Resin Coated Ceramic Foundry Sand Smooth Surface For Castings
1. Ceramic Foundry Sand Introduction
Resin Coated Ceramic Foundry Sand is a commonly used foundry material and a method in foundry practices, it produces castings of high precise dimensions, smooth surface, free of blow holes and devoid of casting defects. It is one of the best moulding sands for cars, tractors and hydraulic parts. This method is now popularly used in core-making and moulding processes in foundry, especially as the well-known “shell method”.
Size: NFS25-35; NFS25-30; NFS30-35; NFS35-40; NFS40-45; NFS45-50; NFS40-50; NFS50-55; NFS55-60; NFS60-65.
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 |
3. Ceramic Foundry Sand General advantages
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Higher refractoriness—-to cast metals with high pouring temperature (cast steel, alloyed cast steel, stainless steel, etc.)
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High strength and toughness—–to produce more complicated cores with thin sections.
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Lower thermal expansion—–to avoid expansion defects
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Higher reclamation yields—-to reduce waste sand disposal, to decline costs.
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Excellent flowability —–to make complicated cores.
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Lower binder consumption—–lower gas evolution,lower manufacturing costs
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Inert chemical characteristics—–can applied in any popular alloys,includes Manganese steel.
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Longer storage period.
Taking advantages of Ceramic Foundry Sand, people can make high quality resin coated ceramic foundry sand, which has exceptional properties such as high refractoriness, low thermal expansion, easy to shakeout, high strength, and less gas evolution. For particularly complex cores, resin coated ceramic foundry sand has good flow-ability, which can solve the problem of being not fully formed.
The shell process of the ceramic foundry sand is of high production efficiency. The casting dimensional accuracy and the castings finish are exceptional. The used sand is easy to recycle, which greatly reduces the emission of solid wastes. The environmental benefits of this process are also remarkable.
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 | |
Properties of RCS using Ceramic Foundry Sand(typical)
| Resin addition,% | Tensile strength,MPa | Bending strength ,MPa | Thermal bending strength,MPa | Gas evolution, ml/g | Softening point,℃ | LOI,% | GFN |
| 1.9 | 2.8 | 6.3 | 2.5 | 11.3 | 92 | 1.8 | AFS 58 |
5. Ceramic Foundry Sand Applications
Resin Coated Ceramic Foundry Sand is a dry, pre-coated sand mix that is cured by heat. Sand is coated with a phenolic novolac resin along with a hexamethylene tetramine (hexa) cross-linker and other additives specific to the core or mold making process.
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