Ferrous Foundry Research Articles

Complexity of green innovation in manufacturing: a case in a foundry

Nowadays the improvement of environmental performances is one of aims of innovation in factories, to implement the sustainable development. For the achievement of the environmental goals, a firm can follow Green Innovation, namely developing environmentally friendly products and processes. In spite of the interest on Green Innovation, the progress towards the Agenda 2030 Sustainable Development Goals, at halfway, is insufficient. In searching for solutions probably the complexity of introducing Green Innovation in factories is an issue.The aim of the paper is to show the complexity of innovation management by a real case: the pretests of new inorganic binders in a ferrous foundry. After a brief description of the Green Casting project case is considered by showing all the activities and entities involved. Finally, the results are discussed, and possible future developments are drawn. Results will show that development of project management tools and new technologies for training could be useful.

Investigation of serum surface active protein D and clara cell protein levels in workers exposed to silica dust in ferrous metal foundry

Objective: To investigate the levels of serum surface active protein D (SP-D) and clara cell protein (CCl6) in workers exposed to black silica dust, and analyze its influencing factors. Methods: From July to September 2021, 174 workers in 37 positions exposed to silica dust in 5 ferrous metal foundry were investigated by cross-sectional research method. The exposure concentration of silica dust workers was obtained through occupational health field investigation and detection, and the general situation of the study subjects was obtained through questionnaire survey and peripheral blood was collected. Double antigen sandwich enzyme-linked immunosorbent assay (ELISA) was used to detect the concentrations of SP-D and CC16 in serum of workers. The mean values were compared by one-way ANOVA, and the influencing factors of SP-D and CC16 concentrations in serum were analyzed by ordered multiple logistic regression. Results: The time-weighted average concentration (C-TWA) of 174 workers exposed to silica dust (respirable dust) ranged from 0.09 mg/m(3)~3.58 mg/m(3), and the C-TWA overstandard rate of dust exposed workers was 32.18% (56/174) , with differences among workers in different positions (χ(2)=28.85, P<0.001) . The highest concentration of silica dust was (0.82±0.11) mg/m(3). Using C-TWA<50% OEL occupational exposure limit (OEL) as reference, serum SP-D concentration in workers with ≥50% OEL was increased (OR=4.95, 95%CI: 1.86~13.17, P=0.001) , while CC16 concentration was decreased (OR=0.15, 95%CI: 0.05~0.40, P<0.001) ; Serum CC16 concentration decreased in workers exposed to silica dust C-TWA≥OEL (OR=0.46, 95%CI: 0.28~0.98, P=0.043) . Compared with those with low occupational health literacy, the serum SP-D concentration of workers with high occupational health literacy decreased (OR=0.48, 95%CI: 0.25~0.92, P=0.027) and CC16 concentration increased (OR=2.09, 95%CI: 1.10-3.97, P=0.024) . Conclusion: When no abnormality was found in the physical examination of workers, the serum SP-D and CC16 concentration levels changed, and the change was related to the concentration of workers exposed to silica dust.

Development of inorganic binder systems to minimise emissions in ferrous foundries

A series of sands with binders based on synthetic resins, which ensure the achievement of some molding sand parameters better than sands with a natural clay binder, do not meet the required expectations related to the impact on the surrounding environment. These include three main classes of sands in which organic binders based on alkyd, phenol-formaldehyde, furan and urea-formaldehyde resins are used. Molding sands subjected to high temperatures of liquid metal generate a number of harmful and even dangerous substances (carcinogenic and/or mutagenic) from the group of benzene, toluene, ethylbenzene and xylenes (BTEX) and polycyclic aromatic hydrocarbons (PAHs). Research carried out as part of the LIFE Green Foundry Project (LIFE17 ENV/FI/000173) concerned the analysis of various types of molding sands in terms of emissions of BTEX and PAHs gases and other compounds (SO2, CO, CO2 and NOx) formed in the process of pouring the mold with liquid metal. In the article, particular attention was paid to the differences in the amount of emitted BTEX and PAHs compounds for two types of sands with organic resins: furan resin (code MF) and phenol-formaldehyde resin (code MA), for which the influence of the regenerate addition on the above values was additionally examined. Three sands with inorganic binders, including 2 binders on water glass base (code MI and code MC) and 1 binder on aluminosilicate base (code MG), and greensand with activated bentonite and coal dust (code MB) were also tested. A comparative analysis of the results evaluated against sand with resin (code MF) containing 85% free furfuryl alcohol, conventionally accepted as a reference sand mix, was performed.It was noted that for a foundry with a uniform (according to the BREF – Best Available Techniques Reference Document for the Smitheries and Foundries Industry) system of molding sands, the obtained Loss on Ignition (LOI) results of the reclaimed fraction compatible with the used molding sand can be used to develop an empirical relationship that allows predicting the approximate content of a given harmful substance (PAHs, BTEX groups) in the molding sand, which makes it easier for the foundry to decide on the need to conduct more advanced tests.The research justifies the opinion about the possibility of reducing the harmful impact of an iron alloy foundry on the surrounding environment by replacing molding sands with organic binders by molding sands with inorganic binders.

