Ceramsite Foundry Sand

Product Introduction

Ceramsite Foundry Sand is an advanced material specifically designed for various casting applications. With its high aluminum content (Al2O3≥70%) and minimal impurities (Fe2O3≤3%, SiO2≤24%), this product offers exceptional properties for the foundry industry. The spherical grain shape and low angular coefficient (<1.1) enhance its fluidity, making it ideal for filling molds and cores efficiently. Ceramsite Foundry Sand provides superior thermal resistance (fire resistance >1790ºC) and stability, which is crucial for producing complex castings with high dimensional accuracy.

Product Advantage

1. High Thermal Stability: With a thermal expansion rate of just 0.13% (after 10 minutes at 1000ºC), Ceramsite Foundry Sand minimizes casting defects such as veins and distortions, ensuring precise final products.

2. Improved Fluidity: The nearly spherical shape of the sand particles results in excellent flow characteristics. This allows for better filling of molds and enhanced permeability in sand cores, leading to better overall casting performance.

3. Binder Efficiency: The smooth surface of Ceramsite reduces the amount of binder needed by 30-50%, which translates to lower costs and better environmental efficiency.

4. Versatile Compatibility: As a neutral material, it works well with both acid and alkali binders, making it suitable for a wide range of casting alloys.

5. Recyclability: Ceramsite Foundry Sand offers excellent recycling capabilities, making it cost-effective and adaptable for various regeneration methods.

6. Customized Solutions: Available in a wide range of particle sizes, this sand can be tailored to meet specific customer requirements, ensuring optimal performance across different applications.

Technical Parameters

• Chemical Composition:

• Al2O3: ≥70%

• Fe2O3: ≤3%

• SiO2: ≤24%

• Other: Trace amounts

• Physical Properties:

• Grain Shape: Spherical

• Angular Coefficient: <1.1

• Packing Density: 1.9-2.1 g/cm³

• pH Value: 7-8

• Thermal Conductivity: 0.5-0.6 (W/m*K) at 1000ºC

• Thermal Expansion Rate: 0.13% (10 min at 1000ºC)

• Fire Resistance: >1790ºC

• Acid Consumption Value: ≤3.0 ml

Product Uses

1. Lost Foam Casting: Ceramsite Foundry Sand excels in lost foam casting due to its excellent fluidity and low thermal expansion. It allows for detailed mold impressions, resulting in high-quality castings.

2. Sodium Silicate Sand: When combined with sodium silicate, Ceramsite enhances mold strength and collapsibility, making it easier to remove patterns and ensuring clean cast surfaces.

3. Casting Coating: The fine grain size and smooth surface of Ceramsite facilitate uniform coating applications, enhancing the surface finish of cast products.

4. Drainage Sand: Its high permeability properties make Ceramsite ideal for drainage applications, preventing water accumulation and ensuring effective moisture control in various foundry operations.

5. Alloy Surface Treatment: The versatility of Ceramsite allows it to be used in alloy surface treatments, improving the overall quality and lifespan of the alloys produced.

6. Phenolic Resin Coated Sand: The compatibility with phenolic resin makes Ceramsite a great choice for producing high-strength molds that withstand high temperatures during the casting process.

7. Hot-Core Box Resin Sand: Ceramsite's properties support the hot-core box method, providing molds that retain shape under extreme temperatures, enhancing the casting process's reliability.

8. Blow Hardening Cold Core Box Resin Sand: The superior grain characteristics of Ceramsite allow for effective blow hardening, providing strong cores that maintain their integrity during pouring.

Product Operate Guide

To achieve optimal results with Ceramsite Foundry Sand, follow these guidelines:

1. Preparation: Ensure that the workspace is clean and free of contaminants. Properly mix Ceramsite with the appropriate binder according to the casting process requirements.

2. Molding Process: Utilize the sand in molding machines or manually compact it into molds. Maintain consistent density for uniform casting results.

3. Pouring: Carefully pour molten metal into the mold, avoiding turbulence to ensure smooth filling.

4. Cooling: Allow sufficient cooling time to prevent defects. Monitor temperature closely to maintain casting integrity.

5. Cleanup and Recycling: After use, reclaim the sand for recycling. Ensure the sand is properly cleaned and reprocessed for future applications.

FAQ

Q1: What is Ceramsite Foundry Sand primarily used for?
A1: It is primarily used in various casting processes, including lost foam casting and resin sand casting, due to its superior thermal properties and fluidity.

Q2: How does Ceramsite compare to traditional sand?
A2: Ceramsite offers better thermal stability, lower thermal expansion, and improved fluidity, resulting in higher quality castings and reduced defects.

Q3: Can Ceramsite be recycled?
A3: Yes, Ceramsite has excellent recyclability, making it a cost-effective choice for foundries looking to reduce waste.

Q4: What is the ideal binder for use with Ceramsite?
A4: Ceramsite is compatible with both acid and alkali binders, providing flexibility depending on the specific casting needs.

Q5: How do I ensure the best results with Ceramsite Foundry Sand?
A5: Proper preparation, mixing, and following the operational guidelines are essential to achieving the best casting outcomes.

By utilizing Ceramsite Foundry Sand, foundries can enhance their casting processes, reduce defects, and ultimately achieve higher quality products that meet industry standards.