Improvements in Sand/Mold/Core Technology: Effects on Casting Finish
The goal of this project is to improve casting surface finish in sand mold/core technology.
Specifically, it will develop a predictive understanding of how density variations control sand structure and casting surface finish and to identify when and how this results in severe penetration. In addition, it will develop a predictive understanding of how binder content and mixing controls both density variations and surface finish. This research also will analyze the behavior of manufactured binders and binder additives at the mold-metal interface. X-Ray Computed Tomography is required to separate the performance of these organics from the effects of density variations.
This research, being conducted by the Ohio State University in conjunction with the American Foundry Society and industry, is examining the issues of surface finish and thermal reclamation costs resulting from the use of sand molds/cores. The results will provide an in-depth understanding of the influence of binder content on density variations that correlate to surface finish.
The results will allow metal casters to improve both casting surface finish and net shape capabilities in sand mold/core technology. This will enable metal casters to reduce time and cost associated with surface cleaning and finishing operations as well as surface finishing metal losses. It also will reduce the amount of binder used each year.