Ceramisite Sand ‘s application in lost foam casting primarily leverages its unique physical and chemical properties to significantly improve casting quality, yield, and production efficiency. The following are its specific applications and advantages:
1. As a Molding Sand Material
Replacing Traditional Sand: Ceramisite Sand can completely replace traditional molding sands such as quartz sand and forsterite sand, serving as filler and base sand in lost foam casting. Its spherical particles and high fluidity ensure high mold density and excellent air permeability, reducing casting defects.
3D Printing Sand Molds: In the manufacture of complex castings (such as piston cooling channels), Ceramisite Sand can be directly formed into sand mold cores using 3D printing technology, improving structural accuracy and reducing subsequent processing.
2. Improving Casting Quality
Reducing Casting Defects: Ceramisite Sand Sand’s high refractoriness (≥1790°C) and low thermal expansion coefficient effectively prevent defects such as sand sticking, sand inclusions, air holes, and scarring. It is particularly suitable for high-temperature castings such as high-manganese steel and alloy steel.
Improved Surface Finish: Its spherical particle structure reduces molten metal penetration, resulting in smoother casting surfaces and over 50% reduction in cleaning effort.
3. Optimized Process Performance
Excellent Air Permeability: The uniform particle size distribution and spherical particle structure of jelly sand facilitate gas escape, preventing problems such as choking and cold shut during pouring, and increasing yield by 5%-7%.
Good Flowability: Compared to polygonal sands (such as quartz sand), jelly sand compacts more easily, reducing defects like rat tails and scarring, making it particularly suitable for filling complex mold cavities.
4. Cost Reduction and Environmental Protection
High Recycling Rate: jelly sand offers high strength and resistance to brittleness, with only 5% waste sand (compared to over 10% for quartz sand). This significantly increases recycling rates and reduces sand loss by 70%.
Reduced Binder Use: In resin sand or water glass sand processes, jelly sand can reduce the amount of binder added (e.g., reducing resin usage by 1/3), further saving costs.
5. Special Application Scenarios
Vacuum Lost Foam Casting: Using a vacuum process (e.g., patent CN108637173A), jewel sand enhances mold stability and improves casting dimensional accuracy, making it suitable for the production of high-precision castings.
Large Castings: For wear-resistant and heat-resistant steel castings, jewel sand’s high-temperature resistance and low expansion rate make it an excellent choice for thick, cross-section castings.
Summary
The use of jewel sand in lost foam casting not only overcomes the shortcomings of traditional sand but also significantly improves casting quality and production efficiency through its spherical particles, high refractoriness, and environmentally friendly properties, making it a key material in modern casting processes.
