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ADVANCED METAL CASTING LAB

LIST OF EXPERIMENTS
Experiment - 1: To learn about Safety norms in foundry industry/laboratory

Experiment -2: Introduction to foundry tools and equipments

Experiment-3: To find the green compression strength of the given specimen at different
percentage of clay and moisture

Experiment-4 : To find the effect of water content, clay content on green permeability of
foundry sand.

Experiment-5: To find the distribution of sand grains using a set of sieves and to find
the average grain fineness number.

Experiment-6: To Find Core Hardness and Mould Hardness of a Specimen.

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Experiment: 1
AIM: To learn about Safety norms in foundry industry/laboratory
Introduction:
Objective: To recognize the importance of safety in a foundry and execute proper safety measures in
carrying out casting processes.
Procedure/methodology:
A. Safety norms of the foundry:
Purpose
The purpose of this compliance code is to provide practical guidance on how employers who undertake
foundry work can meet their duties under the Occupational Health and Safety Act 2004 (the OHS Act) and
Occupational Health and Safety Regulations 2007 (the Regulations).
Scope
This code covers foundry work that predominantly involves the casting of molten metal into a Mould. It can
be done manually (static casting) or automatically (injection, die or continuous casting). A typical process
includes preparing a Mould casting, melting and pouring metal into the Mould, and removing and finishing
the casting.
Because of the diverse and hazardous nature of the work environment, foundries present a range of risks,
including:
• explosion and burns from molten metal
• Respiratory disorders from exposure to gases, vapours, fumes and dusts
• Effects on skin from contact with corrosive chemicals
• Eye injuries from light radiation, metal fragments or chemical splashes
• Heat stress, heat stroke and fatigue from hot working conditions
• Slips, trips and falls
• Joint and muscle sprains and strains
• Mechanical hazards from machinery and equipment (such as entanglement or crushing)
• Non-mechanical hazards from machinery and equipment (such as vibration and noise).
The code provides practical guidance on foundry specific hazards but also refers to other hazards related to
foundry work. Risk controls set out in the code are considered to be a means of meeting a duty holder’s
obligations so far as is reasonably practicable. If the risk controls are not appropriate to the particular
circumstances in a foundry, a duty holder is expected to implement equally effective controls.
B. Foundry hazards:
• Molten metal explosions
• Steam explosions are caused by the introduction of moisture into molten metal.
• chemical explosions
Chemical explosions occur through the introduction of reactive chemical substances to molten metal directly
or as a contaminant in charge material.
Heat stress
Working in hot conditions is hazardous. Health effects range from discomfort or heat rash to heat exhaustion
or heat stroke resulting in permanent damage or death. Heat stress can harm without the worker being aware
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of the degree of effect until it is almost too late. It affects concentration, perception and decision making, so
heat stress is also dangerous in less obvious ways.
Burns
Burns are one of the major types of injuries in molten metal foundries and are generally caused by contact
with hot surfaces, radiation or molten metal splashing.

Light radiation
Eye disorders and skin burns may be caused by intense ultraviolet and infrared radiation from molten metal
in furnaces, particularly around pouring areas and in welding operations. Bystanders and passers by also need
to be protected, preferably by exclusion.
Hazardous substances
Hazardous substances such as lead, amines, formaldehyde, toluene, phenol, furfuryl alcohol and isocyanates
are substances that can harm the health of people exposed to them. They can be inhaled, swallowed or absorbed
through the skin, and employees can suffer immediate or long-term health effects. Exposure may cause
irritation, chemical burns, cancer, birth defects or diseases of certain organs such as the lungs, liver, kidneys
and nervous system.

