AU J.T. 13(3): 170-174 (Jan.

2010)

Effect of Moisture Content on the Moulding Properties of

River Niger Sand Using Tudun-Wada Clay as a Binder
Matthew Sunday Abolarin, Sunday Albert Lawal
and AbdulRahman Asipita Salawu
Department of Mechanical Engineering, Federal University of Technology
Minna, Nigeria
E-mail: <abolarinmatthew@yahoo.com; lawalbert2003@yahoo.com;
asipita68@yahoo.com>

Abstract

This work was conducted in order to investigate the moisture content of the
moulding properties of River Niger sand using Tudun-Wada clay as a binder. All the
result obtained show that the sand properties were affected by the quantity of moisture
content and other factor such as clay. The moisture content has the effect on the sand
properties at varying quantity of moisture, sand and fixed amount of clay. The higher
value of green strength show that the mould produced would have more resistance to
wear and eternal pressure. Increase in permeability number show that Tudun-Wada
clay moulds are better venting out evolved gas, therefore, when hot molten metal are
poured into the mould such defect as blow and holes would be eliminated. River Niger
sand is found to be suitable for use as foundry moulding sand. Tudun-Wada clay could
serve as a satisfactory alternative to bentonite for use as binding clay in foundry and
mould. The moulding mixture of Tudun-Wada clay and River Niger sand with
appropriate water content is suitable for ferrous and non-ferrous alloy casting of
component parts.
Keywords: Binder, casting, moisture, moulding, permeability number.

depend on the presence of some kind of clay

Introduction material or lake sand that is bonded to form
moulds for ferrous (iron and steel) and non-
Sand is the principal moulding material ferrous (copper, aluminum, brass etc) metal
in the foundry shop where it is used for all casting. Finally they must not contain
types of casting, irrespective of whether the impurities which might cause scabbing of the
cast material is ferrous or non-ferrous. This is casting surfaces (Brown 1994).
because it possesses the properties vital for Clays (binders) are added to give
foundry purposes. It’s most important cohesion to moulding sands and it provide
properties include its refractory nature, which strength to the moulding sand and enable it to
enable it to easily withstand the high retain its shape as moulding cavity. The
temperature of the molten metal and it will not principal mineral constituent of clays is
get fused. It’s chemical resistivity, which help kaolinite it is relatively plentiful as the major
it not to chemically react or combine with constituent of china and ball clays and when
molten metal and therefore can be used fired, clay has high alumina content that makes
repeatedly and it’s high degree of permeability, those clay reasonably refractory. Water exists
which allows gas and air to escape from the in many forms in clay (as combined, absorbed,
mould when molten metal is poured without free or hydrated). When clay is dissolved in
interfering with the rigidity and strength of the free water, it forms a suspension called
mould. Foundry sand consist primarily of colloidal solution. But the clay particles
clean, uniformly sized high proportion of flocculate (clump) and settle quickly in saline
quality silica and its bonding quality will water. Clays are easily moulded into a form

Technical Report 170

AU J.T. 13(3): 170-174 (Jan. 2010)

that they retain water when dry, and they rammer and then rammed with three drop of
become hard and lose their plasticity when the standard weight of 6.6kg. After ramming,
subjected to heat. the specimen was ejected from the specimen
tube. After ramming, the specimen was ejected
from the tube with the aid of specimen
Materials and Methods extractor. This procedure was repeated for the
preparation of the standard test specimens for
All the materials required for this the various compositions of the moulding
research work were sourced locally. The silica mixtures.
sand was sourced from River Niger at Lokoja
under Murtala Mohammed bridge. The binding Determination of Grain Size Distribution
clay was sourced from Tudun-Wada Dankadai
near Rafin Magami in Tudun-Wada Local The stocks of sieve were arranged
Government Council, Kano State. Each of the according to the sieve aperture with the largest
test specimens from the various mixture were aperture on top of the stock and then smallest
subjected to the relevant sand mould test such aperture at the bottom (on top of pan). Some
as Green Compression Strength, Green Shear quantity of sand were dried in the air and 100g
Strength, Dry Compression Strength, Dry of the sand sample was taken on to the top of
Shear Strength and permeability test and wee sieve stock and stocks were placed on a sieve
sieve analysis. All the tests were carried out shaker and then switched on, the time was set
with the sand testing equipment at the National to allow for vibration for a period of fifteen
Metallurgical Development Centre, Jos, (15) minutes and after vibrating for a period of
Plateau State of Nigeria. The test sample were 15minutes, the vibration stopped automatically.
prepared in accordance with the standard The sieves were removed one after the other
specification for the preparation of moulding beginning with one on top. The quantity of
sand test samples using Ridsolate standard sand sand remaining on each sieve was weighed.
rammer conforming to imperial (2”diameter x The weight was recorded accordingly on each
2” Height) or DIN (SCM diameter by 5cm sieve in the column corresponding to the sieve
height). Test sample specimens were prepared mesh number, i.e., British Standard Sieve
for laboratory experiment from various number (BSS). Each separate sieve weight was
moulding sand mixtures as shown in Table 1. multiplied by the preceding sieve mesh
number. The sum total of the product was
Sample Preparation divided by the total sample aligned and this
produced the fineness number of the sand.
The required quantity of the sand, clay Table 2 shows the results obtained.
and water for each of the samples A-F were
measured in accordance with the varying Table1. Percentage and weight composition of
proportion and put into the laboratory mixer moulding mixture.
and then mixed for about five minutes. When
thoroughly mixed, the mixture was discharged Water Clay Sand
% g % g % g
from the mixer through the discharge opening
A 1 6 12 72 87 522
at the bottom of the mixer. The quantity that
B 2 12 12 72 86 516
gives the required size of 5cm diameter x 5cm
C 4 24 12 72 84 504
height was weighed on the weigh-balance and D 6 36 12 72 82 492
then poured into the specimen tube. This E 8 48 12 72 80 480
weight differs for different mixtures of sand F 10 60 12 72 78 468
component. The tube with the sand sample
inside it was positioned in the specimen

