The objective of this project is to evaluate the use of non-silica aggregate sands (ceramic sands) in the metal casting industry by providing unbiased information to foundries that will help them to use ceramic sands in a variety of applications.
Sponsored By: Dr. Robert Voigt, PSU IME
Team Members
Adam Legters | Connor Clary | Bernardo Crespo | Clara Tang | Ruyi Man | Shiyan Xu | | | | | |
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Project Summary
Overview
Silica sands, which can be angular or round, are very common to be used in the metal casting industry due to their low price point and mold strength. While they do offer benefits, silica sands produce silica dust when subjected to foundry conditions, which is dangerous to workers due to the possibility of silicosis. Ceramic sands have become more popular in recent years, offering potential health and long term financial benefits. Ceramic sands are still relatively new to the metal casting industry, and therefore can provide challenges to foundries that are switching from silica sands.
Objectives
The PSU IME Team has spent the semester evaluating the ways in which ceramic sands compare to silica sands in terms of mechanical properties, costs, benefits, and applications in foundries. It is the goal of the team to provide unbiased information to the metal casting industry regarding challenges, benefits, and expectations for a foundry switching from silica sands to non-silica aggregates.
Approach
Physical Experimentation
– Dust creation experiments to compare dust levels created under controlled conditions for angular silica sand, round silica sand, and ceramic sand
– Abrasion experiment to test feasibility of removing resin from used ceramic sands through tumbling in a rock tumbler
– Loss of Ignition (LOI) experiment to test feasibility of removing resin from used ceramic sands through applying heat
Survey
– Meetings with foundries that have switched to non-silica aggregates to understand their experience, challenges, and benefits of making the transition
– All meetings will be individual to maintain confidentiality of information
Outcomes
From initial experimentation (cut short due to COVID-19), a trend was noticed in which angular silica sand produced much more dust by weight than ceramic sand
Survey results (once at least six foundries have been interviewed) should be compiled into a database and shared with foundries to allow for the following:
– Foundries that have already switched can benchmark their experience/progress with what is common
– Foundries that are planning to switch can gain a better understanding of what to expect and how to best prepare