CORE
TY PROD-2017-18
CORE
• Used for making cavities and hollow
projections.
• All sides of core are surrounded by the molten
metal and are therefore subjected to much
more severe thermal and mechanical
conditions and as a result the core sand should
be of higher strength than the moulding sand.
Natural and Synthetic molding sand
Natural molding sand:
This is ready for use as it is dug from the ground. Good natural
molding sand are obtained from Albany, New york etc.
The following average compositions are seen
in natural molding sand:
.>5.5% silica grains, 21.7% clay content, 12.8% undesirable impurities.
>Too much clay content and other impurities fill up the gaps between
the sand grains.
> This will hinder the necessary passage of steam and other gases
during pouring of the mold.
>Synthetic molding sand Synthetic molding sand is made by mixing
together specially selected high quality clay free silica, with about 5%
of clay.
>They are tailor made to give most desirable results
Some of the advantages of synthetic
molding sand are:
[Link] grain sizes are more uniform,
2. Higher refractoriness (= 3000oF),
3. less bonding agent is required (about 1/3rd of
the clay percentage found in natural molding
sand),
4. More suitable for use with mechanical
equipment
Advantages of natural molding sand: 1.
moisture content range is wide,
2. molds can be repaired easily
Desired characteristics of a core
• Green Strength: A core made of green sand should
be strong enough to retain the shape till it goes for
baking.
• Dry Strength: It should have adequate dry strength
so that when the core is placed in the mould, it
should be able to resist the metal pressure acting
on it.
• Refractoriness: Since in most cases, the core is
surrounded all around it is desirable that the core
material should have higher refractoriness.
• Permeability: Gases evolving from the molten metal
and generated from the mould may have to go through
the core to escape out of the mould. Hence cores are
required to have higher permeability.
• Permeability Number: The rate of flow of air
passing through a standard specimen under a
standard pressure is termed as permeability
number.
• The standard permeability test is to measure time
taken by a 2000 cu cm of air at a pressure typically
of 980 Pa (10 g/cm2), to pass through a standard
sand specimen confined in a specimen tube. The
standard specimen size is 50.8 mm in diameter and
a length of 50.8 mm.
• Then, the permeability number, R is obtained by
VH
R
pAT
Where V= volume of air = 2000 cm3
H = height of the sand specimen = 5.08 cm
p = air pressure, g/cm2
A = cross sectional area of sand specimen = 20.268 cm2
T = time in minutes for the complete air to pass through
Inserting the above standard values into the expression,
we get
501.28
R
p.T
PERMEABILITY NUMBER
• Calculate the permeability number of sand if it
takes 1 min 25 s to pass 2000 cm3 of air at a
pressure of5 g/cm2 through the standard
sonample.
Solution:
p 5.0 g / cm 2
T 1min 25 s 1.417 min
501.28
R 70.75
5 1.417
IES-2012
What is permeability? Permeability is more
important in the basic process of sand casting
than porosity. Give one important reason for
this feature.
[2 marks]
SOME OF THE PROPERTIES
• Collapsibility: At the time of cooling, casting shrinks, and
unless the core has good collapsibility (ability to decrease in
size) it is likely to provide resistance against shrinkage and thus
can cause hot tears.
• Friability: The ability to crumble should be a very important
consideration at the time of removal.
• Smoothness: Surface of the core should be smooth for good
finish to the casting.
• Low Gas Emission
CORE SANDS
• Used clay free silica sand.
• Binders used are linseed oil, core oil, resins, dextrin,
molasses, etc.
• Core oils are mixtures of linseed, soy, fish and petroleum
oils and coal tar.
• The general composition of a core sand mixture could be
core oil (1%) and water (2.5 to 6%).
Metal Casting
Dr. D. N. Raut