Fused Ceramic Foundry Sand Used in Large Steel Castings

What is Fused Ceramic Sand?

Fused ceramic sand is also known as electric melting ceramic sand. It is mainly to spray the high-quality Calcined Bauxite raw materials in the molten state to obtain spherical or nearly spherical sand particles with smooth performance. Fused ceramic sand has the advantages of high temperature resistance, good air permeability, collapsibility, acid and alkali resistance, and low crushing rate. According to the comparison of Fused ceramic sand with chromite sand and silica sand, the bulk density of Fused ceramic sand is only 0.67 ~ 0.71 times that of chromite sand, and the shape of Fused ceramic sand is spherical, the surface area is the smallest, and the consumption of resin and curing agent will also be the smallest; Fused ceramic sand is neutral and suitable for various steel castings (carbon steel, alloy steel, high manganese steel, etc.). In addition to the above advantages, Fused ceramic sand also has advantages over chromite sand in terms of price and recycling.

Alkaline phenolic resin fused ceramic sand does not contain harmful elements such as N, P, s, etc., and has good high temperature yielding and hard permeability, so it is very suitable for the production of large steel castings. Because the Fused ceramic sand is spherical and has the smallest surface area, the amount of sodium silicate or resin added during sand mixing will also be greatly reduced.


How does Fused ceramic sand prevent sticking sand?

Chromite sand is used to prevent the penetration of molten metal, generally because the fused chromite closes the sand gap. The domestic manufacturers of large steel castings often produce serious sand sticking defects after using chromite sand as surface sand material, which seriously affects the surface quality of steel castings. Some studies have shown that this is due to the oxidation-reduction reaction between chromite sand and high chromium steel at the interface or between chromite sand and resin carbonization film, which reduces the iron in chromite sand. This reduced iron forms a dense mixture with sand particles and adheres closely to the surface of the casting to form "glazed" bonded sand. In addition, the use of chromite sand with high clay content and many impurities will often cause sand sticking defects in castings.

Due to its high refractoriness, the thermal expansion rate of Fused ceramic sand is almost zero, and its anti-sticking mechanism is that its particle size is very small, closing the gap between sand particles. In addition, because the Fused ceramic sand is nearly spherical, it has good fluidity, can make the binder cover evenly, and can obtain a smooth surface, compact structure and good air permeability. Using Fused ceramic sand as surface sand can not only improve the dimensional accuracy of castings, prevent molding sand sintering, sand inclusion, liquid metal penetration, etc., but also greatly reduce the workload of casting cleaning and finishing, and improve the working conditions of workers.



Economic benefits of Fused ceramic sand

(1) Fused ceramic sand can be used as the surface sand of large steel castings instead of chromite sand to prevent sand sticking and make the cleaning work easier.

(2) The use of resin and curing dosage of alkali phenolic resin Fused ceramic sand are lower, which can improve the surface quality of castings, save the production cost of castings for enterprises, and greatly improve the casting production environment.

(3) The addition of Fused ceramic sand sodium silicate is less, and the sand falling of castings is easy to clean, which can improve the environment of the foundry workshop and save the working hours of casting cleaning.

Sanmenxia Qiangxin Foundry Material Co., Ltd. specializes in the production of fused ceramic sand - a new type of casting sand. It is resistant to high temperature, easy to collapse, small thermal expansion, good regeneration performance, smooth surface, high casting precision, and non- sticking sand. It has good casting performance and is recognized by casting experts at home and abroad.