ISSUE 2/2012

/// 04
Ramrattan, S. N.; Makino, H.; Hirata, M.
A study of erosion in aeration green sand molds with various alloys

The design and use of a test casting to evaluate the casting performance in green sand molds produced from aeration sand filling and conventional filling is presented. The test castings described herein are designed to represent operating conditions found in the foundry production environment. Recently aeration sand mold filling technology was introduced to the foundry industry. Aeration sand filling technology uses low air pressure; the aeration technology provides sufficient and uniform sand density before squeeze. Therefore, the aeration technology can save energy. The authors have found that the aeration technology can make a lower friability mold and reduce casting defects.
Through the careful use of test castings, the foundry engineer can compare and select a molding technology and molding parameters which will result in defect free castings processing superior finish. A test casting is designed and developed to provide information on green sand performance. The resulting test castings provide information on casting surface quality, defect tendencies, and the effects of foundry processing variables; such as pouring temperature, head-height, and metal velocity on defect formation. Test castings, molding equipment, test parameters, and methods of interpreting results are described. Tests castings are evaluated for performance in terms of erosion resistance in cast iron, brass, and aluminum alloys. The applicability and interpretation of test casting results to production conditions is also discussed.  

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