Compression Strength of Open-Cell Aluminum Foam Produced by Green Sand Casting using The Energy Conservation Lost-Foam Technique

Permeability and green compression strength are among the important mechanical properties and considered much in the sand casting mould preparation. These molding sand properties play a vital role in determining the optimum moisture content for making green sand casting mould. Tailing sand is the residue mineral from tin extraction, which contains between 94% and 99.5% silica and in abundance in Kinta Valley of state of Perak, Malaysia. In this research work, samples of tailing sands were gathered from four identified ex tin mines located at the Perak State, Malaysia. They were investigated by the standards and testing procedures prescribed by the American Foundrymen Society (AFS). Sand specimens of size Ø50 mm×50 mm in height from various sandwater ratios bonded with 4% clay were compacted on applying three ramming blows of 6666 g each by using a Ridsdale-Dietert metric standard rammer. The specimens were tested for green compression strength using Ridsdale-Dietert universal sand strength machine and permeability number with Ridsdale-Dietert permeability meter. Before the tests were conducted, the moisture content was measured using moisture analyzer. Samples with moisture content ranging from 3 to 3.5% were found to have optimum working range with effective green compression strength and permeability.

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The Effect of Bentonite Clay on Green Compression Strength for Tailing Sands from Old Tin Mines in Perak State, Malaysia for Making Green Sand Casting Mould

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.471-472.769 ◽

2011 ◽

Vol 471-472 ◽

pp. 769-774 ◽

Cited By ~ 2

Author(s):

A. Abdullah ◽

Shamsuddin Sulaiman ◽

B.T. Hang Tuah Baharudin ◽

Mohd Khairol A. Arifin ◽

T.R. Vijayaram

Keyword(s):

Compression Strength ◽

Standard Procedure ◽

Bentonite Clay ◽

Clay Content ◽

Sand Casting ◽

Green Sand ◽

Foundry Sand ◽

Casting Quality ◽

Study Test ◽

Operating Instructions

Clay has an important role in making green sand casting mould beside water. Clay acts as binders, holding the sand grains together. Water is needed to activate the clay bond. Without the addition of water on clay, no strength would be achieved on sand mould, as the sand and clay would be just two dry materials. Bentonite clay was used in this study. Adequate clay content with suitable moisture in moulding sand is important for optimum strength and casting quality. Too little or too much clay will not give proper strength. Green compression strength is one of the mechanical properties to be considered for making green sand casting mould. The green compression strength of foundry sand is the maximum compressive strength that a mixture is capable of sustaining when prepared, rammed and tested according to standard procedure. For this study, test is conducted according to Foundry Sand Testing Equipment Operating Instructions from Ridsdale and Dietert. Result from this study indicates that tailing sand has potential for making green sand casting mould in term of green compression strength. Other factors that must be considered are permeability and shatter index.

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Mechanical Properties of Tin Tailing Sand-Clay Mixture from Batu Gajah, Perak, Malaysia for Making Greensand Casting Mould

Materials Science Forum ◽

10.4028/www.scientific.net/msf.773-774.211 ◽

2013 ◽

Vol 773-774 ◽

pp. 211-217 ◽

Cited By ~ 2

Author(s):

Azhar Abdullah ◽

S. Sulaiman ◽

B.T.H.T. Baharudin ◽

M.K.A. Ariffin ◽

N. Haliza

Keyword(s):

