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Application of alcohol based spraying coating on green sand mould for steel casting

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2015 IOP Conf. Ser.: Mater. Sci. Eng. 103 012012

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4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

Application of alcohol based spraying coating on green sand

mould for steel casting

Z L Xu1,3, J Wang2, S S Yang2, Q L He2 and H Sh Xiong2

1
Wuhan Textile University, Wuhan, 430073, China
2
Tongling Branch, CSR Yangtze Co., Ltd., Tongling, Anhui, 244000, China

E-mail: xzl9675@163.com

Abstract. A kind of coating suitable for green sand steel casting was developed. Thepractical
application showed that the strength of the coating was high enough with no crack and no
peeling under room temperature after drying the spraying coating, the performance of the
coating for anti-cracking was good under high temperature, and the gas evolution of the
coating was low. Using the coating, the casting surfaces finish appearedvery good.

1. Introduction
Sodium silicate or resin sand molding is most used for steel casting production. Due to high cost of
sodium silicate sand and resin sand molding, also difficulty for shakeout, deoxidization and recycling,
many foundries began to use green sand molding instead them. Green sand molding which is low cost,
high efficiency, occupies an important position in the casting production [1-3]. However, directly
using green sand mould to cast steels is liable to bringing about burnt-on sand, sand inclusion, sand
holes or/and other casting defects, therefore, the appropriate coating matching is necessary, and the
development of fireproof coating for steel casting by green sand molding is of great significance.

2. The characteristics of green sand casting steel coating

Pouring temperature in steel casting is high, up to 1550~1600, it requires coating being with
resistance to high temperature and burnt-on sand for steel casting mould. The strength of green sand is
poor, brushing coating on the surface of green sand mould will be easy to bring up the sand, so it is not
suitable for brushing, and spraying is preferred. Water-based paint will further increase the sand
surface moisture, causing sand strength lower, at the same time increase the gas evolution, and drying
process influence the production efficiency, so alcohol based spraying coating is more appropriate.
Since the permeability of green sand mould is low, and gas evolution tendency of it is larger, the gas
evolution of alcohol-based coating should be as small as possible. Spraying process requires that the
refractory particle should be fine, requires that the coating should be in good adhesion strength on
mould sand, be good permeability, and be more resistant to cracking and peeling.
In general, after spraying, the coating could dried by ignition, also can be natural dried. But light
dry may be easy to cause coating peeling and cracking, because the volatile solvent burn fast, the
coating dry too quickly, shrink sharply, and the strength of sand mould surface is basically low and get
to be lower due to the solvent infiltration. Therefore, air drying after spraying coating would be

3
Address for correspondence: Z L Xu, Wuhan Textile University, Wuhan, 430073, China. E-mail:
xzl9675@163.com.

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Published under licence by IOP Publishing Ltd 1
4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

advisable.

3. The component of spraying coating for green sand steel casting

3.1. Refractory aggregate

It is generally believed that zircon powder is the most suitable refractory aggregate for cast steel
coatings [4]. However, the production practice shows that the single zircon powder coating may not
completely resist burnt-on sand, and zircon powder coating is expensive [5]. Besides zircon powder,
other high fire resistance of the aggregate such as white corundum, brown corundum, bauxite, is
relatively economy, with which the burnt-on sand resistance would be better than that of the single
zircon powder coatings as long as the ingredient is appropriate[6, 7].
For a long time, the ingredient of coatings only focus on composition of additives such as binder,
suspending agent and accessory ingredient, ignore the collocation of refractory aggregate. Really for
one kind of good quality coating, the kinds of refractory aggregate, in which the collocation about
particle size are also important to be considered, in addition to the appropriate additives proportion. If
the aggregate particles are too coarse, the spraying nozzle would be blocked, too fine, the coating will
be not conducive to reducing crack tendency [4]. Taken together, a certain proportion of white
corundum and brown corundum blended in with zircon powder as refractory aggregate was adopted in
our scheme. Aggregate particles mesh distribution was between 220 ~ 325 mesh.

3.2. Agglomerant
Coating must have sufficient strength both at room temperature and at high temperature. Agglomerant
of alcohol-based coating for room temperature involve resin, rosin, polyvinyl butyral (PVB), and for
high temperature involve bentonite clay, refractory clay, phosphate, ethyl silicate and so on.
Considering coating strength, crack resistance and fast drying characteristics, an appropriate
constituent of organic and inorganic agglomerant blended as a multiple adhesion agent was proposed
to satisfy the necessary strength for both room temperature and high temperature [8].

