Optimization of Sea Beach Sand Composition for Cast Iron Foundry Applications

Abstract

The increasing demand and exorbitant use of river bed sand in foundries over the years have led to its depletion at an alarming rate. Consequently, many states in India have imposed severe restrictions on the mining of riverbed sand. Therefore, an effort is made to explore the potential use of sea sand for cast iron foundry applications. Experiments were performed for optimizing the composition of molding sand with respect to functional properties namely, strength, mold hardness, and permeability. The optimum composition of molding sand comprised of 8.33 wt% bentonite and 3.12 wt% moisture, and 88.54 wt% sea sand. Trials were conducted in a local foundry to ascertain the suitability of using a mixture of sea sand, bentonite, and water for producing defect-free gray iron casting. The trial was successful and parts were accepted for production purposes.