No Cracking Ceramic Coated Silica Sand 1850C Refractoriness 2.2 g/cm3
1. Ceramic Foundry Sand Introduction
Ceramic Foundry Sand, technically named as “Fused Ceramic Sand for Foundry”, also named as ceramite, is good spherical grain shape which is made from calcined bauxite. Its main content is aluminum oxide, and it is processed by melting, blowing, sieving and blending. Ceramic sand, has much better properties than that of silica sand to gain a better performance in foundry. It has high refractoriness, stable inert characteristics, excellent flowability, intrinsic hardness and wear resistance.
2. Ceramic Foundry Sand Specifications
Thermal expansion :
| Sand Type | Linear thermal expansion | ||
| 20 – 300ºC | 20 – 600ºC | 20 – 800ºC | |
| Silica | 14.0 | 23.0 | 17.0 |
| Chromite | 7.1 | 7.5 | 7.5 |
| Zircon | 3.4 | 4.1 | 4.5 |
| Cerabeads | 3.5 | 4.0 | 4.3 |
| Ceramsite | 7.1 | 7.3 | 7.2 |
Compositions:
| Al2O3 | 78-86% |
| SiO2 | 8-13% |
| Fe2O3 | 3.5% (max) |
| TiO2 | 3.5% (max) |
| Refractoriness | 1850C (3362F) |
| Angle Coefficient | 1.1 (max) |
| Thermal Expansion (at 100°C) | 0.15 |
| Thermal Conductivity | 0.196 W/m.K |
| Specific Heat | 873 J/kg |
| Bulk Density | 1.9-2.2 g/cm3 |
| pH Value | 7.65 |
| Shape | Solid Sphere |
| Binder Content Required | 3-4% |
| Crushability | 113 |
3. Ceramic Foundry Sand General advantages
- The thermal expansion coefficient of ceramic sand is very low, which is similar to zircon sand. Using the Ceramic Foundry Sand to make moulds and cores, the veins and other expansion defects of castings are eliminated;
- Because of the great spherical shape of the particle, Ceramic Foundry Sand has good flowability and easy to fill in. The moulds and cores are of high permeability and easy to shakeout after casting;
- By using Ceramic Foundry Sand, 30-50% of the binder consumption can be saved with the smooth surface and substantial structure;
- Ceramic Foundry sand is a neutral and inert material, so it can be used in acid and alkali binders systems, also adapt to various alloys;
- Ceramic Foundry Sand has high refractoriness and good stability. It is especially suitable for the production of complexity sand cores and steel castings;
- It has wide particle size, which can be combined and mixed arbitrarily to meet specific needs of customers;
- Because of the high value of Moh’s Harness and spherical shape, Ceramic Foundry Sand has good recycling performance and low crushing ratio, so it can be easily reclaimed by many methods.
4. Ceramic Foundry Sand Particle Size Distribution
| TYPICAL CHEMICAL ANALYSIS | |
| AL2O3 | 70-75% |
| SiO2 | 8-20% |
| Fe2O3 | ≤3% |
| TiO2 | ≤3.5% |
| CaO | ≤0.45% |
| MgO | ≤0.35% |
| K2O | ≤0.33% |
| Na2O | ≤0.08% |
| TYPICAL PHYSICAL PROPERTIES | |
| Refractoriness | ≥1800 ºC |
| Specific gravity: | 3.4g/cm3 |
| Bulk density(LPD): | 1.95-2.05 g/cm3 |
| Color: | black brown |
| Grit shape: | spherical ball |
| Thermal expansion coefficient | 6x10-6 /ºC(20-1000ºC) |
| Thermal conductivity | 0.698W/M.K(1200ºC) |
| Thermal expansion ratio | 0.12% |
| Angularity | ≤1.1 |
| Available sizes | |
| AFS15-20,AFS 15-25,AFS25-35,AFS25-30,AFS30-35,AFS35-40,AFS40-45,AFS45-50,AFS40-50,AFS50-55,AFS55-60,AFS60-65,AFS60-70,AFS70-80,AFS95-110 Customized sizes are available upon request | |
5. Ceramic Foundry Sand Applications
Silica sand in dry condition largely apply in Vacuum(V)-casting and Lost-foam casting (LFC).
Silica sand creates a lot of dust in process which is very bad for environment and for workers health.
Ceramsite has high refractoriness than silica sand and high density in the mold by what we can achieve high castings surface quality and decrease the unqualified castings rate.
Ball shape ceramsite has better flowability than silica sand, so it can fill the special area like inside angel, deep groove, horizontal holes easier than silica sand. So it will decrease the defects of the castings and decrease the labor volume.
According to our experience, the sand cost can decrease 90% compared to silica sand and also discharge if the waste material will also be decreased.
In LFC, if we use resin and ceramiste, the resin cost will also be decreased by 1/3.
Ceramsite price is higher than silica sand. But if we take the above advantage into consideration, ceramsite is also the good choice for you. As the ceramsite has lower expansion rate. When we produce, iron castings especially spheroidal graphite iron castings, casting mould has limited expansion resists on the castings expansion because of graphitization. So the castings may has shringage, to avoid which casting head is needed.
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