Hazardous wastes
Legislative controls exist for the safe transport, storage and disposal of hazardous waste. Where no legislative
controls apply, a safe means of transport and disposal (having regard to the nature of the hazard) needs to
be employed (eg sealed, marked containers suitably protected from possible damage and able to be handled
safely).
Dangerous goods
Dangerous goods such as carbon dioxide, formaldehyde, oxygen, sulphur dioxide and xylene are hazardous
for a variety of reasons – they may be highly flammable, explosive, corrosive, acutely toxic, asphyxiant or
highly reactive according to class. They are readily identifiable by class diamonds on the labels.
Slips, trips and falls
Slips, trips and falls are a common hazard in most workplaces, with consequences
ranging from mild (such as scrapes) to severe (such as fractures or fatalities).
Manual handling
Manual handling tasks are those where force is exerted by a person to lift, lower, push, pull, carry or otherwise
move, hold or restrain any object. These occur during pattern and core making, loading furnaces, Moulding,
fettling, dispatch, inspection and surface coating.
Machinery and equipment (plant)
Machinery and equipment are used in pattern and core making as well as casting and Moulding. Plant such
as cranes, hoists, forklifts and conveyors are also used as mechanical handling devices within foundries.
Mechanical hazards
Mechanical hazards include hard surfaces coming together and scissoring action. Risks include entanglement,
crushing, severing, cutting and slips, trips and falls.
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C. Non-mechanical hazards
Noise
Noise levels in excess of 85 decibels (dB(A)) averaged over eight hours, or a C weighted peak hold sound
pressure reading of 140 dB(C) can result in hearing loss. Pattern and core making, Moulding, knockout and
cleaning operations, fettling and some furnaces are among the equipment and processes that produce noise
levels in excess of the acceptable standard. Regular exposure to excessive noise can damage the inner ear and
cause tinnitus leading to difficulties in communications.
Vibration
Whole body (1–80 Hz) vibration takes place during shake out, sand-slinging, on forklifts, cranes and during
pneumatic ramming operations. The adverse effects of whole body vibration include increased blood pressure
and heart problems, nervous disorders, stomach problems as well as joint and spine injuries.
Electricity
Electric shock causes injury or death. A shock can be received through direct contact with live parts, through
contact with a medium such as an unearthed tool or when it arcs across a gap. The risk is increased by
excessive sweating, as wet skin is more conductive than dry skin.
Machinery that may cause non-mechanical injury
Abrasive blasting and rumbling present hazards to employees from airborne contaminants and noise.
Access hazards
Access hazards are often complex, involving several risks at the same time, such as
chemical dosing in confined spaces or working at height.
D. Personal protective equipment (PPE) in the foundry
• Primary protective clothing is used for specific hazardous tasks then removed. It provides protection from
hazards such as metal splash and radiant heat. The garments need to be made from inherently fire-retardant
fabrics to ensure their protective properties are intact as long as the garment is intact. They need to be
comfortable to wear and breathable in very extreme work conditions. Leather options offer some durability
and protective benefits but can compromise comfort and add to heat stress in certain situations.
• Secondary protective clothing is all-day/everyday clothing. The clothing needs to be fire-retardant and the
choice of inherent or treated can take comfort and cost into account, but these garments are the last defence
for the body if primary protection fails. A cotton fabric is the minimum requirement, but specially treated
cotton or wool fabric is recommended

HEAD
Use helmets where there is potential for items to fall from height or where work takes place above head height
(eg on a mezzanine). Industrial safety helmets should be considered. Where tasks result in dust or particulates,
a head covering should be considered.

EARS
The factors that need to be taken into account when selecting hearing protectors need to include compliance
with AS 1270, level of noise, the wearer (eg personal characteristics, comfort), communication requirements,
and compatibility with the job/workplace. Guidance on hearing protectors is provided in AS/NZS 1269.3.
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EYES AND FACE EYES AND FACE

Face shields with neck protection. Industrial safety glasses with side shields are the
minimum.

RESPIRATORY
Respiratory protective devices (RPD) used need to comply with AS/NZS 1716. The type of respirator selected
needs to take into account the operator (ie facial hair, physiological and psychological factors), the task (i.e.
how the job is done, duration, frequency) and the substance (i.e. type of contaminant, concentration). The
standard AS/NZS 1715 provides guidance on the selection, use and maintenance of respiratory protective
devices. Guidance can also be obtained from suppliers of respiratory protective equipment.

