Brief Introduction of Fused Ceramic Sand Production Process
Fused ceramic sand is the custom ceramic particles with a spherical shape, high refractoriness and low thermal expansion being made by spraying the molten calcined bauxite. It provides a very simple but effective way for the foundation men to improve the quality of the castings, reducing the production cost and avoiding environmental pollution, because of that it has the higher price ratio comparing with chrome sand and zircon sand.
Physical and Chemical Indexes of Fused Ceramic Sand
1. Shape: sphere
2. Angle factor: ≤ 1.1, very spherical
3. Bulk density: 1.95-2.05 (g/cm3)
4. Refractoriness: ≥ 1790 ℃
5. Thermal expansion: 0.13% (10 minutes at 1000 ℃)
6. Main chemical composition:
Composition | Al2O3 | FeO3 | SiO2 | TiO2 | Cao | MgO | K2O | Na2O |
Representative Value | 72.56 | 2.23 | 19.86 | 3.53 | 0.43 | 0.35 | 0.78 | 0.08 |
As the raw sand used in the foundry industry, Fused ceramic sand has the following excellent properties.
·The particles are spherical, with good fluidity and easy compaction.
·The thermal expansion coefficient is small, and the molding sand prepared with it will not produce expansion defects, which is comparable with zircon sand.
·The molding sand prepared with fused ceramic sand has good demolding performance, and it is easy to come out even if there are deep pits in the shape.
·There is no harm of silicon dust.
·It is not wetted by metal liquid and does not interact with metal oxides, which can eliminate sand sticking defects.
·Ceramic foundry sand is neutral, and all kinds of acid and alkali binders can be used.
·High fire refractoriness, good air permeability, easy to collapse, and the mullite phase of fused ceramic sand is much higher than that of sintered products, with good fire resistance.
·Good recycling performance and high cost performance. Compared with chromite sand and zircon sand, its price is greatly reduced.
·Due to the spherical shape of Fused ceramic sand, the amount of resin added is significantly reduced, thus reducing the production cost and reducing the gas emission.
·Quantity. The casting defects caused by the binder are also greatly reduced, thereby improving the yield of castings.
·The surface is smooth and the structure is dense, so that the binder can be evenly covered, high thermal conductivity, good stability and no cracking.