68th WFC - World Foundry Congress OP-24

7th - 10th February, 2008, pp. 127-132

Green Sand Management – Role & Application of Carbonaceous

ABSTRACT Because, this for example, could affect the GFN of the sand
which in turn will affect the moisture demand or “temper
The advent of High Volume, High Density & High Pressure water “ of the system sand.
Molding Lines has changed the logistics of Molding Techniques
and selection of additives significantly. Having 4 main Simplicity and Complexities of a Unit Sand System
ingredients, Sand , Bentonite, Water & Additives, the properties Having 4 main ingredients :
of the Sand Mold resulting from this simple mixture to deliver
target casting quality is complexly variable. Modern machine . Sand
molding parameters demand increasing efficiency from the
. Bentonite
additives, many of which are natural resource based; having
limitations for developing their inherent properties under the . Water
speed, force and load conditions of modern foundry
installations. This challenge to optimize a given natural resource . Additives,
escalates sand preparation and management from being an ‘art’ the properties and effectiveness of the Sand Mold resulting
to being a ‘science’. Consequently, the importance of from this simple mixture to deliver target casting quality is
maintaining range-bound values of the prepared Sand in addition complexly variable & besides the quality of the inputs
to the promotion of a ‘reducing’ atmosphere in the metal-mold themselves, is, among other reasons, also a function of:
interface can minimize the occurrence of sand related defects.
– Sand to Metal ratio

SAND PREPARATION& IMPORTANCE OF – Grain Fineness (GFN) of the sand & the Bentonite
& Additives
MOLDING ADDITIVES IN MODERN FOUNDRY
INSTALLATIONS: – Molding & Mixing Machine types and
configurations
Sand Control is an “Art” as any foundryman will willingly
emphasize. It is well accepted that no two foundry sand The multiplicity of input sources and the complexity of newer
systems are the same. Even a single foundry Unit or foundry machine molding parameters demand increasing efficiency
group having two or more molding lines, along with separate from the sand molding additives, many of which are natural
Sand preparation lines, whether in the same campus or in resource based and therefore have inherent, natural
different locations, sand preparation and sand parameters limitations for developing their inherent properties under the
will normally differ in each sand loop. speed, force and load conditions of modern foundry
installations. This challenge to optimize a given natural
The advent of High Volume, High Density & High Pressure
resource escalates sand preparation and management to being
Molding Lines has changed the logistics of Molding
a ‘science’.
Techniques significantly.Today’s foundry manager rarely gets
to see the sand being mixed, or the additive being added, or The escalation of the sand mixing process from ‘mulling’ to
the prepared sand being transported to his molding machine, ‘intensive mixing’ and the importance of Bentonite
physically. development to target bond conditions from 3 minutes in
mulling to < 1.5 minutes in the intensive mixer is a classic
The role of quality in additives has therefore become even
example of this statement.
more important than when one could “feel” the sand & make
changes accordingly. Now, additives and ingredients have to DIFFERENTIATING ‘REAL’ AND ‘ABSOLUTE’
be engineered precisely for the application with assured
VALUES
reproducibility in chemistry, grain fineness & other
parameters. By themselves however, none of the above figures signify
the “real” quality of the prepared Sand. A well formulated
INTERPLAY OF MOLDING ADDITIVES IN LCA would give more optimum results in terms of sand peel
SAND MANAGEMENT AND CONTROL and surface finish @ 5% LOI than which an LCA which is
formulated from more passive sources of carbonaceous
For example, the lustrous carbon additive has to have the
additive; cannot give at even 6% LOI. Similarly, for example,
right grain fineness to match the GFN of the Molding sand.
an active Clay reading of 7.5% may be equal, in performance
terms, to a 8.5% active Clay reading, depending on the quality additive has just the right amount & right temperature type
of Bentonite that has been used in the Sand preparation of volatiles to evolve & maintain a gas cushion to match with
process. the permeability of the mold. Otherwise the result could be
pinholes, blowholes.
An outlook for applying any additive in the green sand
Therefore, it is an accepted view that any addition to Sand “REDUCING ATMOSPHERE” CONCEPT
for preparation of a mould should be viewed as an essential Seamlessly, the “Fixed Carbon” starts to volatize around
contaminant. If being termed as a “necessary contaminant” 680°C & the carbon evolved from the total volatiles
is acceptable; correspondingly its addition to the molding combines with the free oxygen in the mold cavity to
Sand should be as low as possible to achieve target molding form Carbon Monoxide(CO). Generation of CO reduces
properties to optimize the prepared sand mould for achieving the availability of oxygen to create a “reducing
a well dimensioned, clean and smooth casting surface, free atmosphere” in the mold cavity.
from Sand related defects. Quality of the inputs is therefore
very important to ensure that with minimal additions, maximum This prevents oxidization & metal mold reactions at
efficiency of intended use is achieved. metal mold interface. Possibilities of pinholes &
penetration defects are also reduced.
Concepts and Role of Carbonaceous Additives in improving
The extent of this phenomena will depend on the Volatile
Casting Surface Finish
Matter & the Fixed Carbon content of the Additive, to
. “Gas Cushion” Concept be present in the correct proportion to: match the weight
. “Reducing Atmosphere” Concept & configuration of the Casting, Sand Metal ratio,
permeability of the sand & its compactibility.
. “Lustrous Carbon” Concept
LUSTROUS CARBON CONCEPT
GAS CUSHION CONCEPT
While the carbonaceous additive is decomposing:
When Molten Metal is poured into the mold cavity, the
radiant heat causes particles of the carbonaceous additive – The Carbon in the Additive starts to coke, expanding in
distributed through the mold, to both carbonize (thermal Size, filling the voids between grains of sand. At the
decomposition) & ignite. The particles closest to the cavity mold’s inner surface this results in a smooth surface
surface, volatize faster and donate most of their volatiles presentation to the liquid metal as it solidifies there
between 300°C- 680° C and while volatizing, generate gas against. Throughout the mold, it reduces mold wall
which tries every route possible to escape from the mold movement & prevents expansion defects.
cavity, either through the casting itself, if it was so possible – Some fractions of volatile gases carry or donate particles
or through the pores of the sand Mold; into the atmosphere, of carbonized matter which form a thin layer of Pyrolitic
whichever is the route of least resistance, thereby forming a Carbon, generally termed as Lustrous Carbon, on the
temporary cushion of Gas. internal mold surface. This forms a thin non-wetting
It is therefore most important therefore to ensure that the barrier between sand & metal, contributing to smooth
parting of the Casting from the sand.