Technical Report 171

AU J.T. 13(3): 170-174 (Jan. 2010)

Table 2. Grain size analysis.

Sieve Aperture BSS No. Wt % wt Cumulative Product
(mm) Retained Retained % wt
Retained
1.4 10 0.15 0.15 0.15 -
1.00 16 3.26 3.26 3.14 32.6
0.71 22 6.61 6.61 10/02 105.76
0.50 30 9.21 9.21 19.23 202.62
0.355 44 23.98 23.98 43.21 719.40
0.250 60 38.76 38.76 81.97 1705.44
0.180 100 12.73 12.73 94.97 763.0
0.125 150 3.36 3.36 98.06 336
0.090 200 0.86 0.86 98.92 129
0.063 300 0.41 0.41 99.33 82
-0.063 350 0.14 0.14 99.47 42
4118.62

Determination of Green Compression Determination of Dry Compression Strength

Strength
The prepared standard sample of 5cm
The Green Compression Strength was diameter x 5cm height was dried in an oven at
carried out using the universal sand strength a temperature of 1100C for a period of
testing machine. A prepared standard sample 30minutes and then removed and allowed to
was positioned in the compression head which cool in the air to ambient temperature. After
was already fixed into the machine. The sample cooling, the sample was fixed into the universal
was loaded gradually, while the magnetic rider sand-testing machine with the compression
moved along the measuring scale. As soon as head in place. The compressive load was
the sample reached its maximum strength, the applied and the samples failed at the ultimate
sample experienced failure and the magnetic compressive strength of the sample. The point
rider remain in position of the ultimate at which the failure occurs was recorded at
strength, while the load was gradually released. GCS and it is shown in Table 3.
This experiment was repeated for water content
varied thus; 1%, 2%, 4%, 6%, 8% and 10%. It Determination of Dry Shear Strength
was discovered that the GCS reduced with
increase percentage of water content in the The prepared standard sample of 5cm
sample as shown in Table 3. diameter x 5cm height was dried in an oven at
a temperature of 1100C for 30 minutes and then
Determination of Green Shear Strength removed from the oven to cool in an air to
ambient temperature. The same universal
The Green Shear Strength (GSS) which testing machine was used for dry compression
is the measure of the shear strength of the strength. In this case, the shear head was
prepared sample, when shear load is applied in replaced for the compression head. The shear
its green state. The machine used for the GCS strength was recorded at the point of failures of
was also used for the determination of green the standard test sample. The failed sample due
shear strength (GSS), except that the shear load is shown in Table 3.
compression head was replaced with shear
head in the machine. The shear strength was Determination of Permeability
recorded at the point of failures of the sample
loaded. It was discovered that as the percentage Gas permeability of a moulding sand is
of water increased, the GSS decreased as the ability of the sand mould to allow the
shown in Table 3. passage of gaseous product from the mould
cavity to the atmosphere. The permeability test
Technical Report 172
AU J.T. 13(3): 170-174 (Jan. 2010)