Mechanical Properties ◽

Grain Size ◽

Moisture Content ◽

Compression Strength ◽

Vital Role ◽

Sand Casting ◽

Green Sand ◽

Test Pieces ◽

Average Grain Size ◽

Cylindrical Test

Tailing sand from ex-tin mine in Batu Gajah containing between 95.9 to 98.9% silica. In this research involved the process of, conducting the mechanical sieve grading to identify the size spread, plotting the grain size distribution and calculating the average grain size. Further on with the effects of controlled additions of clay (bentonite) and water and determining the working range on the mechanical properties. The investigation involved comparing the mechanical properties of the tailing sand to the requirement for foundry sand applications listed by Foseco Ferrous Foundrymans Handbook (Foseco). Permeability and green compression strength are the important mechanical properties and considered much in the sand casting mould preparation. These mechanical properties play a vital role in determining the allowable clay and moisture content for working range of tailing sand for making green sand casting mould. Experiments for this investigation were conducted according to American Foundrymen Society (AFS) standard of procedures. Cylindrical test pieces dimensioning of Ø50 mm×50 mm in height from various sandwater ratios bonded with 3.8%wt clay and then 7.4%wt clay, were compacted by applying three ramming blows of 6666 g each using Ridsdale-Dietert metric standard rammer. The specimens were tested for green compression strength using Ridsdale-Dietert universal sand strength machine and permeability number with Ridsdale-Dietert permeability meter. Before the tests were conducted, the moisture content was measured using moisture analyser. Tailing sand with allowable moisture content ranging from 3 to 3.5% (bonded with 3.8%wt clay) and 5.5 to 6% (bonded with 7.4%wt clay) were found to have optimum working range with effective green compression strength and permeability.

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Green strength properties of waterjet abrasive waste as potential composition in green mould by Taguchi and ANOVA approach

JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES ◽

10.15282/jmes.15.4.2021.06.0672 ◽

2021 ◽

Vol 15 (4) ◽

pp. 8529-8539

Author(s):

NUR FARAH BAZILAH BINTI WAKHI ANUAR ◽

M.L. Mohd Khusairi ◽

R.M. Saad ◽

S.A. Hassan ◽

Z. Marjom ◽

...

Keyword(s):

Shear Strength ◽

Compression Strength ◽

Negative Impact ◽

Coal Dust ◽

Strength Test ◽

Sand Casting ◽

Silica Sand ◽

Green Sand ◽

Sand Mixture ◽

Waterjet Cutting

The sand casting process still continues today due to the cost-effectiveness of materials and processes. There is a wide variety of castings related to composition and size, but silica sand is widely available from coastal line mining and has a negative impact on the environment. Moreover, waste from waterjet cutting of non-ferrous and ferrous metals is practically unhazardous and may potentially be used in sand casting mould. The aim of this paper is to optimize the proportion of coal dust, water and bentonite added to the silica sand mixture and the waterjet cutting abrasive waste as a new way of handling waste with the potential to be used in sand casting manufacturing. The method used was L9 orthogonal array optimization and the composition was qualitatively measured using a green compression strength test and a green shear strength test. Factors were evaluated using the analysis of variance (ANOVA) to find the the critical factors while confirmation test was conducted for the optimal material proportion. The study concluded that the ideal ratio for silica sand mixture with waterjet abrasive waste is bentonite-12%, coal dust-5%, and water-7% for green compression strength while bentonite-12%, coal dust-6%, water-7% for green shear strength. With proper selection, the incorporation of waterjet abrasive waste into the green sand mixture is promising to potentially be used in green sand mould casting without undermine the quality of mould.

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Pressure Drop Measurements for Air Flow Through Open-Cell Aluminum Foam

Fluids Engineering ◽

10.1115/imece2004-60428 ◽

2004 ◽

Cited By ~ 5

Author(s):

Nihad Dukhan ◽

Angel Alvarez

Keyword(s):

Reynolds Number ◽

Pressure Drop ◽

Flow Rate ◽

Aluminum Foam ◽

Flow Direction ◽

The Other ◽

Turbulent Regime ◽

Thick Sample ◽

Open Cell ◽

Two Samples

Wind-tunnel pressure drop measurements for airflow through two samples of forty-pore-per-inch commercially available open-cell aluminum foam were undertaken. Each sample’s cross-sectional area perpendicular to the flow direction measured 10.16 cm by 24.13 cm. The thickness in the flow direction was 10.16 cm for one sample and 5.08 cm for the other. The flow rate ranged from 0.016 to 0.101 m3/s for the thick sample and from 0.025 to 0.134 m3/s for the other. The data were all in the fully turbulent regime. The pressure drop for both samples increased with increasing flow rate and followed a quadratic behavior. The permeability and the inertia coefficient showed some scatter with average values of 4.6 × 10−8 m2 and 2.9 × 10−8 m2, and 0.086 and 0.066 for the thick and the thin samples, respectively. The friction factor decayed with the Reynolds number and was weakly dependent on the Reynolds number for Reynolds number greater than 35.

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