Effects in sand parameters when using high Fixed Carbon content Lustrous Carbon additive: Example:

Proceedings of 68th World Foundry Congress 128 7th-10th February 2008, Chennai, India
Narration to Chart # 1 well the sand has been controlled to form a firm, Refractory,
At start of introduction of high FC content LCA, target & smooth surface for the metal to solidify there against.
foundry was using a LCA whose low temperature volatiles
GOOD SAND MANAGEMENT - THE
were higher than the high temperature volatile. Result was
that; at the commencement of trials with Higher FC content IMPORTANCE OF PROCESS CONSISTENCY
LCA, the VM and LOI readings on 17.2.97 were almost equal. “A recent survey shows that there are 211 different categories
Lack of adequate Fixed Carbon in the system would have of ferrous casting scrap. Of these, 42 are attributable to
been resulting in an inadequate ‘reducing atmosphere’ in the melting practices and melting materials. There are 126 types
mold cavity. associated with core making and sand control. The balance
Customer was facing severe sand burn-on and surface of 83 categories of casting defects, are caused by molding,
roughness on the casting surface. S:M ratio was 3:1. It didn’t pouring, and cleaning. These are a few examples of what can
help that the return sand temperature was very high due to happen when management does not give proper
fast return sand cycles mandated by production pressures as consideration to changes which occur in the overall scheme
also a lack of mechanized sand cooling facilities. of operations.”1

From 17.2 to 21.2, there was a distinct increase in the gap Having achieved/targeted the ideal Molding Sand parameters
between LOI and VM readings. From 21.2 To 28.2 , that is a for your foundry, the next step is to ensure that each of
period of 4 days, the gap between the LOI and VM started these are range-bound. Please refer column 2 for the range
increasing and between 28.2 to 7.3; stabilized at a ratio of parameters in Table # 1 in earlier portion of this article
VM being 65%-70% of the LOI. This gap is perceived as the
development of the FC in the Unit sand.
IMPORTANCE OF PROCESS CAPABILITIES
Within 10 days, the sand peel improved and there was a The importance of maintaining range-bound values in
perceptible improvement in surface finish on the casting molding Sand parameters can never be understated. It
surface. does not just reflect good Sand practice; it speaks of
the underlying process capabilities developed by the
Sand Control foundry in managing Sand and optimizing the same for
It is emphasized that notwithstanding the Concepts of Gas the casting process.
Cushion, Reducing Atmosphere & Lustrous Carbon, these Normally, once a foundry has achieved this kind of
concepts/theories are not enough to prevent the metal from process capability, the occurrence of sand related defects
hitting the sand surface. The final quality of the surface is totally minimized. If there are defects, it can be
finish as well as defect free castings will depend now on how narrowed down to their incidence and cause, more
precisely since the other variables are standardized.