Alkaline Activation of Ferrous Foundry Sand: A Look at the Effect of Activator Concentration, Liquid-Solid Ratio and Curing Temperature

In this study, ferrous foundry slag was used as a precursor for the synthesis of a geopolymer. The effect of NaOH concentration, liquid solid ratio (L/S), and curing temperature on the unconfined compressive strength (UCS) of the synthesized geopolymer was investigated. The optimum concentration was found to be 15 M as it yielded a geopolymer brick with the highest UCS of 8.2 MPa. It was observed that as the concentration of NaOH increases the dissolution of alumina, calcium and silica increases resulting in higher UCS. The SEM results showed zeolite formation in large quantities at 15 M which shows that the geopolymerization reaction was near completion and the calcium, alumina and silicates dissolved in large quantities leading to increased gelling of C-S-H and C-A-H over time filling more pores inside the geopolymer brick. The liquid to the solid ratio that gave the highest UCS of 8.2 MPa was 0.15. The optimum temperature was found to be 80 °C. This increased temperature favoured the dissolution of reactive species and contributed to higher UCS. The results reveal that ferrous foundry sand geopolymers have the potential to be used as a building and construction material.

Characteristics and occupational risk assessment of occupational silica-dust and noise exposure in ferrous metal foundries in Ningbo, China.

To investigate the major existing occupational hazards and to assess the occupational health risks for ferrous metal foundries (FMFs) in Ningbo, China. Unified questionnaires were formulated to investigate the information on the basic situations, occupational hazards, and occupational health management for 193 FMFs in Ningbo. Furthermore, we used the semi-quantitative risk assessment model, which was developed by the International Council on Mining and Metals (ICMM), to assess occupational health risks for 59 of 193 the FMFs. The casting process of FMFs in Ningbo was mainly divided into sand casting and investment casting, and silica-dust and noise were the major occupational hazards in both sand casting and investment casting foundries. Silica-dust mainly occurred in industries with such work as sand handling, modeling, falling sand, and sand cleaning, with the median of the permissible concentration-time weighted average (PC-TWA) was 0.80, 1.15, 3.52, 0.83 mg/m3, respectively. The noise mainly existed in industries with such work as sand handling, core making, falling sand, sand cleaning, cutting and grinding, and smelting with median of PC-TWA was 81.72 dB(A), 82.93 dB(A), 90.75 dB(A), 80.18 dB(A), 90.05 dB(A), 82.70 dB(A), respectively. In addition, the results of the ICMM assessment model indicated that 100 and 98.7% of the jobs exposed to silica-dust and noise in 59 FMFs have an "intolerable risk" level of risks of causing pneumoconiosis and noise deaf, respectively. The hazard risk of silica-dust and noise is serious for FMFs in Ningbo. It is necessary to supervise enterprises to improve operating environmental conditions, accelerate the reduction of silica-dust and noise exposure risks, and promote the healthy and sustainable development of the foundry industry.

Analysis of dust hazard characteristics in 59 ferrous metal foundry enterprises in Ningbo City