TRUNK AND ARMS TRUNK AND ARMS

A jacket of leather or other suitably resistant Long-sleeved shirt made from flame- resistant fabric such
material must be worn outside all other clothing. as wool, heavy cotton drill, Firewear, TuffWeld and
It must be free of features such as cuffs and Indura, or fabrics with flame-retardant coatings such
pockets that may trap molten metal. It must be as FlameShield, aramid or Trevira CS. Employers must
worn properly and fastened at all times. provide reflective clothing where there is a risk radiation
and heat may affect health. Garments need to fasten at the
neck and wrists to prevent molten metal splashes, dust,
chemicals and other substances from entering through the
collar and cuffs.

HANDS HANDS
A jacket of leather or other suitably resistant Gloves selected need to take into account the hazard (eg-
material must be worn outside all other clothing. burns, abrasion, chemicals, cuts), the work environment
It must be free of features such as cuffs and and the wearer (eg fit, comfort, dexterity).
pockets that may trap molten metal. It must be
worn properly and fastened at all times.
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LEGS LEGS
Where risk of molten metal spills or splashes Heat-resistant trousers.
exists, trousers of leather or other suitably
resistant materials must be worn. The trousers
need to cover the top of the footwear and be free
of features such as cuffs and pockets that may
trap molten metal.
FEET
Employees must wear safety footwear at all times in the workplace unless a legally qualified medical
practitioner certifies that wearing safety footwear would injure the wearer. In such cases, the reason for
such an opinion must be given and the most appropriate alternative protective equipment sought.
PPE commonly used in foundry; from left to right: heat resistant glove, safety shoe, leather apron, faces
shields.

Primary protective clothing the manner prescribed by Secondary protective clothing

the manufacturer or supplier. (molten metal work) (General foundry work)
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Storage and care of protective equipment

For foundry purposes, compliance is demonstrated by employers ensuring that:
• All protective equipment and clothing provided is maintained in sound condition,
• Tested routinely and capable of performing the protective functions for which it was provided.
• Employees are trained in the need for, effective use and care of, and means of testing the fit of
protective equipment (when trained employees must cooperate in the care and maintenance of the
equipment).
• Equipment and clothing is only worn by the employee to whom it was issued, and
• Is marked with the name of that employee.
• Clean storage is provided for all protective equipment and clothing.
• Maintenance of clothing and equipment is conducted when required.

E. Following safety norms of foundry must be followed:

• Always wear safety glasses, or face shields designed for the type of the work
• operating any machine
• Wear safety shoes if heavy work is being done.
• Wear clothing suited for the job, wear shoes with thick soles.
• Don’t wear rings, watches, bracelets or other jewellery that could get caught in moving machinery.
• Don’t wear neck ties or loose turn clothing of any kind.
• Wear shirts or uppers with sleeves cut-off or rolled above the elbows.
• Always remove gloves before turning on or operating a machine. If material is rough and sharp then
gloves must be of work place or handle material with machine turned off.
• Keeping floor free of oil, grease or any other liquid. Clean up spilled liquid immediately they
are sleeping hazards.
• Aisle should be clear, at all time to avoid tripping of other accident.
• Store materials in such a way that they cannot become tripping hazards.
• Don’t leave tools or work on the table of a machine even if the machine in not turning. Tools or
work may fall off and cause an injury.
• Put tools always when not in use.
• Place the scrap box.
• Even trace amounts of Moisture and Molten Metal don’t mix!!! Steam explosions are the cause of
death in foundries.
• Wear safety gear!! This includes, but is not limited to, leather shoes, leather apron, proper gloves,
wire mesh face shield, safety glasses and a helmet. A leather foundry hat is the best choice.
• Have a DRY pile of sand and a shovel ready to put out fires or to control metal spills. NEVER put
water on a metal fire. This can cause a HUGH EXPLOSION!
• Have a sand bed under all areas. The sand bed should be at least 3 inches thick. This will help in
containing metal spills and will help protect flooring.
• Never pour over wet ground. Remember, even TRACE AMOUNTS of MOISTURE can cause
EXPLOSIONS.
• Molten metal spilled on concrete will cause the concrete to explode. Use a thick sand bed over
concrete.
• Always use clean metal as feedstock. Combustion residues from some lubricants and paints can be
very toxic.
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• Always operate in a well ventilated area. Fumes and dusts from combustion and other foundry
chemicals, processes and metals can be toxic.
• Always use a dust mask. Dusts from sand, parting dusts and chemicals can be hazardous or cancer
causing. Protect your lungs!
• Always use safety glasses. Even minor mishaps can cause blindness.
• Never use a crucible that has been damaged or dropped. It’s just not worth the risk. Imagine what
would happen if a white hot crucible of brass crumbled as you were carrying it.
• Always charge crucibles when cold. Adding metal to a hot crucible is really dangerous. If there is
moisture on the metal, even just a haze, the metal can cause the entire contents of the crucible to
explode.
• Spilled molten metal can travel for a great distance. Operate in a clear work area.
• Think about what you are doing at all times. Focus on the job at hand and the
next step. Have all moves planned and rehearsed prior to any operation.
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Experiment -2
AIM: Introduction to foundry tools and equipments
Introduction:
Objective: Each student should get introduced with foundry tools and make a report on the list of foundry
tools, their drawing and uses in foundry.

