Foundry Sand Types

According to the different binders, foundry sand used for moulding can be divided into
green sand, water glass sand and resin sand.

Green Sand (Clay Sand)

Clay sand is the mixture of natural silica sand, clay, additives and water. The clay used
to make wet clay sand is bentonite clay. The compressive strength is generally 0.05 to
0.1 Mpa. The water content is 3.5 to 5%, and air permeability is more than 80. It is
commonly used in machine molding and hand molding.

The sand made can be used to pour liquid metal without drying, which has the
advantages of low production cost and short production cycle. Wet clay sand used
in sand casting production accounts for about 60%. As the wet sand has a high moisture
content, low strength and air permeability, the castings can easily have the porosity,
coarse, sticky sand and sand expansion defects. In hand molding, the dimensional
accuracy is low, so it is generally used only for the production of small and medium sized
iron castings and non-ferrous alloy castings; while in mechanical modeling, the castings
have high dimensional accuracy, so it is widely used for high-volume production of
castings. 

The clay used to make dry sand clay is ordinary clay, and its moisture content is high.
The sand made should be dried in the temperature of about 250 ~ 400 ℃ and then be
combined cast, and it is generally used for steel castings. Because of the high energy
consumption, long production cycle, low dimensional accuracy, dry sand is gradually
phased out.

Water Glass Sand (Sodium Silicate Sand)

Sodium silicate sand is a kind of foundry sand made by sodium silicate (aqueous solution
of sodium silicate) as the binder. The sodium silicate added accounts for 6% to 8% of
the sand quality.

Water glass hardening is necessary before pouring to improve strength. The hardening
methods are: chemical hardening with CO2 gas and drying the heating surface. You can
also put the hardening agent in the sand, and then it will harden by itself. By eliminating
or greatly reducing the drying process, the emergence of sodium silicate sand simplified
greatly the sand molding process. 
However, because its collapsibility is poor and falling sand, sand cleaning and the sand
recycling are very difficult, in iron casting, the sand sticks seriously, so it is not suitable
for iron casting, but mainly used in steel casting production.

Resin Sand (Phenolic, Furan)

Resin sand is a kind of foundry sand with synthetic resin (phenolic resin and furan resin,
etc.) as the binder. The resin added is about 3% to 6% of the sand quality. Resin sand
can harden fast when heated 1 to 2 minutes, and its dry strength is high, so the castings
made are accurate in size, the surface is smooth, and the collapsibility is excellent. 

Since it has quick-drying and self-hardening characteristics, the modeling process is

easier to become mechanization and automation. Resin sand is a promising new type of
modeling material, and at present, it is mainly used in the manufacture of complex sand
cores.

Since different sands have different advantages, in metal casting, we should adopt the
right one to meet different needs.

Clay Sand, Green Sand

Furan Resin Sand

 Dry Sand, Water Glass Sand

1. Green Sand
 Green sand is a mixture of silica sand and clay. It constitutes 18 % to 30 % clay and 6 % to 8
% water.
 The water and clay present is responsible for furnishing bonds for the green sand.
 It is slightly wet when squeezed with hand. It has the ability to retain the shape and
impression given to it under pressure.
 It is easily available and has low cost.
 The mould which is prepared in this sand is called green sand mould.
 It is commonly used for producing ferrous and non-ferrous castings

2. Dry Sand
 After making the mould in green sand, when it is dried or baked is called dry sand.
 It is suitable for making large castings.
 The moulds which is prepared in dry sand is known as dry sand moulds.
 If we talk about the physical composition of the dry sand, than it is same as that of the green
sand except water.

3. Loam Sand
 It is a type of moulding sand in which 50 % of clay is present.
 It is mixture of sand and clay and water is present in such a quantity, to make it a thin plastic
paste.
 In loam moulding patterns are not used.
 It is used to produce large casting.

4. Parting Sand
 Parting sand is used to prevent the sticking of green sand to the pattern and also to allow the
sand on the parting surface of the cope and drag to separate without clinging.
 It serves the same purpose as of parting dust.
 It is clean clay free silica sand.

5. Facing Sand
 The face of the mould is formed by facing sand.
 Facing sand is used directly next to the surface of the pattern and it comes in direct contact
with the molten metal, when the molten metal is poured into the mould.
 It possesses high strength and refractoriness as it comes in contact with the molten metal.
 It is made of clay and silica sand without addition of any used sand.

6. Backing Sand
 Backing sand or flour sand is used to back up facing sand.
 Old and repeatedly used moulding sand is used for the backing purpose.
 It is also sometimes called black sand because of the addition of coal dust and burning when it
comes in contact with the molten metal.

