Abstract
Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.
Highlights
Lead is one of the first metals used in manufacturing, its use dating back to around 3000 BC [1,2].The Romans used sand cast lead sheet for the manufacture of water pipes and coffins amongst other artefacts [3]
Experiments were conducted on a 7000 mm long casting bench under identical conditions at a foundry based in Derby, UK
To to all all casting casting processes, processes, lead lead sheet sheet casting casting suffers suffers from ofof defects
Summary
Lead is one of the first metals used in manufacturing, its use dating back to around 3000 BC [1,2].The Romans used sand cast lead sheet for the manufacture of water pipes and coffins amongst other artefacts [3]. Lead is one of the first metals used in manufacturing, its use dating back to around 3000 BC [1,2]. Lead is used for a wide variety of applications including battery grids, ammunition and radiation protection. One of the most common lead products is sheet lead, being widely used in the construction industry mainly for roofing and flashing applications. The high malleability and ductility of lead combined with its high resistance to corrosion makes it an appropriate material for roofing applications and architectural cladding [4]. Lead sheet are used in the manufacture of lead lined boards for radiation protection in the healthcare industry due to their high density (11,340 kg/m3 ) and attenuation coefficient (5.549 cm2 /g at 100 KeV) especially for high energy
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