PROCEDURE/METHODOLOGY:
Part A: Introduction to foundry tools
Some important tools used in foundry are given below:
1. Showel: It consists of iron pan with a wooden handle. It can be used for mixing and conditioning the
sand.

2. Trowels: These are used for finishing flat surfaces and comers inside a Mould. Common shapes of trowels
are shown as under. They are made of iron with a wooden handle.

3. Lifter: A lifter is a finishing tool used for repairing the Mould and finishing the Mould sand. Lifter is
also
used for removing loose sand from Mould.

4. Hand riddle: It is used for ridding of sand to remove foreign material from it. It consists of a wooden frame
fitted with a screen of standard wire mesh at the bottom.
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5.Strike off bar: It is a flat bar, made of wood or iron to strike off the excess sand from the top of a box
after ramming. Its one edge made beveled and the surface perfectly smooth and plane.

6. Vent wire: It is a thin steel rod or wire carrying a pointed edge at one end and a wooden handle or a bent
loop at the other. After ramming and striking off the excess sand it is used to make small holes, called
vents, in the sand Mould to allow the exit of gases and steam during casting.

7. Rammers: Rammers are used for striking the sand mass in the Moulding box to pack it closely around
one pattern. Common types of rammers are shown as under.

8. Swab: It is a hemp fibre brush used for moistening the edges of sand Mould, which are in contact
with the pattern surface, before withdrawing the pattern. It is also used for coating the liquid blacking
on the Mould faces in dry sand Moulds.

9. Sprue pin: It is a tapered rod of wood or iron, which is embedded in the sand and later withdrawn to
produce a hole, called runner, through which the molten metal is poured into the Mould.
10. Sprue cutter: It is also used for the same purpose as a sprue pin, but there is a marked difference
between their use in that the cutter is used to produce the hole after ramming the Mould. It is
in the form of a tapered hollow tube, which is inserted in the sand to produce the hole.
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Equipment:
Some common equipments used in foundry are given below:
(i) Sand Muller: To bind the sand particles together binder such bentonite, water and other additives are
needed to be added. All of the ingredients are required to be mixed again if the mixture has been used or
new additives to be refilled. For mass production, sand muller is employed to prepare green sand mixture
whereas sand mixer is used for small scale production. Figure below shows a typical configuration of
industrial used sand muller.

Figure.: Schematics of continuous (left) and batch-type (right) sand muller. Plow blades move the
sand and the muller wheels mix the components
(ii) Moulding Machine: Moulding machine uses high static squeeze force and high dynamic squeeze force
to make the Mould uniformly. It can make full use of sand and maintain the quality of Mould. Therefore,
the Mould preparation costs can be reduced when large production of casting is needed. Figure below shows
a typical Moulding machine and a set of core pattern.

Figure: Left; semi-automatic Machine, Right; core pattern plate

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Experiment -3

COMPRESSION STRENGTH TEST FOR MOULDING SAND

AIM: To find the green compression strength of the given specimen at different percentage of
clay and moisture

Materials used: Base sand, clay, water,

Apparatus used: Sand Ramming machine (Rammer) with specimen tube with base, stripper,
universal sand testing machine with Compression shackles, weighing pan, measuring jar, steel
scale, Electronic weighing scale.
OBJECTIVE: To learn how to find Green Compression strength of a sand specimen experimentally.

