USAGE OF CARBON DIOXIDE IN FOUNDRY INDUSTRY

Foundry Work

Process of making a metal casting of an object
By pouring molten metal into a mould.
Mould is made using a pattern of the article required

Two Types of Foundries

1. Ferrous foundry – to produce Iron & Steel Castings
2. Non-Ferrous – to produce Copper based alloys (brass, bronze & copper)
to produce Aluminium Based Alloys (lead, zinc, nickle, magnesium)
to produce other Alloys

Foundry Process Map

1. Sand Mixing Once sand (refractory), clay (bentonite) and water are mixed to a desired consistancy, the sand must be mulled. Spread sand on a clean hard floor to a depth of about 6". Stomp down hard on the sand until it is all packed tight.

2. Pattern & Moulding Section Keep the required pattern – items to be moulded – inside the box. The mixed sand (core material – silica sand and sand binders) is filled in the frame over the patterns. The filled-in sand is ramming hardly on the pattern. This is called core. Cores are moulded sand shapes placed inside moulds to define a cavity inside the final casting. In general, cores must be strong to withstand molten metal and at the same time, should become loose to breakdown into sand after pouring & cooling.

3. Moulding Process – Adding Co₂ Moulding is a process of mixing sand and binders to give the necessary strength to the core. Sand binders are liquid resins / catalysts and its selection is based on their curing (hardening) time of the sand mixture. “Cold-box” systems require gassing or curing at room temperature. Core is cured using a vaporised (gas) catalyst – the most preferred one is Carbon Dioxide (Co₂)

• In short, Co₂ is referred to as silicate binder in core making
Development of Co₂ mould laid the foundation for future success of foundry industry. Co₂ sodium silicate facing sand with green sand backing became the standard technique employed on all moulds.

4. Pouring & Cooling
Liquid metal is poured into the core

For any information / Co₂ requirements, contact :

SICGIL INDIA LIMITED
VI Floor, Dhun Building, # 84, (Old No. 827), Anna Salai, Chennai-600 002.
Phone : 91 - 044 - 2852 1644 / 2852 1467 / 2852 0657 / 2852 0870
Fax : 91 - 044 - 2852 1249, E-mail : sicgil@vsnl.com, vijay@sicgil.com,

Contact Persons
V.N.Vijay Kumar		Mobile no:98402 53253
Ruqshad Dadabhoy

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