Objective: To analyze the post distribution of dust concentration in ferrous metal foundry enterprises and evaluate the occupational health risks, and provide basis for policies of the formulation of pneumoconiosis prevention and control. Methods: From August to September in 2020, the basic information, dust hazard information and occupational health management information of 59 ferrous metal casting enterprises were investigated, the dust concentration distribution was analyzed, and the risk assessment was carried out by using the quantitative assignment model. The dust concentration is tested by LSD method after logarithmic treatment. The 3 times time weighted average allowable exposure concentration of dust is taken as the peak concentration limit of dust; The time weighted average allowable exposure concentration of dust converted by exposure time is taken as the time weighted average exposure concentration limit of dust, and whether the time weighted average exposure concentration and peak concentration of dust at the same post exceed the limit is taken as the basis for exceeding the limit of dust post concentration to calculate the post exceeding the limit rate. Results: The dust hazards were mainly distributed in the posts of sand treatment, molding, sand falling, sand cleaning and cutting and grinding. Dust exposure time weighted average concentration was 0.44 (0.03, 5.11) mg/m(3), peak exposure concentration was 1.30 (0.18, 10.94) mg/m(3), and the over standard rate of Posts was 38.92% (79/203) . Weighted average exposure concentration of other dust (total dust) in the cutting and grinding post is 1.50 (0.15, 7.40) mg/m(3), peak exposure concentration is 0.90 (0.07, 12.48) mg/m(3), and the post exceedance rate is 4.88% (2/41) . Weighted average exposure concentration of silica dust (exhaling dust) in dust operation posts of investment casting enterprises is 0.43 (0.05, 6.35) mg/m(3), peak exposure concentration is 0.90 (0.12, 8.28) mg/m(3), and the post over standard rate is 35.77% (49/137) ; Weighted average exposure concentration of other dust (total dust) at the cutting and grinding post is 2.00 (11.00, 21.00) mg/m(3), and the post exceedance rate is 2.50% (2/80) . There was no significant difference in the concentration of respirable dust between sand casting and investment casting (P>0.05) . The concentration of respirable dust in sand casting was higher than that in sand treatment, molding and sand cleaning posts (P<0.05) . The concentration of silica dust in investment casting was higher than that in sand treatment and molding posts, and that in sand cleaning posts was higher than that in sand treatment posts (P<0.05) . 98.48% (454/461) of the dust operation posts have an occupational health risk value greater than or equal to 400, and 1.52% (7/461) of the dust operation posts have an occupational health risk value of 200~399. Conclusion: there is a high rate of exceeding the standard in the dust work posts in the ferrous metal foundry enterprises in Ningbo, and the workers have a high occupational health risk of pneumoconiosis or metal and its compound pneumoconiosis. Targeted measures should be taken to reduce the occupational health risk.

TP 78 An Interactive Genetic Algorithm and Machine Learning approach for validating the effect of preheated air combustion on fuel consumption of oil-fired industrial furnace

This paper presents an interactive approach of Genetic Algorithm and Machine Learning being used as tool for optimizing the Fuel Consumption of oil-fired rotary furnace operating with 20% preheated excess air. The author has attempted to solve a crucial problem of optimizing fuel consumption in ferrous foundries. Based on experiments carried on a self-designed and developed 200 kg rotary furnace in a foundry, it was found that crucial operating parameters like preheated excess air not only affects the flame temperature and melting rate but also significantly the fuel consumption An attempt has been made to establish a correlation between fuel consumption as output parameter and all others as input parameters It is expected that this model may prove practically beneficial for industry by estimating the effect of input process parameters for predicting the fuel consumption The results of Genetic Algorithm and Machine approach correlates with the experimental results

Application of the Technique For Order Preference By Similarity To Ideal Solution Method in Determining Contract Employees to Become Permanent Employees

Refratech Mandala Perkasa (RMP) is a refractory cement manufacturing company. The company also operates in the manufacture of refractory cement made for repair of hot coatings, boilers, rotary kilns, incinerators, ovens and chemicals for steel metals, as well as ferrous &amp; non ferrous foundries. In this company there are contract employees and permanent employees, contract employees are employees or workers whose working period is limited by a certain time according to the agreement within the company. While permanent employees are workers whose working period is approximately until they receive certain benefits according to the work agreement. This research was conducted to assist companies in decision support using the Topsis method in determining the appointment of contract employees to permanent employees based on predetermined criteria, namely Knowledge and Skills at work, Quantity and Quality of Work, Job Responsibilities, Initiatives in Work, and Compliance. on rules or discipline. The results of this study indicate that the determination of the ranking of prospective permanent employees can be obtained from the calculation results of the TOPSIS method, where the results of prospective employees are based on predetermined administrative criteria. Prospective permanent employees who have the highest rank have the right to be selected first. The accuracy of the implementation of the TOPSIS method on the system plays a major role in the effectiveness and efficiency of the company's services to consumers compared to before the system was implemented. With the implementation of this DSS system, it can help companies to make it easier to make decisions to survey prospective permanent employees and optimize employee performance.

