Fused Ceramisite Sand for Precision Casting

Regarding foundry sand, people all wish to choose those with high refractoriness, small thermal expansion, and perfect round shape. Artificial sand, rather than natural sand, could better meet these requirements.
  Ceramic sand has good shape, high refractoriness and perfect stability under high temperature. It is a great cost-effective alternative for chromite sand and zircon sand and has been recognized by foundry experts home and abroad.

Specifications for the Product:

1. Main Chemical Composition: Al2O3: 65~80% ,Fe2O3≤3%  K2O≤0.5%
2. Shape: Sphere, Angle Factor ≤ 1.1
3. Refractoriness: 1825ºC
4. pH: 7.6-7.8
5. Thermal Expansion Rate: 0.13% (10 minutes under 1000 oC)
6. Mineral Phase: Mullite Phase≥85%, Corundum phase + Glass phase ≤15%
7. Bulk Specific Weight: 1.95~2.05(g/cm³)
8. Mohs hardness: 7.5-7.8

Features of Ceramic Sand

1. High Refractoriness  
Refractoriness: ≥1800oC, same level with magnesite and chromite sand, and higher than silica sand, with less sand burning.

2. Low Expansion Rate
Better than magnesite, chromite sand and silica sand, could meet higher accuracy requirement.

3. Low Breakage Rate
 Moh's hardness of ceramic Sand being 7.8, and the spherical shape, make it hard to break ceramic Sand.

4. pH: 7.0 - 7.8
As a neutral material, Ceramic Sand is suitable for different kinds of alkalinity or acidity adhesive. For example: water glass, clay, resin curing agent.
 
5. Good Spherical shape
The shape of Ceramic Sand is spherical and the angle factor is less than or equal to 1.1. With smooth surface and perfect shape, Ceramic Sand has smallest superficial area, making the volume added to adhesive and curing agent much less (average 40% - 50% less). So application of Ceramic Sand could lower the production cost, reduce exhaust emission, and improve casting environment. The spherical shape is also beneficial to the gas emission of pouring process and also reduce the porosity in castings. With the reduction of adhesive could also help to lower the strength of the casting model and the recycle of the sand.

6. Proportion
As a kind of special artificial sand, the bulk specific weight of Ceramic Sand is smaller than magnesite and chromite sand. The reduction of the casting model and increased ratio of the iron sand will help to lower the production cost.

7.Pollution-free
Compared to the radioactivity of zircon sand and the pollution of chromite sand (some countries have forbidden the use of chromite sand), Ceramic Sand is a more environmental friendly material, with higher re-use ratio and lower discharge.

Application of Ceramic Sand

The chemical composition and performance character of Ceramic sand make it have broad application prospects in casting fields.

1. Application in production of steel castings
The scab phenomenon is quite common and serious in large scale steel castings, which affects the surface quality of the castings and bring lots of trouble in cleaning. Ceramic sand, instead of zircon sand and chromite sand, has been used on the hot spots on the large scale steel castings.
Applicable sand size: AFS20, AFS30

2. Application in the production of engine castings
In the core of engineer casting oil passage and water passage, the use of Ceramic Sand could reduce the gas emission and porosity, avoid casting leakage, and is easy for sand cleaning.

3. Hydraulic Pressure Casting: Similar with engine casting.

4. Stainless Steel Casting
The features of Ceramic Sand is especially significant in the casting of resin sand. Many renowned companies, such as Japan Mucun Casting, Shou Casting, Mitsubishi Heavy Industries, Korea M-TEK, Hyundai, Tianjin Xin Wei San Industrial CO.,LTD, China Rong Xing Casting, Huaihai Casting, all use Ceramic Sand as casting sand, covering casting material like cast steel, cast iron, and stainless steel. With the reduced volume of resin curing agent, and more than 95% re-use ratio of the sand, Ceramic Sand could create great economic benefit and social benefit.
Applicable sand size: AFS30, AFS40, AFS50, AFS60, AFS75.
 
5.  Application in V-shaped method and lost foam casting
In V-shaped method and lost foam casting, the repeated change in temperature makes ganister sand atomized. Ceramic Sand could solve such problem.
Applicable sand size: 20Mesh, 30Mesh

6.  Application in smelting industry
In iron and steel smelting industry, Ceramic Sand is also used more and  more commonly as the stuffing sand in molten steel refining.
Applicable sand size: 30Mesh

7.  Application in other industries
Ceramic Sand could also be used in abrasive blasting in steel rust removal, surface cleaning for nonferrous castings and furniture.
Applicable sand size for furniture surface cleaning: 200Mesh

Partical Size Distribution Table