CHART # 2

7th-10th February 2008, Chennai, India 129 Proceedings of 68th World Foundry Congress
 Table 1
Fundamental and Ideal Sand parameters of prepared sand

Active Clay Tolerance range 7.8% to 8.5% depending on the swelling Index or bonding (montmorillonite)
from established capacity of the Clay.
mean level
Inert Fines ± 0.15 3.0% - 4%
Total Clay ± 0.20 the sum of the Active Clay + Dead Clay should normally be 11% -12%
Volatile Matter Should normally be 60% - 70% of the LOI
Loss on Ignition ± 0.15 5.5% - 6.0% - in conventional lines
4.5 – 5.0% in high pressure lines
4.0 – 4.5% in high pressure, flaskless Lines
Moisture (at ± 0.15 3.8% - 4.0% in Conventional Lines
molding 3.2% to 3.7% in High pressure lines
machine)
GCS ± 0.15 Depending on type of line. Conventional lines normally operate between
1100 – 1300 gm/cm sq. Compactibility 32– 45 depending on the molding machine
type

Narration to Chart # 2 prepared with return sand of Cylinder block a drastic drop in
Normally, an addition rate of Lustrous carbon additive is LOI values was observed. A search for causes of LOI drop
suggested between 0.2% to 0.4% depending largely on sand came up with following observations;
to metal ratio and casting shape and configuration. This Metal to sand ratio was low, i.e., 1:3.5 causing higher
range may increase due to core sand infiltration at shake out than normal burn out of the additives.
due to heavy weight cold box/ shell cores.
Cooling time after pouring was around 2 to 2.5 Hrs.
A study during a LCA change over program was conducted adding to extra burn out of Lustrous carbon material
in a reputed foundry manufacturing Cylinder Blocks & Heads
castings to determine reasons for a higher than normal Core sand introduction was high – around 105 kgs/box
addition rate of Lustrous Carbon additive & fluctuations in of cylinder block.
LOI on a wide range. Range bound LOI values after fine tuning additions based
Observation: There were fluctuations in LOI over a wide on return sand and core sand calculations for different
range: 4.5% to 5.2%. Especially, when molding sand was patterns.