3.3. Suspending agent

Coating must be of good suspension stability, so as to facilitate transportation, storage and stirring to
be uniform seriflux before spraying. Due to the compatibility problems to be blended into alcohol
solvent, the suspending agent for alcohol-based coating is not a lot, and the suspensibility of alcohol-
based coating is always less than that of water-based coating. The suspending agent for alcohol-based
coating involves PVB, sodium-based bentonite, lithium-based bentonite, organic bentonite, and some
commercial suspending agent such as SN suspending agent, etc. PVB and resin would form a dense
protective film which does not facilitate the resin combustion gas to go out of coating and prone to
blistering while burning coating, should not be added much. Sodium-based or lithium-based bentonite
need water to be swelled, water will be increased in coating, which reduce the strength of sand mould
surface, and is not conducive to quick drying, meanwhile, water precipitation would decrease coating
stability. It is clear that neither sodium-based bentonite nor lithium-based bentonite is suitable for
spraying coating. No matter what kind of coating, bentonite can't be added much, otherwise cracking
will be likely to occur on coating.[4, 8, 9] As comprehensive consideration, the organic bentonite, a
small amount of PVB, were added as the suspending agent.

3.4. Solvent
The solvent of coating was a kind of mixture based on anhydrous ethanol with other alcohol solvent,
in which compatibility of mixture within coating would be improved, leading to quick drying.

3.5. Additives
Adding additives can improve wettability, dispersion, permeability, adhesion strength of coating,
reduce or eliminate the tendency of cracking and peeling. Additives commonly used that could

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4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

enhance permeability and dispersion are JFC and OP-10[3, 4, 9].

In order to improve the agglomeration of the coating, and to reduce the tendency to burnt-on sand,
an oxide sintering agent was appended.

4. Testing of coating performance

4.1. Viscosity, Baume degree and suspension property

Test of viscosity was by flow cup with a tapping hole of diameter 6 mm on the bottom, Baume
degree test was by Baume scale, and the test of suspension property was by quiet placing in graduated
flask.[4]

4.2. Coating strength at room temperature

Sand particles falling down from a viscosity cup to hit a coated glass surface until the coating was
chafed, weighing the weight of the sand dropped out once the coating was abraded, the total weight of
the sand was as the evaluation index of surface coating strength, seeing the reference for specific
operation. [4]

4.3. Crack resistance at high temperature

A 60mm 60mm cylinder specimen was made from green sand with washing silica sand 50/100
mesh (old and new sand ratio of 1:9), which contain 3.0% bentonite and 3.5% water. The sample was
sprayed coating with thickness of 0.5-0.8 mm, air dried, then was put inside a furnace within which
high temperature atmosphere was to 1200, staying 2 minutes, the coating crack could be observed if
it was likely to crack. [4, 5]

4.4. Gas evolution

Scraping coating powder and crushing down, weighing accurately for 1.0 g, the gas evolution of
coating at 850 could be measured by SFL type recording gas evolution test apparatus. [4, 5]

4.5. Cracking and peeling resistance at room temperature

Evaluation of cracking situation of coating while drying after spraying on green sand moulds at room
temperature was by actual observation.

4.6. Sintering and stripping property

Casting steels actually, sintering and strippingperformance of the coating was evaluated by actual
observation.

5. Ingredient of coating and the main performance

Referring to the domestic and foreign literature [1-11], by some tests in laboratory and production trial
in workshop, an appropriate ingredient of coating was determined, which is shown in table 1. Coating
performance is shown in table 2.
Table 1.Ingredient of coating for spraying alcohol-based green sand mould (%).
Zircon powder + Organic Organic Inorganic PVB Additives Mixture
corundum bentonite binder binder solvent
66 2.0-3.0 1.0-2.0 1.5-2.5 0.2-0.5 2.0-5.0 remainder
Table 2.Performance of coating for spraying alcohol-based green sand mould.
Viscosity Baume Suspension Density/ Coating Resistance to Gas
( 6 flow degree/ property gcm-3 strength at cracking at evolution
cups)/s Be (24 h)/% R.T./g H.T. /mlg-1
(1200,120s)

3
4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

14 63 >95 1.7~1.9 459 grade I <18.5

6. Application of the coating

6.1. Production trial and effect show

Alcohol-based spraying coating for green sand was used in steel foundry, in Tongling Branch, CSR
Yangtze Co., Ltd.. Surfaces of the green sand moulds for casting bolsters and frames were sprayed
with coating. After drying in the air, no crack or peeling was observed on the coating film, and the
casting surfaces finish were good, as shown in figures 1 and 2.

(a) (b)

(c) (d)
Figure 1.Spraying coating on (a) half mould of a side frame (b)an end of mould of side frame
(c) upper mould of a swing bolster and (d) lower mould of a swing bolster in production.

(a) (b)

(c) (d)

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4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

Figure 2.Surface finish of (a) side frames (b) low beam surface of a side frame (c) swing
bolsters and (d) local area of a swing bolster marked part number before shot blasting by
spraying coating on green sand moulds.

6.2. Discussion

6.2.1. Influence of bentonite and agglomerant on coating. Appropriate amount of bentonite and
agglomerant, is the guarantee for good suspending and rheological properties of the coating, also the
guarantee for wet strength after spraying, for dry strength at room temperature after drying, for high
temperature strength while casting, of the coating. If bentonite in coating were not enough, or too
much, cracking or peeling is likely to occur on the coating after spraying. This is because insufficient
bentonite could lead to low wet strength, and too much of bentonite could lead to big shrinkage and
cracking. If agglomerant were not enough, dry and wet strength of the coating would be low, that is
liable to cause crack. Once crack occur at wet coating in the process of drying, the crack will be easy
to extend, become a long crack and cause peeling on the coating after drying, as a result, the coating
would have to be out of effect. Too much of organic agglomerant, maybe beneficial to the
improvement of the wet and dry strength, but would cause a large gas evolution, thus pinholes might
appear on casting surfaces.