Theory:

1. Periodic tests are necessary to check the quality of foundry sand and compression
strength test is one among them.
2. The constituents of moulding sand are silica sand, clay, water and other special additives.
3. Clay imparts the necessary bonding strength to the moulding sand when it is mixed with
water etc. bentonite.
4. Compression test determines the bonding or adhesiveness power of various bonding
materials in green sand.
5. The green compressive strength of foundry sand is the maximum compression strength a
mixture is capable of developing when it is in most condition.

Procedure:
1. Conduct the experiment in two parts:
a) Vary the clay content keeping the water content constant
b) Vary the water content keeping the clay content constant
2. Take weighed proportions of sand and clay and dry mix them together
in a Muller for 3 minutes.
3. Adjust the weight of the sand to get standard specimen
4. Remove the standard specimen by the stripper and place it between shackles which are
fixed in the sand testing machine.
5. Rotate the handle of the testing machine to actuate the ram. Thus hydraulic pressure is
applied continuously till the specimen raptures.
6. Read the compression strength from the gauge and record the same.
7. Conduct the experiment for the above said two cases and tabulate the result.
Result and discussion

Plot the graphs with compression strength on y-axis & percentage clay on x-axis and the other with
compression strength on y-axis v/s percentage water on x-axis.
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Discuss the result with respect to the variation of percentage of clay on compression strength
and percentage of water on compression strength.

TABULAR COLUMN

VARYING THE % OF CLAY

VARYING THE % OF WATER

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Figure- Universal Sand Strength Machine

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Figure - Sand Rammer

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EXPERIMENT-4

PERMEABILITY TEST

AIM: To find the effect of water content, clay content on green permeability of foundry sand.

Materials used: Base sand, clay and water.

Apparatus used: Sand rammer, Permeability meter, Electronic weighing scale, stripper, stop
watch, measuring jar, specimen tube, specimen tube cup.

OBJECTIVE: To evaluate experimentally the water content, Clay content and permeability of foundry
sand.

Theory:

1. Molten metals always contain certain amount of dissolved gases, which are evolved when the
metal starts freezing.
2. When molten meal comes in contact with moist sand, generates steam or water vapour.
3. Gases and water vapour are released in the mould cavity by the molten metal and sand. If
they do not find opportunity to escape completely through the mould, they will get entrapped
and form gas holes or pores in the casting. The sand must therefore be sufficiently porous to
allow the gases and water vapour to escape out. This property of sand is referred to as
permeability.
4. Permeability is one of the most important properties affecting the characteristic of moulds
which depends upon the grain size, grain shape, grain distribution, binder content, moisture
level and degree of compactness.
5. Permeability is a physical property of the physical sand mixture, which allows gases to
pass through it easily.
6. The AFS (American Foundry Men Society) definition of permeability is “the number
obtained by passing 2000cc of air through a standard specimen under a pressure of 10 gm/cm2
for a given time in minutes”.
7. The permeability number PN can be found out by the equation.

Where

V = Volume of air passing through the specimen, 2000cc

H = Height of the specimen = 50.8 mm (standard value) P

= Pressure as read from the manometer in gm/cm2

A = Area of the specimen = d2/4

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Where d = 50.8 mm (standard value)

T= time in minutes for 2000 cc of air passed through the sand specimen.

Experimental setup details:

Permeability meter has a cylindrical water tank in which an air tank is floating. By properly opening
the valve, air from the air tank can be made to flow through the sand specimen and a back pressure
is setup. The pressure of this air is obtained with the water manometer. The meter also contains the
chart, which directly gives the PN depending on pressure.

Procedure:

1. Conduct the experiment in two parts. In the first case vary water percent keeping clay
percent constant. In the second case vary clay percent and keep water percent constant.

2. Take weighed proportions of sand dry mix them together for 3 minutes. Then add required
proportions of water and wet mix for another 2 minutes, to get a homogeneous and mixture. Take
the total weight of the mixture between 150-200 grams. The correct weight has to be determined
by trail and error method.

