lA'tt:1lmr"':'llC""t'llnn ~n~u"ul::li>CI the to complex parts to meet a variety engine blocks to plumbing fixtures.
    [Show full text]
  • Casting Skin Literature Search
    Ductile Iron Society RESEARCH PROJECT No. 47 Literature Summary: Deteriorated Graphite in Casting Surfaces Ductile Iron Society Research Committee Report Compiled by Doug White - Elkem DUCTILE IRON SOCIETY Issued by the Ductile Iron Society for the use of its Member Companies – Not for General Distribution DUCTILE IRON SOCIETY 15400 Pearl Road, Suite 234 Strongsville, Ohio 44136 (440) 665‐3686 JANUARY 2012 Ductile Iron Society- Research Committee Report literature Summary: Deteriorated Graphite in Casting Surfaces SUMMARY DIS Research has shown that a considerable drop in the fatigue life of ductile iron castings occurs when there are surface defects or deteriorated graphite in the skin of castings. Papers demonstrate this can be due to reactions with the mold or cores due to the presence of S from seacoal or binder systems, oxygen such as moisture in greensand, or N bearing gases from some sand binder systems. Other researchers have studied additional surface quality issues that impact properties. Means to minimize or eliminate these issues have been proposed. DIS Hot Topic articles and DIS Research reports are available to members on the DIS website. AFS Transaction papers will be available to people who have previously purchased AFS Transactions. Other AFS literature such as Modern Casting articles or copies of AFS Transaction papers may be obtained by contacting AFS. Doug White: Technical Service Manager, Elkem Materials, Inc. January 2012 Literature search - Deteriorated Graphite Structures on Cast Iron Skins. DIS Literature DIS Research Project No. 17 Sulfur in Molding Sand Effect on Flake Graphite at the Cast Surface of Ductile Iron Castings George DiSylvestro and Robert Christ Ductile Iron Society Research Report No.
    [Show full text]
  • Sodium Silicate and Hydrolyzed Collagen As a Hybrid Core Binder for Pollution Prevention in Foundries
    The Pennsylvania State University The Graduate School College of Engineering SODIUM SILICATE AND HYDROLYZED COLLAGEN AS A HYBRID CORE BINDER FOR POLLUTION PREVENTION IN FOUNDRIES A Thesis in Environmental Engineering by Joshua F. Allen © 2014 Joshua F. Allen Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Science August 2014 The thesis of Joshua F. Allen was reviewed and approved* by the following: Fred S. Cannon Professor of Environmental Engineering Thesis Adviser Robert C. Voigt Thesis Co-Advisor Professor of Industrial and Manufacturing Engineering Peggy A. Johnson Professor of Civil Engineering Head of the Department of Civil and Environmental Engineering *Signatures are on file in the Graduate School. ii Sodium Silicate and Hydrolyzed Collagen as a Hybrid Core Binder for Pollution Prevention in Foundries Joshua Allen (Abstract) Pollution management is an essential task in the manufacturing of cast metals. Conventional foundry production practices are currently being challenged by ever tightening environmental regulations. Herein, an emerging pollution prevention core binder is studied as a potential sustainable and cost efficient alternative to help meet volatile organic compound (VOC) air emission standards. Petrochemical sand core binders are favored for their thermal stress resistance during metal pouring and then for their ability to subsequently shake-out after metal solidification. However, when the molten metal is poured into the mold and around the petrochemical cores, the core binder decomposition releases VOCs that are then released into the surrounding environment. The goal of this research was to evaluate and advance the development of a sodium silicate and hydrolyzed collagen core binder to prevent VOC formation by petrochemical binder replacement.
    [Show full text]
  • Abst Head – Abstract Heading
    2020 AFS Proceedings of the 124th Metalcasting Congress Paper 2020-074 (11 pages) Qualification Case Study for Chemically Bonded Sand System P. Patel, L. Wells, S. Ramrattan Western Michigan University, Kalamazoo, MI Copyright 2020 American Foundry Society ABSTRACT INTRODUCTION Chemically bonded sand systems have been used to BACKGROUND manufacture complex near-net-shape castings for more The United States is the third largest supplier of castings than sixty years. Over this period, many foundries have in the world and the metal casting industry is the sixth substantially invested in advanced technologies for largest industry in the United States, according to melting and filling processes, such as automated pouring American Foundry Society.1 Metal castings are essential systems, spectrometers, etc. Despite these investments, to a majority of industries such as defense, automotive, the casting industry still suffers from high variability and construction, agriculture, aerospace, oil and gas, mining, scrap/rejection rates. One cause of these quality issues is railroad, transportation, and health care. Casting quality is the inability to effectively monitor the quality of incoming a major contributor to the success of these industries. sand-binder systems. Most foundries are dependent on their sand-binder suppliers to detect differences in Casting quality losses and rejection rates are directly incoming sand-binder systems as foundries expect to related to foundry operational costs, such as; labor, receive consistent sand-binder systems. This dependency energy, raw material, and delayed customer delivery. In stems from the fact that foundries use traditional addition, sand consumption and cost continue to increase. chemically bonded sand tests, such as the hot tensile Metal casting industries use about 9% of the industrial strength test, which suffer from excessive levels of sand for foundry purposes.2 Figure 1 shows the dramatic variability that makes them insensitive sand-binder increase in unit price of sand and gravel3 over the last system shifts.
    [Show full text]