6.2.2. Influence of additives on coating. Two additives are worth noting. First, wetting agent, which
promote wetting between coating and mould, should be in moderation, too much would lead to poor
film-forming, even to local crack, and too little, would lead to poor permeability and poor adhesion on
mould surface in some local surfaces, as a result, it would be difficulty for coating to "take root", bring
about uneven shrinkage strain on the coating in the process of drying, thus would lead to peeling and
cracking. Sometimes, even though no cracking and peeling at coating, the whole coating is going to
fall off due to inadhesion to moulds, which immediately lose shielding effect because of cracking or
being washed away at high temperature while casting pouring. The second, flake sintering additives,
involve several oxides added, are to counter the oxide consumption in reaction with such as SiO2 and
Al2O3 existing in sand mould surfaces. Redundant oxide would accumulate on the metal surface, form
a kind of molten sintering layer that would be easy to peel off from casting due to the difference of
contraction coefficient, avoiding burnt-on sand on casting, and casting surfaces would be clean. Too
little oxide added would lead to poor/no resistance to burnt-on sand, and too much, would lead to
deterioration of the coating strength.

6.2.3. Influence of the solvent. A kind of mixture solvent based on anhydrous ethanol added other
alcohol solvent such as isopropyl alcohol, methanol and n-butyl alcohol under the appropriate
proportion, was used, which would be the guarantee of wet strength of coating. Single use of ethanol
or industrial alcohol, coating is prone to crack. This may be the consequence that the single anhydrous
ethanol solvent would evaporate too fast, causing the coating drying fast before it penetrate into sand
mould.

6.2.4. Influence of coating spraying process. Spraying process is important besides the quality of
coating must be qualified, and the adjustment of process would be necessary to adapt depending on the
change of seasons. In 20-25 environment, the baume degree suggestion of coating 58-63 would be
more appropriate. In hot summer above 30, the baume degree suggestion 56-60, and in cold winter
below 10, the baume degree could be adjusted to 60-63, but not more than 65. If baume degree were
too high, it is difficult for the coating to penetrate into the sand mould before air dried, and if baume
degree were too low, solvent permeability is too much to deteriorate sand strength, that would be easy
to cause the coating crack and peeling. Spraying pressure suggestion is 0.2-0.35 Mpa. If the pressure
were too high, coating grain will rebound, make against form coating. The spraying nozzle height to
the mould surfaces should be appropriate with 500-700 mm, too low for the height is similar to the

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4th Global Conference on Materials Science and Engineering (CMSE 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 103 (2015) 012012 doi:10.1088/1757-899X/103/1/012012

consequences of too high for the pressure. Conversely, too high for the height is similar to the
consequences of too high baume degree because the solvent would be lost fast in the air.

7. Summery

7.1. The developed coating is good and feasible

The spraying coating developed for green sand casting steel, is of high wet strength, of good cracking
resistance at room temperature and high temperature. No burnt-sand occurrence on steel castings and
the surface finish of castings were good, after spraying on green sand moulds before casting.

7.2. Matters needing attention about preparing coating

To prepare coating for green sand casting steel as spraying coating, attention should be paid to the
amount of bentonite, appropriate addition of additives and the use of mixed alcohol solvent, so as to
avoid crack and peeling, to ensure the coating sintering layer formed under high temperature reaction,
then the surface of casting to be easily peeled off and to avoid burnt-sand.

7.3. The correct spraying process is necessary

The correct spraying process could ensure to achieve the best effect of the coating.

References
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mould casting J. B.Voc.Tech. Coll.11 1-2
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Work.Technol. 35 44-5
[3] Feng S S and Zhu S L 2005 The application of new alcohol based spraying coating for green
sand mold Foundry 54 65-9
[4] Li Y C 2008 Foundry Coating and Applications (Beijing: Mechanical)
[5] Wang G H 2000 Study of zircon and emery powder alcohol based compound coating Journal of
Shenyang University and Technology 22 196-9
[6] Wang G H 2000 Investigation of alcohol based compound coatingfor steel castings Foundry 49
279-81
[7] Liu F L 2002 Development and application of alcohol-based coating Modern Cast Iron 2002(1)
54-6
[8] Qu Y H, Gao Y M, Xing J D, Jiang X and Fu P 2002 Preparation of zirconite ointment coating
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[10] Hong Y 2009 Choice of burning-on defect preventing coating for heavy castings Modern Cast
Iron 2009(1) 81-3
[11] Xiao Q G and Jin Y 2010 Development of efficient coating with environmental protection for
casting Ningxia Machinery 32 21-3