3. Fill the sand mixture into the specimen tube and ram thrice using sand rammer. Use the
tolerance limit provided at the top end of the rammer for checking the specimen size. If the top
end of the rammer is within the tolerance limit, the correct specimen is obtained. If it lies below
the limit, increase the weight of sand mixture and prepare a new specimen. The specimen
conforming to within limits represent the standard specimen required.

4. Now the prepared standard specimen is having a dia.50.8mm and height 50.8mm.
5. Place the standard specimen along with the tube in the inverted position on the rubber seal
or on the mercury cup (specimen in the top position in the manometer reading).

6. Operate the valve and start the stop watch simultaneously. When the zero mark on the
inverted jar just touches the top of water tank, note down the manometer reading.

7. Note down the time required to pass 2000cc of air through the specimen. Calculate the
permeability number by using the formula given.

Direct scale reading:

The permeability can also be determined by making use of the graduated marker provided near
the manometer.
Procedure to be followed:

• Coincide the graduations on the transparent scale with the meniscus of the manometer
liquid.
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• Note the reading of the scale.

• This reading represents the permeability number of the sand.

TABULAR COLUMN

Varying the percentage of Clay and keeping percentage of Water constant. Indicate percentage of
Clay (No. of arms = 3)

Varying the percentage of water and keeping percentage of Clay constant. Indicate percentage of
Water (No. of arms = 3)

Draw graph:
Permeability number v/s % Clay
Permeability number v/s % water
Discuss the effect of Moisture and clay on Permeability
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Figure - Permeability Meter

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EXPERIMENT-5
SIEVE ANALYSIS TO FIND GRAIN FINENESS NUMBER OF BASE SAND

AIM: To find the distribution of sand grains using a set of sieves and to find the average grain
fineness number.

Materials used: Base sand- Silica sand.

Apparatus used: Electronic weighing scale, stop watch, sieve shaker.

Theory:
1. The base sand is a mixture of grains having a variety of shapes such as
a) Round b) sub-angular c) angular d) compounded grains.
Base sand is relatively free from any binder or additives.
2. Depending on the average size of the grains, the sand can be grouped into: a) Fine
b) Medium and c) Coarse grains.
3. The shape and size of grains has a large influence on the permeability of sand mix as well
as on the bonding action.
4. The shape and size of grains determine the possibility of its application in various types of
foundry practice.
Ex: Fine grain sand results in good surface, on the casting but gases cannot escape out of the
mould made from it. Coarse grain sand allows gases to escape out easily but the casting
surface will be very rough. Hence grain size should select appropriately.
5. The given size of sand grains is designated by a number called grain fineness number that
indicates the average size of grains in the mixture.
6. The size is determined by passing the sand through sieves having specified apparatus
which are measured in microns.
7. The sieve number designates the pore size through which the sand grains, may pass
through it or retained in it.
8. Average grains fineness number can be found out by the equation
GFN = Q/P

Where Q = sum of product of percentage sand retained in sieves and Corresponding

multiplier.
P = sum of percentage of sand retained in sieves.
Procedure:
1. Take 50 gm or100 gm of dry sand and place in the top sieve of a series and close the lid.

2. Place the whole assembly of sieves on the vibratory sieve shaker and clamp it.

3. Switch on the motor and allow the sieve assembly to vibrate for 5 minutes. Then switch off
the motor.
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4. Collect the sand particles retained in each of the sieve separately and weigh in Electronic
weighing scale and enter into the tabular column. Calculate the percentage weight retained by
each of the sieves. Multiply this value with the multiplier for each sieve.
(Calculate the average GFN using the formula as shown below.)

Tabular Column:

Total weight of sand taken = 100g.

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% Retained C = Weight of sand in each sieve x 100

Total weight of sand

Calculation: AFS grain number = Q (sum) / P (total) Results; The average grain fineness number

is =

Graph: Percentage of sand retained v/s sieve number and cumulative % of sand retained vs Sieve
number

Figure- Sieve Shaker

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EXPERIMENT-6
CLAY CONTENT TEST

AIM: To determine the percentage of clay present in base sand.