CHART # 3

Proceedings of 68th World Foundry Congress 130 7th-10th February 2008, Chennai, India
Narration to Chart # 3 account of LCA is normally to be a function of evaluation
The study of the system return sand pattern and core sand of the following achievements of a good quality and
introduction into the system sand, estimated that core sand well planned LCA program.
was being introduced from Cylinder Block cores at 8.8% – Improved Surface Finish
which was apparently causing maximum dilution of LOI. – Reduced consumption of shots
Average core sand infusion was 3.5 to 4%. Raw sand addition – Reduced Fettling
rate was 1 to 3 %. Hence average, total new sand addition
(core sand + fresh silica sand) in the sand system was – Reduced sand related casting defects
adding up to 5%. – Reduced Man-hours on pre-dispatch casting
preparation = faster throughout times.
Action was taken to add LCA in variable amounts based on
the return sand pattern. Example: it was to be higher when – Reduced variables in sand Control =
sand was coming in from casting of cylinder blocks and Standardization of the sand molding process =
lower when tackling return sand from the brake drums and consistent, reproducible results.
lowest when accepting sand returning from smaller casting
Concept and Significance of Total v/s ‘active’ Carbon in the
bunch weights.
green sand system
RESULT OF ACTION: If we accept that most foundry sand related casting
After implementation of variable addition rate and reduction surface defects are mainly a result of metal-mold
in new sand addition in the cylinder block return sand; reaction, the solution to reducing these defects, if not
fluctuations in LOI showed reduction & a gradual rise in LOI eliminating them, is to focus on the de-oxidation of the
was also observed. Most importantly the LOI variations atmosphere in mold cavity. Namely, promotion of a
stabilized in range bound parameter of 0.3%. Result on the ‘reducing’ atmosphere in the metal-mold interface as
casting was a considerable drop in sand burn on/fusion in explained in previous slides.
several patterns. However, it is important to understand what is ‘total
carbon’ in a system sand and which of these types of
Using a Lustrous Carbon Additive - An Outlook for better
carbon are going to play the “active” role in this process.
understanding of the Role of a Lustrous Carbon Additive
• The use of a Lustrous Carbon Additive should be viewed Total carbon
as an essential component of the Unit Sand system and Carbon content of the carbonaceous additive added in
not in isolation of the system. If added in a well balanced the green sand mix.
manner it enhances sand properties towards better
surface finish. However, by itself a Lustrous Carbon Residual/coked/partially coked carbon from the thermal
Additive may minimize, but it cannot totally offset, degradation/decomposition of carbonaceous additive
effects of other imbalances of a sand system if already and other ingredients.
present due to other variables. In imbalance it could Residual/thermally decomposed carbon from the
cause casting defects. hydrocarbon resin used to bind the core
Matching the Additive to the Unit Sand Dynamics – not vice- Carbon from the un-burnt refractory material of the
versa coating such as graphite
• Since each sand loop is subject to different sand metal “Active” carbon
ratio, sometimes different molding machines, different
molding pressures, different density of molds & other As distinct from ‘activated’ carbon, in this article
numerous variables, by the same token of reasoning, “active” is the terminology used for purposes of this
the additives, be it clay or carbonaceous, have to match presentation to emphasize the useful carbon in a green
with the dynamics & parameters of the target sand sand mixture. it is the amount of the total carbon of the
system. The sand system does not & should not have carbonaceous additive, comprising the low-temperature
to adapt or compromise itself to the additives. The volatiles and the high-temperature volatiles (commonly
development of proprietary blends is the direct referred to as fixed carbon) which evolve as a result of
consequence of the varying Unit Sand dynamics. the thermal decomposition of the organic carbon present
However, wherever natural resources of required in the additive.
specifications are available, they are used with good This organic carbon is as distinct from processed carbon
results by foundrymen worldwide. such as synthetic graphite.
Lustrous Carbon Additive – Quality as a cost control tool Carbons generated during the thermal decomposition of
hydrocarbon products like camphor, petroleum fuels,
• A single percent increase in rejection due to sand related
polystyrene, also evolve lustrous carbon quite similar to
casting defect or deterioration of casting surface finish
that obtained from carbonaceous compounds like coal,
can account for the entire value of a LCA addition
coal tar pitch, asphalt, etc.
program of a foundry. Therefore casting cost control on

7th-10th February 2008, Chennai, India 131 Proceedings of 68th World Foundry Congress
The reason for using ‘active’ carbonaceous additives matter, both as elemental carbon as well a highly pyrolitic
carbon precipitating as Lustrous carbon film at the metal
The difference between carbonaceous additives used in
mold interface.
greensand molding like coal dust or equivalents, and
that of products like camphor and polystyrene is that It has to be available and/or formulated to contain
the latter evolve their carbon-rich gases at much lower sufficient high temperature volatiles that evolve at 6800C
temperatures than required in casting process. Typically in addition to the Volatile matter which volatizes between
between 180-200 degrees C. 300-680oC
Empirically, it is reasoned that the lustrous carbon This winning combination combined with other
additive should start donating its carbon and precipitate important characteristics such as its lustrous carbon
lustrous carbon from 300°C onwards in order to be most content and expansion/coking value co-efficient is what
effective in providing for the “reducing” atmosphere in enables it to contribute its mite to better and cleaner
the mold cavity to prevent oxidation defects due to surface finish on the casting, free from blow-holes,
metal-mold interaction. pinholes, explosive penetration, rough surface, sand
fusion and other related defects.
A true carbonaceous Carbon additive
It is important therefore to ensure that the carbonaceous REFERENCE
additive has “active” carbon element which is released 1. Art Spengler Lecture No.1 – Ductile Iron Society Publication”
in the process of thermal decomposition of the organic

Proceedings of 68th World Foundry Congress 132 7th-10th February 2008, Chennai, India