was carried out on the standard sample dry shear strength of sample of moulding
specimen of 5cm diameter x 5cm height. The mixture was observed to increase with moisture
specimen, while still in the tube, was mounted content reaching a maximum at 10% water
on permeability meter. The permeability meter addition as shown in Table 3.
is an electrical perimeter and it employed the River Niger sand is sub-angular in shape
orifice method for rapid determination of sand and brownish in colour. It is very fine silica
permeability. Air at a constant pressure is sand, the free content of clay of the sand makes
applied to the standard sample specimen, it suitable for use as core sand in addition to its
immediately after producing the sample and the suitability for use as a moulding sand. Tudun-
drop in pressure was measured on the pressure Wada clay is very fine clay and has a high
gauge, which is calibrated directly in plastic in nature when mixed with water. This
permeability numbers. The result was recorded characteristic of the clay makes it suitable for
as shown in Table 3. foundry application as a binder. The grain
fineness number of River Niger sand is 41.412
AFS fineness number. This grade of fineness
Results and Discussion number is suitable for all types of alloys steel
as this belongs to the group of fineness number
The Green Compression Strength (GCS) that has a wide range of application. The other
of the moulding sand mixture decreased from grades of the sand are very much available
11.11psi (76.59KN/m2) to 4.2 psi within the shore of the river. The selection of
2
(28.98KN/m ) of 1% and 10% water addition the appropriate grade of grain size for a
respectively. This shows that Tudun-Wada clay specific application largely depends on
has good bonding characteristic at 1% water experience and the nature of the alloy
addition. Metals can be cast with 1% water production in a particular foundry industry.
addition to the moulding sand mixture, mould River Niger sand and Tudun-Wada clay
wall erosion could occurred during pouring of when mixed together with varying percentage
hot liquid metal as a result of friable nature of of water produce a plastic mass with varying
the mould. degree of strength. In the green state of the
The Green Shear Strength (GSS) of the mixtures; the strength decrease with increasing
moulding sand mixture was observed to be moisture content, reaching its ultimate strength
decreasing from 1.2psi (8.28KN/m2) to 0.2 psi at 1% water addition which is friable. The level
(1.38KN/m2) of 1% and 10% water addition of strength reach between 2% to 6% water
respectively. The Dry Compression Strength additions conforms to the standard
for 1% water content is 62psi (427.8KN/m2) specification for metal casting moulding sands.
and this value increases with further increase in Although the strength level of 8% and 10%
moisture content of the mixture reaching the water addition are relatively lower enough
maximum value of 467.5 psi (3225.75KN/m2). these levels of moisture content are
It was discovered that the strength of the dry considerably much higher for some alloys such
sample is greater than that of calibrated as ferrous alloys, under green application.
strength on the universal testing machine. The

Table 3. Properties of mould sand mixtures with 12% clay.

Water (%) 1 2 4 6 8 10
Green compression strength (psi) 11.1 9.2 6.8 4.9 4.7 4.2
(KN/m2) 76.59 63.48 46.92 33.81 32.43 28.98
Green shear strength (psi) 1.2 1.1 0.6 0.5 0.3 0.2
2
(KN/m ) 8.28 7.59 3.6 3.45 2.07 1.38
Dry compression strength (psi) 62 73.5 465 467.5 >467.5 >467.5
(KN/m2) 427.8 507.15 3208.5 3225.75 >3225.75 >3225.75
Dry shear strength (psi) 8.5 22 110 140 205 230
(KN/m2) 58.65 151.8 759 966 1414.5 1587
Permeability (mmws) 280 360 420 350 300 260

Technical Report 173

AU J.T. 13(3): 170-174 (Jan. 2010)

Fig.5. Effect of moisture content (%) on

permeability (mmws).
Fig.1. Effect of moisture content (%) on the
green compression strength (KN/m2).
When mould is applied under dry
condition, high moisture content could be an
advantage as shown in Figs. 1-5 and when the
strength is the major factor under
consideration. These important properties, such
as permeability, green compression strength,
and dry compression strength attain their
highest value with moisture of 2% and 4%
water addition. This makes 2% and 4% water
addition more suitable for optimum moulding
properties requirement. Water and clay are the
Fig.2. Effect of moisture content (%) on the major property variables that influence the
green shear strength (KN/m2). strength of the moulding (Jain 1986; Uhvotu
2006).

References
Brown, J.R. 1994. Foseco foundry man’s
handbook. 10th ed., Pergamon Press PLC,
Oxford, UK, pp. 28-55.
Jain, P.L. 1986. Principles of foundry
technology. 2nd ed., Tala McGraw-Hill, New
Fig.3. Effect of moisture content (%) on dry Delhi, India.
compression strength (KN/m2). Uhvotu, M.S. 2006. Determination of the
moulding properties of Dindima river sand
using Alkaleri clay as a binder. A
Postgraduate Diploma Thesis submitted to
the Department of Mechanical Engineering,
Abubakar Tafa Balewa University, Bauchi,
Nigeria.

Fig.4 Effect of moisture content (%) on dry

shear strength (KN/m2).

Technical Report 174