Development of Fused Ceramic Sand
Over the past two decades, the production of Fused Ceramic Sand has continued to grow, the production capacity has increased significantly, and the distribution of producing areas has become wider. By 2020, the total sales of Fused Ceramic sand will be nearly 200,000 tons. At the same time, its production process, from bauxite roasting, arc melting, to iron removal and impurity removal, screening and mixing and other processes, has been continuously improved through technological innovation, realizing environmental protection, high efficiency, green and sustainable development, and fully meeting the growing demand of the foundry industry.
Basic Information of Fused Ceramic Sand
The particle size of fused ceramic sand for casting is generally 0.053 ~ 3.53mm (270 ~ 6 mesh). The mineral phases of fused ceramic sand are mainly corundum and mullite, as well as a small amount of amorphous phase. The main chemical components of fused ceramic sand are aluminum oxide (Al203) and silicon dioxide (SiO2), and the refractoriness is above 1800 ℃. It is a kind of nearly spherical, high strength and high hardness aluminum silicon foundry sand.
Production Technology of Fused Ceramic Sand
Fused ceramic sand is a kind of casting sand with different particle size composition, which is made of calcined bauxite with aluminum oxide as the main component, through arc melting, compressed air spraying, international-standard sieve screening and grading mixing.
Present Situation of Fused Ceramic Sand
Fused ceramic sand is a kind of spherical special sand with excellent performance for casting. It has been widely used in sand casting (wet mold sand, sodium silicate sand, resin self-hardening sand, hot core box, shell mold, cold core box, etc.), lost foam casting and other casting processes, as well as cast iron, cast steel, nonferrous alloy and other casting alloys, and has achieved remarkable economic benefits and good environmental protection effects.
Application Scope of Fused Ceramic Sand
The application scope of fused ceramic sand is expanding from surface sand, filling sand, to hot box, shell mold, cold box core making, and then to the application of the overall self-hardening sand production line. According to the statistics for several consecutive years, its largest application is in the engine casting industry, accounting for about 1/3 of the total sales.
Advantages and Characteristics of Fused Ceramic Sand
·The thermal expansion coefficient is small, and the performance is comparable to that of zircon sand. When using it to prepare molding sand, the casting will not produce expansion defects.
·The sand particles are spherical, with good fluidity, easy compaction and good air permeability
·The surface is smooth and the structure is compact, so that the adhesive can be evenly covered·Fused ceramic sand is a neutral material, which can be used as acid and alkali binders, and is suitable for all kinds of casting alloys.
·Good recycling performance and high cost performance
Compared with chromite sand and zircon sand, its price is only 25-50% of zircon sand and chromite sand. At the same time, as the sand is spherical and its surface area is small, the amount of resin addition can be reduced by nearly 30-50%, and the amount of sodium silicate addition is less than 4%. The casting defects caused by binder are reduced and the yield of castings is improved.
·High refractoriness and easy to collapse
·High thermal conductivity, good stability and barely no cracking.