Product Introduction
Ceramsite Foundry Sand is a premium material designed for various casting applications. With a chemical composition of Al2O3≥70%, Fe2O3≤3%, and SiO2≤24%, it delivers superior performance and efficiency in metal casting processes. This advanced foundry sand is characterized by its nearly spherical grain shape, high thermal resistance, and excellent fluidity. It is an ideal choice for those looking to achieve precision and quality in their castings.
The unique properties of Ceramsite Foundry Sand make it highly suitable for use in lost foam casting, sodium silicate sand applications, and various casting coatings. Its ability to minimize thermal expansion defects enhances the dimensional accuracy of castings, while its smooth surface allows for efficient binder application, significantly reducing material costs.
Product Advantage
Thermal Stability: With a fire resistance greater than 1790ºC and a thermal conductivity of 0.5-0.6 (W/m*K) at 1000ºC, Ceramsite Foundry Sand can withstand extreme temperatures, ensuring the integrity of the casting process.
Dimensional Accuracy: The low thermal expansion coefficient, comparable to zircon sand, helps eliminate casting veins and other defects, enhancing the dimensional precision of the final product.
Fluidity and Permeability: The nearly spherical shape of the sand allows for excellent fluidity, making it easy to fill molds. Its high permeability and collapsibility after pouring facilitate better casting outcomes.
Binder Efficiency: The dense structure and smooth surface of the sand enable even binder coverage, resulting in a significant reduction of 30-50% in binder usage.
Versatility: Being a neutral material, Ceramsite Foundry Sand is compatible with both acid and alkali binders, allowing it to be used with a wide range of casting alloys.
Recyclability: The sand exhibits good recycling performance, making it cost-effective and adaptable to various regeneration methods.
Customizable Particle Size: With a wide range of particle sizes available, Ceramsite Foundry Sand can be tailored to meet specific customer requirements.
Technical Parameters
Chemical Composition:
Al2O3 ≥ 70%
Fe2O3 ≤ 3%
SiO2 ≤ 24%
Other: Trace
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) (1000ºC)
Thermal Expansion Rate: 0.13% (1000ºC heating for 10 minutes)
Fire Resistance: > 1790ºC
Acid Consumption Value: ≤ 3.0 ml
Product Uses
1. Lost Foam Casting
Ceramsite Foundry Sand is ideal for lost foam casting processes. Its excellent fluidity allows for complete mold filling, ensuring that intricate designs are captured accurately. The high thermal stability of the sand minimizes distortion, resulting in high-quality castings that meet exact specifications.
2. Sodium Silicate Sand Applications
In sodium silicate sand applications, the smooth surface of Ceramsite Foundry Sand enhances the bonding of sodium silicate, resulting in stronger mold structures. This feature is crucial for achieving detailed shapes and reducing the incidence of defects in the final product.
3. Casting Coatings
The sand’s fine particle size and spherical shape contribute to superior casting coating applications. This allows for a more uniform application of coatings, enhancing surface finish and reducing surface imperfections in the casted parts.
4. Drainage Sand
Ceramsite Foundry Sand is also used as drainage sand in various applications. Its high permeability allows for efficient drainage, preventing the buildup of moisture and ensuring consistent casting quality.
5. Alloy Surface Treatment
For alloy surface treatments, the neutral nature of Ceramsite Foundry Sand enables its use with both acid and alkali binders. This versatility makes it suitable for a variety of alloys, enhancing the overall quality and performance of the surface treatment processes.
6. Phenolic Resin Coated Sand
When used as a phenolic resin coated sand, Ceramsite Foundry Sand’s low thermal expansion and high refractoriness allow for the creation of durable molds that withstand high temperatures, improving the longevity of the molds and reducing costs.
7. Hot-Core Box Resin Sand
In hot-core box resin sand applications, the sand’s excellent collapsibility after pouring helps in achieving cleaner releases from the mold, resulting in better surface finishes and lower post-casting cleanup efforts.
8. Blow Hardening Cold Core Box Resin Sand
Ceramsite Foundry Sand is also effective in blow hardening cold core box resin sand processes. Its high packing density and superior fluidity contribute to efficient filling and hardening, resulting in precise core production that meets stringent tolerances.
Product Operate Guide
To achieve optimal results with Ceramsite Foundry Sand, follow these guidelines:
Preparation: Ensure that the workspace is clean and that all necessary materials, including binders and coatings, are ready for use.
Mixing: Combine the sand with the chosen binder at the recommended ratio, ensuring even distribution for optimal performance.
Mold Creation: Utilize appropriate mold-making techniques, considering the properties of the sand to ensure proper filling and hardening.
Pouring: Carefully pour the molten metal into the mold, allowing the sand’s properties to facilitate smooth flow and minimize defects.
Cooling: Allow adequate cooling time to ensure the casting solidifies properly before removing it from the mold.
Recycling: Implement a recycling process for the used sand to maintain sustainability and reduce costs.
FAQ
Q: What are the main benefits of using Ceramsite Foundry Sand?
A: Ceramsite Foundry Sand offers numerous benefits, including high thermal stability, excellent dimensional accuracy, and enhanced fluidity, making it ideal for a variety of casting applications.
Q: Can Ceramsite Foundry Sand be recycled?
A: Yes, Ceramsite Foundry Sand has good recycling performance and can be adapted to various regeneration methods, making it a cost-effective option.
Q: What types of binders can be used with Ceramsite Foundry Sand?
A: Ceramsite Foundry Sand is neutral and can be used with both acid and alkali binders, accommodating a wide range of casting alloys.
Q: How does Ceramsite Foundry Sand compare to traditional sands?
A: Ceramsite Foundry Sand provides superior thermal resistance, lower thermal expansion, and better fluidity compared to traditional sands, leading to higher-quality castings.
Q: What particle sizes are available for Ceramsite Foundry Sand?
A: Ceramsite Foundry Sand is available in a wide range of particle sizes, allowing for customization based on specific application requirements.
By choosing Ceramsite Foundry Sand, you ensure high-quality castings with exceptional performance in various applications, enhancing your production efficiency and product reliability.
