THE UNIVERSITY OF ZAMBIA
SCHOOL OF MINES
DEPARTMENT OF METALLURGY
NAME: MOSES MUSHEHENU
COMPUTER ID: 2020558485
COURSE CODE: MET 5349
TITLE: ASSIGNMENT 1
ATTENTION: DR. L. SUBASHINI
Tests normally done on molding sands
i. Moisture content
Moisture content may be determined by loss of weight, after evaporation.
Procedure :
To test the moisture of a moulding sand a carefully weighted test sample of 50 g is dried
at a temperature of 105°C to 110°C for 2 hours by which time all the moisture in the sand
would have been evaporated. The sample is then weighted. The weight difference in
grams divided by the weight of sample (50 g) and multiplied by 100 gives the percentage
of moisture contained in the moulding sand.
Alternatively a ‘moisture teller’ can also be used for measuring the moisture content. In
this arrangement the sand is dried by suspending the sample on a fine metallic screen
and allowing hot air to flow through the sample. This method of drying completes the
removal of moisture in a matter of minutes compared to 2 hours as in the earlier method.
Another ‘moisture teller’ utilises calcium carbide to measure the moisture content. A
measured amount of calcium carbide (a little more than that actually required for complete
reaction) in a container along with a separate cap consisting of measured quantity of
moulding sand is kept in the moisture teller (Sand and calcium carbide should not come
into contact with each other).
The apparatus is then shaken vigorously such that following reaction takes place:
CaC2 + 2H2O ̶ C2H2 + Ca(OH)2
The amount of C2H2 produced is proportional to the content of the moisture in the sand.
The moisture content is directly measured from a calibrated scale on the instrument.
ii. Permeability
Permeability (or porosity of the moulding sand) is the measure of its ability to permit air
to flow through it. It is measured in terms of “Permeability number”.
Procedure. To carry out this test, a test specimen of moulding sand (50.8 mm dia × 50.8
mm long) is placed in a specimen tube. Time taken for 2000 cm 3 of air at a pressure of
980 Pa (10 g/cm2) to pass through the specimen is noted. Then, the permeability number,
P is given as:
where, V = Volume of air = 2000 cm3
H = Height of the sand specimen = 50.8 mm = 5.08 cm
p = Air pressure = 10 g/cm2
A = Cross-sectional area of sand specimen =
π /4 × (5.08)2 = 20.268 cm2
t = Time in minutes for complete air to pass through.
Substituting the above standard values into the expression, we get,
This permeability number is a relative number. It does not necessarily tell the permeability
of a would made with the same sand which depends on the compactness of the sand.
The permeability test is conducted for two types of sands:
— Green permeability is the permeability of the green sand.
— Dry permeability is the permeability of the moulding sand, dried at 105 to 110°C to
remove the moisture completely.
iii. Strength
The strength of moulding sands can be carried out on the universal sand strength testing
machine. The strength can be measured in compression, shear and tension. The sands
that could be tested are green sand, dry sand or core sand. The compression test and
shear test involve standard cylindrical specimen that was used for the permeability test.
Green compression strength. It refers to the stress required to rupture the sand
specimen under compressive loading. The sand specimen is taken out of the specimen
tube and is immediately (any delay causes the drying of the sample which increases the
(strength) put on the strength testing machine and force required to cause the compressor
failure is determined. The green strength of sands is generally in the range of 30 to 160
kPa.
Green shear strength. With a sand similar to the above test, a different adapter is fitted
in the universal machine so that loading now be made for the shearing of the sand sample.
The stress required to shear the specimen along the axis is then represented as the green
shear strength. The green shear strength may vary from 10 to 50 kPa.
Dry strength. The test similar to the above can also be carried with the standard
specimens dried between 105 and 110°C for 2 hours. Since the strength greatly increases
with drying, it may be necessary to apply larger stresses than the previous tests.The
range of dry compression strengths found in moulding sands is from 140 to 1800 kPa,
depending on the sand sample.
iv. Clay content
The clay content of moulding sand is determined by dissolving or washing it off the sand.
Procedure :
(i) A 50 g sample of moulding sand is dried at 105 to 110°C. This dried sample is
taken in a one litre glass flask and added with 475 ml of distilled water and 25
ml of a 1% NaOH solution (NaOH 25 g per litre). This sample is thoroughly
stirred.
(ii) After the stirring, for a period of 5 minutes the sample is diluted with fresh water
upto a 150 mm graduation mark and sample is left undisturbed for 10 minutes
to settle. The sand settles at the bottom and the clay particles washed from the
sand would be floating in water. 125 mm of this water is siphoned off the flask
and it is again topped to the same level and allowed to settle for 5 minutes.
(iii) The above operation is repeated till the water above the sand becomes clear,
which is an indication that all the clay in the moulding sand has been removed.
(iv) The sand is removed from the flask and dried by heating. The difference in
weight of dried sand gives the clay content.
v. Size and distribution
Fineness test. This test determines the size of grains and the distribution of grains of
different sizes in the moulding sand. This test is performed on completely dry and clay
free sand.
Procedure. To carry out this test the dried clay-free sand grains are placed on the top
sieve of a sieve shaker which contains a series of sieves one upon the other with gradually
decreasing mesh sizes. The sieves are shaken continuously for a period of 15 minutes.
After this shaking operation, the sieves are taken apart and the sand left over on each of
the sieve is carefully weighed. Each weight is converted to a percentage basis. Each
percentage is multiplied by a weighting factor and these are added to get the sum of
products. Then the grain fineness number (GFN) is expressed;
According to AFS (American’s Foundrymen’s Society), the various sieve mesh numbers
and the corresponding multiplying (weightage) factors are as follows:
REFERENCES
1. A Textbook of Manufacturing Technology Manufacturing
Processes by R. K. Rajput · 2007
2. Manufacturing Technology – I By C. Elanchezhian, B. Vijaya
Ramanath · 2006