Application of thermal analysis in ferrous and nonferrous foundries

This paper is devoted to the memory of Professor Ljubomir Nedeljkovic (1933-2020), Head of the Department of Iron and Steel Metallurgy University of Belgrade, Serbia. Assessment of the melt quality is one of the most important casting process parameters, which allowed sound production of intricated cast parts. At the present time, various devices have been applied at foundry floors to control melt quality. Thermal analysis is one of them, widely used for melt quality control in ferrous and non-ferrous casting plants. During solidification, metal and alloys released latent heat, which magnitude is dependent on the type of phases that form during the solidification process. Plotting temperature versus time data during solidification provides useful information related to the actual solidification process. The applied technique is called thermal analysis, whereas the cooling curve is the name of such a plot. The main aim of this paper is to give a short overview of the present thermal analysis application in various foundries and to indicate the future potential use of this technique.

Computer Aided Foundry Mold Design.(Dept.M)

In the late 1980's and early 1990's, use of CAD/CAM and computer graphics in both ferrous and non-ferrous foundries increased considerably. An interactive computer system has been developed using an Autocad software as a base for this system. Several routines have been used to utilize the geometrical data. surface area and volume of the product drawn by the Autocad techniques. A pattern model was built and splitted at parting surface to show parts of casting in the cope and drag. It can also be viewed from any direction to check the facility of Withdrawing the pattern from the molding sand. The system results in a complete planning sheet that include casting weight, core prints, flask, gating and riser dimensions. The results can be saved for any modification and new results can simultaneously be found. Some case studies were described and presented.

Foundry Sand Source Reduction Options: Life Cycle Assessment Evaluation

Foundries represent a significant part of the world’s economy and are a large consumer of energy and producer of solid waste. Sand-handling processes can use 5–10% of a foundry’s total energy. The goal of this research was to explore source reduction and waste minimization at a foundry, using both economic and Life Cycle Assessment (LCA) techniques to compare three secondary sand-reclamation options. LCA software modeled all sand processes at a mid-sized ferrous foundry in the USA. The LCA showed all secondary reclamation technologies, while more energy intensive at the foundry, lowered life cycle environmental impacts, including GHG emissions, ecotoxicity, and human health indicators, due primarily to source reduction and corresponding reduction in transportation both from the virgin sand source and to the landfill. Varying transportation distance had a large impact on LCA results to the point where the life cycle benefit of secondary reclamation became a liability in a zero distance scenario. Varying electricity generation to favor greener sources was also examined, but proved to have minimal impact on the LCA results. This research suggests that the greatest reduction of life cycle impacts in the sand-handling processes for a foundry is to find a geographically closer source for virgin sand.

Modeling and Optimization of Experimentally Verified Effect of Preheated Excess Air on Fuel consumption of Rotary Furnace using PSO (Particle Swarm Optimization) Technique

The energy consumption in ferrous foundries has been reported as a serious concern. The prevailing natural sources may not last long. By the time of availability of new resources we have to optimize the usage of prevailing resources to avoid serious conditions later on.The authors have attempted to analyze the effect of aspects of combustion of furnace oils in an oil fired rotary furnace with highly preheated air, and to verify the experimental results using PSOM (Particle Swarm Optimization) technique. The authors conducted a series of experiments on an oil fired rotary furnace of 200 kg capacity installed in a leading ferrous foundry. Detailed in measurements of temperature, and heat transfer, flame temperature, fuel consumption etc has been performed. During experimentation furnace was supplied with 10% excess air, preheated using multipass counter flow heat exchanger. The experimental investigations revealed that using 10% excess air drastically reduces the fuel consumption, increase melting rate, and the heat transfer rates due to enhanced flame temperature. The PSOM (Particle Swarm Optimization) technique also verified the experimental results.

Mechanical Properties of Ultra High Performance Fiber Reinforced Concrete Made with Foundry Sand

The ferrous and non-ferrous foundry industry produces approximately 6 million tons of foundry sand (FS) waste annually in the United States and estimates have shown that only 15% of the waste is being recycled. This study utilized FS waste in the production of Ultra High Strength Concrete (UHSC) as a partial replacement for natural sand. Natural sand was replaced with FS at the replacement levels of 0%, 10%, 20%, and 30% by volume. UHSC mixtures produced were tested to determine the compressive strength, splitting tensile strength, flexural strength, elastic modulus, and Poisson's ratio at 7, 14, and 28 days. The results showed an increase in mechanical performance up to 10% FS replacement. The results also indicate an insignificant decrease in mechanical performance at 20% replacement levels. FS had no significant impact on the Poisson's ratio of UHSC.

