Table 1. Binders, Additives and Environmental Issues Present for Green Sand Cast Steel, Iron, Aluminum and Copper-Base Alloys Factors
Steel Binder
Sodium Bentonite Calcium Bentonite
Bentonite With Processed Carbon Bentonite Processed With Magnesium Fireclay
Carbon Additives
Seacoal Gilsonite
Causticized Lignite Cellulose
Cereal/Starch Polymers or Surfactants Inorganic Additives Soda Ash Advanced Oxidation Core Sand Additions
Coldbox Hotbox Shell
Sodium Silicate Other Additives
Dust Collector Fines Release Agents
Environmental Issues
Emissions (Pouring, Cooling, Shakeout) Without Cores Emissions (Pouring, Cooling, Shakeout) With Cores ) Without Cores
Greenhouse Gases (CO & CO2
Emission Characteristics as Related to the 1,800F LOI Molding Sand % >5 LOI or >1.25 Volatiles
5-3 LOI or 1.25-0.75 Volatiles
Reduction of Emissions as Related to LOI & Volatiles in Molding Sand Reduce LOI & Volatile Matter With Less Carbonaceous Additives
Change Carbon Form From Gilsonite to Causticized Lignite Change Carbon From Gilsonite to Seacoal
Change Carbon From Seacoal to Seacoal/Causticized Lignite Blend Lowest
Medium Lowest
Highest Highest Highest
Medium Highest Medium
Lowest Lowest Lowest
No Yes
Yes Yes
Yes Yes
Yes Yes
Yes n/a n/a Yes
Yes Yes Yes n/a
Yes Yes Yes n/a
Yes n/a Yes Yes
No No
Yes Yes
Yes Yes
No No
No No No No
Predominant Yes
Predominant Yes Yes Yes Yes Yes
Predominant Yes No
Yes No
Yes
No No No No
Yes Yes
Predominant Rare No
Yes No
Predominant Yes Yes Yes Yes
Yes
Predominant Yes Yes No
Yes
Predominant Yes Yes Yes
Iron Brass
Aluminum
Highest Medium Lowest
Highest Medium Lowest
Highest Medium Lowest
Highest Medium Lowest
Medium
No Reference No Reference No Reference
Highest Highest Medium Lowest
Highest Medium Medium Lowest
Medium
No Reference No Reference No Reference
Reading the Table If a factor is marked “predominant,” that binder or additive is frequently used in sand casting of that particular metal. If a
factor is marked “rare,” it is rarely used. If a binder or additive is marked “no,” it is not used in casting that metal type. If “yes,” then it is used. For the environmental factors, “lowest,” “medium” and “highest” refers to the extent an emission characteristic is present in conjunction with a metal type. The abbreviation n/a means there is no information available.
28 MODERN CASTING / October 2010
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