Coal has often been regarded as a problem additive to solve and improve the surface finish of iron castings,but at the same time causes other issues such as increased loss on ignition,total fines and moisture in syste...Coal has often been regarded as a problem additive to solve and improve the surface finish of iron castings,but at the same time causes other issues such as increased loss on ignition,total fines and moisture in system sands.Although many altermatives have been tried,there is no real substitute for thw all round properties of this wonderful natural resource.With the correct choice of coal,the combination of low ash,high volatile and swell index properties coupled with the key element of grading size,ensures castings are produced free from metal penetration and surface related problems.By careful selection,safe handling and processing coal continues to offer a good simple cost effective solution.Coal is subject to regulations in storage,processing and transportation and then further subjected to safe handling and use by the foundry.Despite these handicaps,it is still economical to the end user and modern processing and grading methods ensure it is used in the optimum condition to help produce quality castings.展开更多
The need for control of raw materials is critical to the success of iron casting production from greensand systems. The base silica sand is often overlooked with the main focus on bentonite additions. Carbonaceous add...The need for control of raw materials is critical to the success of iron casting production from greensand systems. The base silica sand is often overlooked with the main focus on bentonite additions. Carbonaceous additives can be considered a "necessary evil" to ensure a good surface finish and reduction in sand related surface defects. Other additives are used when systems get out of balance and these in turn add further to the complex nature of greensand systems. For castings requiring cores this becomes a bigger issue as many differing resin systems are employed for core production and these must be taken into consideration when controlling both the carbonaceous levels and the overall grading of the sand system. The twin effects on additional carbon and loss-on-ignition and overall sand grading need careful understanding and control. Various control methods are examined including traditional methods such as volatiles and loss-on-ignition along with bentonite determination methods and grading methods. Newer control methods such as total carbon are reviewed along with the overall package of testing and control methods.Various predictive methods are looked at as a control feature as well. The quality of additives and their role and more importantly their interaction is highlighted,as this is an area often neglected as foundrymen battle for success in consistent quality castings. Suggested in-coming control tests are discussed allied to additions at the mixer. Also reviewed is the interpretation of results and the action required to ensure control and more importantly consistent quality castings from greensand systems with the emphasis on the understanding and control of carbonaceous additive on casting performance.展开更多
文摘Coal has often been regarded as a problem additive to solve and improve the surface finish of iron castings,but at the same time causes other issues such as increased loss on ignition,total fines and moisture in system sands.Although many altermatives have been tried,there is no real substitute for thw all round properties of this wonderful natural resource.With the correct choice of coal,the combination of low ash,high volatile and swell index properties coupled with the key element of grading size,ensures castings are produced free from metal penetration and surface related problems.By careful selection,safe handling and processing coal continues to offer a good simple cost effective solution.Coal is subject to regulations in storage,processing and transportation and then further subjected to safe handling and use by the foundry.Despite these handicaps,it is still economical to the end user and modern processing and grading methods ensure it is used in the optimum condition to help produce quality castings.
文摘The need for control of raw materials is critical to the success of iron casting production from greensand systems. The base silica sand is often overlooked with the main focus on bentonite additions. Carbonaceous additives can be considered a "necessary evil" to ensure a good surface finish and reduction in sand related surface defects. Other additives are used when systems get out of balance and these in turn add further to the complex nature of greensand systems. For castings requiring cores this becomes a bigger issue as many differing resin systems are employed for core production and these must be taken into consideration when controlling both the carbonaceous levels and the overall grading of the sand system. The twin effects on additional carbon and loss-on-ignition and overall sand grading need careful understanding and control. Various control methods are examined including traditional methods such as volatiles and loss-on-ignition along with bentonite determination methods and grading methods. Newer control methods such as total carbon are reviewed along with the overall package of testing and control methods.Various predictive methods are looked at as a control feature as well. The quality of additives and their role and more importantly their interaction is highlighted,as this is an area often neglected as foundrymen battle for success in consistent quality castings. Suggested in-coming control tests are discussed allied to additions at the mixer. Also reviewed is the interpretation of results and the action required to ensure control and more importantly consistent quality castings from greensand systems with the emphasis on the understanding and control of carbonaceous additive on casting performance.