Minimize the competence gap between ferrous foundry small firms and vocational high school in Indonesia readiness industry 4.0

the purpose of this paper is to identify the Competence that should be taught in Vocational High School which still takes care of the skills needed for the future. The research method used is descriptive qualitative. To get the required Competence of metal Ferro casting industry from Vocational High School students through two sides. The first side is observation and interviewing in the ferrous foundry to get the required Competence. The next side is by way of interviews and observations at Vocational High School to know the difference Competence is taught. Competences that should be taught are provide material on the foundations of metal casting, pattern-making techniques and power points or Prezi, engineering drawings and AutoCAD, manual and modern casting technique, Solidwork and the solid cast, mold making techniques and core, and Ferro metal casting techniques with industry.

Case Studies on Integrating 3D Sand-Printing Technology into the Production Portfolio of a Sand-Casting Foundry

Metal casting foundries all across USA are increasingly adopting the recent development in additive manufacturing including 3D sand printing (3DSP) due to its unique ability to fabricate molds and cores without any tooling requirement such as patterns, cores, core boxes, flasks among others. This new method of rapid mold fabrication can accelerate process cycle times, reduce shrinkage defects, offer part consolidation, functional integration and customization that could facilitate the growth of foundry industries. This study demonstrates how the adoption of 3DSP technology has contributed to a conventional ferrous metal casting foundry that specializes in manufacturing impellers, turbine housings and other mining equipment. Four industrial case studies are presented to illustrate novel opportunities via 3DSP. These case studies validate that 3DSP has the ability to (1) reduce shrinkage by allowing casting in optimal orientation without hard-tooling requirements, (2) reduce lead time through rapid mold fabrication by easier facilitation of nesting multiple parts into a single mold, (3) allow hybrid molding by integrating 3DSP with conventional mold making and (4) fabricate tooling-less complex castings, respectively. Findings from this study would help foundries rethink their design process from traditional pattern-drawing to a new and radical freeform-based design process via 3DSP.

Thermophysical aspects of reclaimed moulding sand addition to the epoxy-SO2 coremaking system studied by Fourier thermal analysis

The most important advantage of foundry purpose moulding sand is that it can be reclaimed and reused through the casting manufacturing process. Supplying the foundry with a new source of material, sand reclamation brings along both environmental and economic advantages. Utilization of used sand can be considered as a common technological routine in the production of most types of chemically bound moulding materials. The epoxy-SO2 process is prevalent in the processing of cast iron engine components worldwide. Based on its excellent properties, it is mainly suitable for producing internal sand cores with complex geometry. Even though reclaimed sand addition is an active and well-functioning feature in ferrous foundries, the scientific and thermophysical background of its effects on the casting process is yet to be explored. In this work, the thermal aspects of different reclaimed sand levels in the epoxy-SO2 moulding system were examined. Thermogravimetry and differential thermal analysis of the epoxy-SO2 and reclaimed sand in focus were carried out to obtain basic understandings about their high-temperature behaviour. A state-of-the-art Fourier thermal analysis method presented in a recent paper was used at temperatures corresponding to actual cast iron production (1300 ± 10 °C), contrary to the previous tests at the typical temperature range of aluminium melt processing (660 ± 10 °C). By the right of the method, the effects of reclaimed sand addition on the heat absorption (cooling) capacity of the epoxy-SO2 moulding mixtures were investigated.

Correlation between airborne manganese concentration at the workstations in the iron foundry and manganese concentration in workers' blood.

Manganese (Mn) used as raw material for melting process in the ferrous foundry is considered as hazardous neurotoxic substance because it accumulates in the central nervous system and may cause neurological disorders. The furnace-men and melting department workers are potentially exposed to manganese particles or fume in the workplace. The objective of the research has been to investigate the sources and levels of manganese exposure in the foundry by correlation of blood-manganese (B-Mn) and air-manganese (air-Mn) measurement. Air-Mn and Mn of blood serum were measured involving workers who worked in a big-sized foundry during 1 year. The standard method of the Occupational Safety and Health Administration (OSHA) ID-121 was used for air and blood assessment and atomic absorption spectroscopy (AAS) was carried out for air and blood sample analysis. The air sampling results have revealed that there is a high exposure to manganese (4.5 mg/m3) in the workplace as compared to the National Institute for Occupational Safety and Health's (NIOSH) time weighted average (the reference time-weighted average (TWA) = 1 mg/m3). The average blood serum Mn concentration was 2.745 μg/l for subjects working for shorter than 3 months and 274.85 μg/l for subjects working 3-12 months. Against the research hypothesis there was no correlation between the air-Mn concentration and the B-Mn (serum) level of manganese in the serum of the exposed subjects. It may be due to short time of air sampling of manganese airborne particles, and a real-time monitoring of airborne manganese particles is suggested for any future study. Med Pr 2017;68(4):449-458.

