• Journal of Korea Foundry Society
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• v.43 no.3
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• pp.107-136
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• 2023

Natural silica sand was commonly used for sand casting of cast steel products, and chromites sand was used to suppress seizure defects due to the lack of thermal properties of silica sand. However there are disadvantages such as deterioration by repeated use, system sand mixing problem, difficulty separating and removing, increased during mold according to high density and to being waste containing chrome. Recently, industrial waste reduction and atmospheric environment improvement have been highlighted as important tasks in the casting industry. In order to solve the problems that occur when using foundry Sand and to improve the environment of casting factories, various artificial sands that can be applied instead of natural silica sand have been developed and introduced. Artificial sands can be classified into artificial sand manufactured by the electric arc atomization or gas flame atomization, artificial sand manufactured by the spray drying & sintering process, artificial sand manufactured by the sintering & crushing process and exhibit different physical properties depending on the type of raw-minerals and manufacturing method. In this study, comparative evaluation tests were conducted on the physical properties of various foundry sands, mold strength, physical durability, thermal durability, and casting test pieces. When comprehensively considering the actual amount of molding sand used according to density, the mold strength according to the shape of sand, the physical and thermal durability of foundry sand, and the heat resistance characteristics of foundry sand, 'Molten artificial sand A1' or 'Molten artificial sand B' is judged to be the most suitable spherical artificial sand for casting of heavy steel castings.

• Journal of Korea Foundry Society
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• v.44 no.1
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• pp.3-8
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• 2024

Reducing industrial waste and improving the atmospheric environment recently have emerged as important tasks for the casting industry. Various types of artificial sand that can replace natural sand have been developed and used to solve problems that arise with the use of conventional foundry sand and to improve the foundry environment. However, only limited physical properties provided by overseas suppliers are known and in-depth comparative analyses with existing natural sand are lacking. For the design of the casting process, a wide range of thermal properties must be secured not only at room temperature but also at high temperatures. In addition, it is important to compare and analyze the differences in thermal properties between existing natural and artificial sand because changes in thermal properties require changes in the design of the casting method. In this study, the thermal behavior of the mold was analyzed through a thermal expansion test of mold blocks for natural and artificial sand., To this end, a thermal property test to evaluate thermal conductivity was performed by determining a temperature range. The results of the experiment, revealed that the thermal conductivity was 5-40% higher in artificial sand than in natural sand, and the coefficient of thermal expansion was about 15% lower for artificial sand. However, there was not a significant difference in specific heat regardless of the composition.

• Journal of Korea Foundry Society
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• v.43 no.4
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• pp.194-200
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• 2023

The heat transfer of the mold in the casting process has been calculated by considering the mold as a uniform isotropic material. Since the mold was not a uniform isotropic material, however, the calculation was performed with approximate values, and in particular, estimated values were used when considering compaction and the amount of added binder. In this study, a calculation algorithm of the thermal properties of the sand mold was developed. An algorithm for calculating the thermal conductivity and specific heat based on a thermal resistance model in the case of mono-dispersed sand grains was also developed and applied to sand molds with various size distributions. The thermal properties of sand were calculated for artificial sand, and relatively close values compared to the experimental values were obtained.