be in for a rough patch, whether they have heard about it or not. “[Sand suppliers] are taking care of
their good long-term customers like us,” said Rob Peaslee, president and co-owner of Manitowoc Grey Iron Foundry, Manitowoc, Wis. “But if I said I needed to double my order, I’m guessing I would get a polite no.” Mary Wolfe, process manager for
Deeter Foundry Inc., Lincoln, Neb., said she has already seen changes in her facility’s silica supply and heard similar concerns from other metalcasters. “We have had a lot of variation in
the percentage found on the diff erent screens,” she said. A representative for Deeter’s sand supplier told Wolfe the company is in the midst of an expansion to acco- modate new energy market business, and it is having diffi culty delivering a consistent product during the project.
Other Sands According to Peaslee’s in-house
accounting, Manitowoc Grey Iron’s silica sand pricing has actually gone down by 2% since 2008, whereas his core sand has gone up 2%, and his blended additive has risen 60%. Peaslee said his supplier attributes the spike to an increase in its raw materials costs and rising freight prices. What about some of the other mate-
rials used in a sand casting plant? On the nonferrous side, olivine sand has recently hit a signifi cant stumbling block that could make the material scarce and drive prices sky-high. According to sources close to the transaction, a major North American processor of olivine is planning to exit the business in the fall. While another company could be in line to pur- chase the processing plant, an interrup- tion in the sands fl owing from the site is possible, and long-term prospects are in limbo. Reports indicate the company is currently servicing all its existing foundry accounts, but it is not seeking additional customers. T e issue is expected to be resolved some time in mid-summer. Consumption of zircon, a sand
used in some specialty metalcasting applications, also is on the rise, which stands to drive prices higher, according to metals and minerals research fi rm Roskill Information Services. Roskill said in a recent report demand for the sand rebounded in 2010 after a down year and is projected to grow 5.4% annually in the near future. Use of zircon sand in metalcasting
applications has not grown over the past decade, according to Roskill, but as with silica sand, growth in other markets, such as ceramics and chemi- cals, have pushed the demand higher. T is tightening of supply stands to continue to make zircon expensive for
METALCASTING 101: SAND PRIMER
Of the metalcasting sands, silica sand is the most abundant in nature. Its deposits are easily mined and universally located, and the material is available in a variety of grain sizes and distributions, adequate hardness and abrasion resistance. Silica sand has excellent refractory properties, but it also has high non-linear expansion characteristics, relatively poor thermal conductivity and lower thermal proper- ties (fusion point).
Specialty sands have the low- est thermal expansion, high thermal conductivity, high density and are compatible with most binders. Following is a look at each of the
30 | MODERN CASTING July 2011
metalcasters. But Roskill expects these demand increases to infl uence some users to use less material or fi nd alter- natives. Bob Idzi, president and chief executive offi cer of stainless steel caster Ancast Inc., Benton Harbor, Mich., said on an internet forum his company has in some applications looked at changing the binder systems of a silica based sand system rather than using zircon for its chilling properties. “Prior tests using a sodium silicate
system showed greater chilling proper- ties than the phenolic resins using the same silica sand,” he said. “While not applicable for all zircon applications, it’s promising in a signifi cant number.”
The Supplier’s Dilemma For suppliers of silica sand, the
development of the fracking industry is a potential boom. Frack sand costs more to refi ne and produce than other types of sand, meaning processors can charge more for it, and customers are willing to pay more, as well. “On the supply side, there are com- panies building sand plants,” Jablonksi said. “Anyone building a sand plant or expanding, they are targeting that expansion for the frack industry. It is easier to justify, if you have increased revenue to defer.” Some sand companies have there- fore decided to adjust their process to
Fig. A. The four major types of casting sand show unique thermal expansion characteristics.
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