Innovative Laboratory Procedure to Estimate Thermophysical Parameters of Iso-exo Sleeves

Abstract The paper is focused on properties testing of materials used in form of iso-exo sleeves for risers in ferrous alloys foundry. They are grainyfibrous materials, containing components which initiate and upkeep exothermic reaction. Thermo-physical parameters characterizing such sleeves are necessary also to fill in reliable databases for computer simulation of processes in the casting-mould layout. Studies with use of a liquid alloy, especially regarding different sleeves bring valuable results, but are also relatively expensive and require longer test preparation time. A simplified method of study in laboratory conditions was proposed, in a furnace heated to a temperature above ignition temperature of sleeve material (initiation of exothermic reaction). This method allows to determine the basic parameters of each new sleeve supplied to foundries and assures relatively quick evaluation of sleeve quality, by comparison with previous sleeve supplies or with sleeves brought by new providers.

Prevention of occupational injuries: Evidence for effective good practices in foundries

IntroductionOccupational injuries are a relevant research and practical issue. However, intervention studies evaluating the effectiveness of workplace injury prevention programs are seldom performed. Method: The effectiveness of a multifaceted intervention aimed at reducing occupational injury rates (incidence/employment-based=IR, frequency/hours-based=FR, severity=SR) was evaluated between 2008 and 2013 in 29 Italian foundries (22 ferrous; 7 non-ferrous; 3,460 male blue collar workers/year) of varying sizes. Each foundry established an internal multidisciplinary prevention team for risk assessment, monitoring and prevention of occupational injuries, involving employers, occupational physicians, safety personnel, workers' representatives, supervisors. Targets of intervention were workers, equipment, organization, workplace, job tasks. An interrupted time series (ITS) design was applied. Results: 4,604 occupational injuries and 83,156 lost workdays were registered between 2003 and 2013. Statistical analysis showed, after intervention, a reduction of all injury rates (−26% IR, −15% FR, −18% SR) in ferrous foundries and of SR (−4%) in non-ferrous foundries. A significant (p=0.021) ‘step-effect’ was shown for IR in ferrous foundries, independent of secular trends (p<0.001). Sector-specific benchmarks for all injury rates were developed separately for ferrous and non-ferrous foundries. Conclusions: Strengths of the study were: ITS design, according to standardized quality criteria (i.e., at least three data points before and three data points after intervention; clearly defined intervention point); pragmatic approach, with good external validity; promotion of effective good practices. Main limitations were the non-randomized nature and a medium length post-intervention period. In conclusion, a multifaceted, pragmatic and accountable intervention is effective in reducing the burden of occupational injuries in small-, medium- and large-sized foundries. Practical Applications: The study poses the basis for feasible good practice guidelines to be implemented to prevent occupational injuries, by means of sector-specific numerical benchmarks, with potentially relevant impacts on workers, companies, occupational health professionals and society at large.

Molding and casting behavior of ferro chrome slag as a mold material in ferrous and non-ferrous foundry industries

ABSTRACTIn the present investigation, efforts are made to use Ferro Chrome (Fe-Cr) slag as a mold material for the replacement of silica sand in the foundry industry. The sodium silicate-Fe–Si process is adopted for evaluating the same. The process parameters considered for this investigation are % of sodium silicate, % of Fe–Si powder as a binder, and mold setting time. A series of sand tests are carried out on sand, slag individually, and for various combinations of these two. Three types of molds are made with sand, slag individually, and combination of these two with 6% sodium silicate and 1.5% Fe–Si. Various ferrous and non-ferrous castings are performed on these newly developed slag molds. The results reveal that the Fe-Cr slag with mold permeability, compression, and shear strength is a suitable candidate for either partial or full replacement of silica sand. During casting neither fusing, dripping, nor collapse of the mold walls is observed in slag molds; this is true for both ferrous and non-ferrous castings. Castings with good surface finish and no surface defects are made by slag molds. Faster heat transfer in slag molds enable to obtain castings with enhanced metallurgical and mechanical properties.