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The use of sands to make moulds and cores is nearly universal in the metal casting industry. A pattern (often made of wood) is used to make the mould, which establishes the external shape of the metal casting. To make a sand mould, clean sand is mixed with small amounts of hydrophilic clay, usually bentonite, and pulverized coal. Water is added to facilitate handling, and the mixture is placed in two boxes called the "cope" and the "drag." The pattern is then used to transfer the desired external shape of the metal casting in the packed sand in the cope (top of the casting) and the drag (bottom of the casting). The two boxes with the pattern impression constitute the mould.THE CORE SEPARATES A SPACE THAT BECOMES THE HOLLOW INSIDE OF THE CASTING! -The core is the interior piece of the mould needed to make hollow castings. In the core room of a metal casting facility, new sand is mixed with resin and sometimes a catalyst and formed into the core. The core is then placed in the mould, and the two mould boxes are assembled into a ''flask'' ready for casting.
In the mould production process for investment casting, a wax pattern is repeatedly dipped into ceramic slurry and coated with dry ceramic grit until the mould is of adequate thickness. The mould is then dried via water evaporation before it can be used. Drying is the rate-limiting step for this kind of mould production, and the metal casting industry would benefit from a separation technology that reduced drying time in investment casting mould production (Carter, 1997).
Casting Production
During casting, molten metal is poured into the mould. The flask is then set aside to cool. In the shake-out house, when the metal casting is solid but still hot, it is removed from the mould. After further cooling, the casting is transferred to the cleaning room where remnants of the core are removed. The metal casting that comes out of the mould includes metal that was cast into the "gates" (openings through which molten metal reaches the mould and through which gases are vented) and "risers" (reservoirs from which metal flows into the casting as it cools and contracts). The gates and risers are excess metal and comprise between 5 and 50 percent of the casting. They must be removed either mechanically or by hand.
During the mould production and casting production operations, dust is created. Most metal casting operations have dust control facilities to maintain high-quality ambient air, but disposal of the captured dust is a problem. Better dust removal technologies would benefit the industry as a whole.
Removal of Impurities from Molten Metal
Both ferrous and nonferrous metals are melted in furnaces prior to casting. Removal of impurities from the molten metal is an important separation issue for the metal casting industry. Technologies currently used include the addition of deoxidants, usually silicon or aluminum, and the addition of magnesium to certain alloys for the removal of oxygen and sulfur. Improved, cost-effective technologies to remove impurities from molten metal would be of great interest to the metal casting industry.
Gas inclusions, caused by gases given off during casting, are often found in the gates and risers removed from mould castings. These impurities increase the difficulty of recycling foundry-generated scrap. Methods for preventing or minimizing gas inclusions in castings would be beneficial to the industry.QUOTE FROM "Separation Technologies for the Industries of the Future (1998)
National Materials Advisory Board"
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