Disadvantages of fused ceramic sand -- the price is more expensive than silica sand, and the workshop is required to have a high level of management to reduce the loss of molding sand in each link of production.
Application of fused ceramic sand in large steel castings
A factory that produces steel castings for construction machinery such as loaders and excavators. It has used resin silica sand process to produce steel castings such as axle housings and bearings for more than 20 years.
The resin silica sand process has the following problems:
(1) Serious sand sticking on the surface of castings. Because the castings of the author's factory are relatively thick and large, even if the best pure zircon powder coating is used, the problem of sand sticking on the castings cannot be completely solved, and it is very difficult to clean the castings.
(2) The surface of riser root at the thick and large position of large castings is seriously concave, the workload of air gouging welding repair is heavy, and the quality is difficult to guarantee.
(3) The amount of resin curing agent is large, which requires expensive pure zirconium powder coatings, and the production cost is high.
(4) There are many shrinkage cavities in the casting, and the air leakage of the axle housing is serious.
(5) Environmental protection issues are prominent, and solid waste treatment is difficult.
Because many inherent shortcomings of silica sand are difficult to overcome, the factory started to use ceramic foundry sand instead of silica sand products in batches after many discussion and investigations. After a quarter of application, the quality improvement, production efficiency improvement and cost reduction have been achieved.
Application results of fused ceramic sand
Due to the high refractoriness of the fused ceramic sand and the high molding sand strength under the condition of the same amount of resin, the problem of sand sticking at the thick position of the casting has been greatly improved, the sand sticking at the groove of the axle housing and the thick wall of the support has been eliminated, the workload of cleaning and polishing the casting has been greatly reduced, and the production efficiency has been significantly improved.
(1) The application of fused ceramic sand instead of silica sand in the production of steel castings can significantly improve the sand sticking quality of castings.
(2) The application of fused ceramic sand instead of silica sand in the production of steel castings can reduce the tendency of shrinkage porosity, shrinkage cavity and porosity, and is conducive to improving the density of castings
Compactness.
(3) The use of fused ceramic sand instead of silica sand in steel casting production can reduce the solid waste emissions in the old sand recycling process and reduce the pressure of environmental protection.
(4) Replacing silicon sand with fused ceramic sand in steel casting production can improve production efficiency and reduce production costs.