Materials used: Base sand, 5 % NaoH solution and water.
Apparatus used: Wash bottle, measuring jar, mechanical stirrer and siphon tube.
Theory:

1. Clay can be those particles having less than 20 microns size. Moulding sand contains 2
to 50 percent of clay. When mixed with water it imparts, binding strength and plasticity.
2. Clay consists of two ingredients a) Fine silt and b) True clay. Fine silt as no binding
power where as true clay imparts the necessary boundary strength to the moulding sand;
thereby the mould does not loose its shape after ramming.
3. Clay also can define as those particles which when mixed with water, agitated and then
made to settled, fails to settle down at the rate of 1”/mm.
4. The particles of clay are plate like from and have a very large surface area compared to
its thickness and therefore have a very high affinity to absorb moisture.
5. Clay is the main constituent in a moulding sand and mixture other than sand grains. Clay
imparts binding action to the sand and hence the strength.
6. Clay is of mineral origin available in plenty on earth. It is made of alumina silicate. The
types of clay are a) montmorillonite b) Kaolinite and c) illite the first type is generally
referred to as Bentonite.
Clay is the main constituent in a moulding sand mixture other than sand grain. Clay help
impart binding action to the sand and hence strength to the sand.
Procedure:

1. Take 100g of base sand in a wash bottle and add 475ml of distilled water and 25ml of
NaOH solution to it.
2. using the mechanical stirrer, stir the mixture for about 5 minutes add distilled water to make
up the level to 6"height. Stir the mixture again for 2 minutes. Now allow the content of the
bottle to settle down.

3. Siphon out 5” level of unclean water using a standard siphon.

4. Add distilled water again up to 6" height and stir the content again. Allow the mixture to
settle down for 5minutes.

5. Siphon out 5” level of water from the bottom of the bottle

Repeat the above procedure for 3-4times till the water becomes clear in the wash bottle.
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6. Transfer the wet sand from the bottle in to a tray and dry in it in an oven at 110 o C to remove
moisture. Note down the dry sand weight accurately. Using the calculations find percentage of
clay.

Calculations
Weight of sand W1= 100 gms

Weight of dried sand W2 = ----------- gms

% of clay= ( W1- W2) X 100

100
Results and discussion:

The % of clay is -----------------%

Observation was done whether the % of Water is present is high or low and whether this % is
enough to act as binder in the sand.

Figure- Clay Washer

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EXPERIMENT-6
AIM: TO FIND CORE HARDNESS AND MOULD HARDNESS OF A SPECIMEN

Materials used: Sand Mould Specimen and Hardened core specimen.

Apparatus used: Mould Hardness Tester

Procedure:
Mould and core hardness can be found out by the hardness – tester which is based on the same
principle as Brinell hardness tester. A steel ball of 50 mm diameter weighing 237 gm is pressed on
the mould surface. The depth of penetration of steel ball will give the hardness of mould surface
on the direct reading dial. This hardness test is useful in finding out the mould uniformity.
The hardness achieved by ramming the Moulding sand mixture can be measured by using an
indentation-type Mould hardness tester where a spring-loaded 1/2 inch diameter steel ball is pressed
into the AFS Standard sand sample and the hardness number is read directly from a dial guage which
reads from 100 to 0. If no penetration occurs, the hardness reading is set arbitrarily to 100. If the ball
sinks completely into the sand up to the limiting surface of the tester, the reading is set to 0; i.e. the
sand is very soft. A “hard rammed” Mould generally reads 90, while a “soft” Mould reads 50 to 60.
Severe penetration by the liquid metal and washing of the sand occur when the hardness reading is
below 50. A hardness tester is shown in the Figure below

Figure- Mould Hardness Tester

The following are the moulding hardness numbers for

Moulding sand (1 number = 1/100 mm)

Soft rammed moulds = 100
Medium rammed moulds = 125
Hard rammed mould = 175
 26

Tabular column for Core Hardness Test

S. % of sodium silicate Core Hardness Number

% of Sand
No.
1
2
3

Tabular column for Mould Hardness Test

S. % of water Mould Hardness Number

% of Sand
No.
1
2
3