7. System Sand
 In mechanical sand preparation and handling units, facing sand is not used. The sand which is
used is cleaned and reactivated by adding of water, binder and special additives. And the sand we get
through this is called system sand.
 System sand is used to fill the whole flask in the mechanical foundries where machine
moulding is employed.
 The mould made with this sand has high strength, permeability and refractoriness.

8. Core Sand
 The sand which is used to make core is called core sand.
 It is also called as oil sand.
 It is a mixture of silica sand and core oil. Core oil is mixture of linseed oil, resin, light mineral
oil and other binding materials.
 For the sake of economy, pitch or flours and water may be used in making of large cores.
Types of Moulding Sand:
According to the use, moulding sand may be classified as
below:
1. Green Sand:
The green sand is the natural sand containing sufficient moisture in
it. It is mixture of silica and 15 to 30% clay with about 8% water.
Clay and water act as a bonding material to give strength. Molds
made from this sand are known as green sand mould.

The green sand is used only for simple and rough casting products.
It is used for both ferrous and non-ferrous metals.

2. Dry Sand:
When the moisture is removed from green sand, it is known as dry
sand. The mould produced by dry sand has greater strength, rigidity
and thermal stability. This sand is used for large and heavy castings.

3. Loam Sand:
Loam sand is a mixture of 50 percent sand and 50 percent clay.
Water is added in sufficient amount. It is used for large and heavy
moulds e.g., turbine parts, hoppers etc.

4. Facing Sand:
A sand used for facing of the mould is known as facing sand. It
consists of silica sand and clay, without addition of used sand. It is
used directly next to the surface of the pattern. Facing sand comes
in direct contact with the hot molten metal; therefore it must have
high refractoriness and strength. It has very fine grains.

5. Parting Sand:
A pure silica sand employed on the faces of the pattern before
moulding is known as parting sand. When the pattern is withdrawn
from the mould, the moulding sand sticks to it.

To avoid sticking, parting sand is sprinkled on the pattern before it

is embedded in the moulding sand. Parting sand is also sprinkled on
the contact surface of cope, drag and cheek.

6. Backing or Floor Sand:

The backing sand is old and repeatedly used sand of black colour. It
is used to back up the facing sand and to fill the whole volume of the
box. This sand is accumulated on the floor after casting and hence
also known as floor sand.

7. System Sand:
The sand employed in mechanical heavy castings and has high
strength, permeability and refractoriness, is known as system sand.
It is used for machine moulding to fill the whole flask. In machine
moulding no facing sand is used. The system sand is cleaned and
has special additives.

8. Core Sand:
ADVERTISEMENTS:

A sand used for making cores is known as core sand. It is silica sand
mixed with core oil (linseed oil, resin, mineral oil) and other
binding materials (dextrine, corn flour, sodium silicate). It has
remarkable compressive strength.

9. Molasses Sand:
A sand which carries molasses as a binder is known as molasses
sand. It is used for core making and small castings of intricate
shapes.

Properties of Moulding Sand

Following are the important properties of moulding sand:
1. Porosity:
Porosity also known as permeability is the most important property
of the moulding sand. It is the ability of the moulding sand to allow
gasses to pass through. Gasses and steam are generated during the
pouring of molten metal into the sand cavity. This property depends
not only on the shape and size of the particles of the sand but also
on the amount of the clay, binding material, and moisture contents
in the mixture.

2. Cohesiveness:
Cohesiveness is the property of sand to hold its particles together. It
may be defined as the strength of the moulding sand. This property
plays a vital role in retaining intricate shapes of the mould.

Insufficient strength may lead to a collapse in the mould particles

during handling, turning over, or closing. Clay and bentonite
improves the cohesiveness.
3. Adhesiveness:
Adhesiveness is the property of sand due to which the sand particles
sticks to the sides of the moulding box. Adhesiveness of sand
enables the proper lifting of cope along with the sand.

4. Plasticity:
Plasticity is the property of the moulding sand by virtue of which it
flows to all corners around the mould when rammed, thus not
providing any possibility of left out spaces, andacquires a
predetermined shape under ramming pressure.
5. Flow-Ability:
ADVERTISEMENTS:

Flow-ability is the ability of moulding sand to free flow and fill the
recesses and the fine details in the pattern. It varies with moisture
content.

6. Collapsibility:
Collapsibility is the property of sand due to which the sand mould
collapse automatically after the solidification of the casting. The
mould should disintegrate into small particles of moulding sand
with minimum force after the casting is removed from it.

7. Refractoriness:
Refractoriness is the property of sand to withstand high
temperature of molten metal without fusion or soften.

Moulding sands with poor refractoriness may burn when the molten
metal is poured into the mould. Usually, sand moulds should be
able to withstand up to 1650°C.