Abstract
The availability of silica sand is diminishing and as a result, the price of silica sand increasing. Therefore, there is a need to evaluate the suitability of local riverbed sand for nonferrous alloy casting in Indian foundries. The present investigation focuses on the suitability of Mahanadi Riverbed Sand (MRS) for nonferrous alloy casting. The sand particle size, chemical composition, density, and fusion point, are evaluated and found suitable for nonferrous alloy casting. The mold ingredients are designed and optimized through the design of the experiment and response surface methodology, respectively. It is found that 11.5 wt.% of bentonite clay, 5 wt.% of moisture, and 3.5 wt.% of coal dust is suitable to achieve the desire sand mold properties. The fusion point of MRS shows that it is not suitable for ferrous casting. Therefore, aluminum alloy (A356) casting is performed using MRS and silica sand mold. The as-cast surface roughness (Ra), hardness, and microstructures of A356 alloy casting are evaluated and compared between MRS and silica sand mold castings. It is observed that the mechanical properties of MRS mold casting are better than silica sand mold casting and may be used as an alternative to silica sand for aluminum alloy casting in Indian foundry industries.
Similar content being viewed by others
References
C. Saikaew and S. Wiengwiset, Applied Clay Science, 67–68, 26–31 (2012).
R. Alonso-Santurde, A. Coz, J.R. Viguri, and A. Andrés, Construction and Building Materials, 27, 97–106 (2012).
M.C. Zanetti and S. Fiore, Resources, Conservation and Recycling, 38, 243–254 (2003).
P. Karunakaran, C. Jegadheesan, R. Chinnusamy, and P. Sengottuvel, International Review of Mechanical Engineering, 7, 1207–1212 (2013).
P. Karunakaran, C. Jegadheesan, P. Dhanapal, and P. Sengottuvel, Russ. J. Non-Ferrous Metals, 55, 247–253 (2014).
J. Sadarang and R.K. Nayak, Journal of Manufacturing Processes, 68, 1553–1561 (2021).
P. Munusamy, R. Balaji, and C. Sivakandhan, International Journal of Mechanical Engineering and Technology (IJMET), 8(1), 292–303 (2017).
P. SrinivasaRao and A.K. Birru, Materials Today: Proceedings, 4, 1186–1192 (2017).
I.N. Murthy, N.A. Babu, and J.B. Rao, Procedia Environmental Sciences, 35, 597–609 (2016).
I.N. Murthy and J.B. Rao, Int J Miner Metall Mater, 24, 784–793 (2017).
J.B. Rao and I.N. Murthy, International Journal of Cast Metals Research, 31, 360–372 (2018).
I.N. Murthy and J.B. Rao, Procedia Environmental Sciences, 35, 583–596 (2016).
B.R. Jinugu and N.M. Inampudi, Archives of Foundry Engineering 17(1), 179–191 (2017).
J. Sadarang, R.K. Nayak and Panigrahi I, Trans. Indian Inst. Met 74, 2939–2952 (2021). https://doi.org/10.1007/s12666-021-02370-y
J. Sadarang, R.K. Nayak, and I. Panigrahi, Mater. Today Proc. (2020).
N. Sinha and J. Singh, Int. J. Metalcast. (2021).
M. Holtzer and A. Kmita, “Mold and Core Sands in Metalcasting: Chemistry and Ecology: Sustainable Development”, Springer International Publishing (2020).
R.W. Heine, C.R. Loper, and P.C. Rosenthal, “Principles of Metal Casting”, Tata McGraw-Hill Education, (1967).
J. Sadarang, R.K. Nayak, and I. Panigrahi, Trans Indian Inst Met, (2021).
M.B. Parappagoudar, D.K. Pratihar, and G.L. Datta, International Journal of Cast Metals Research, 20, 1–13 (2007).
T.-S. Shih, J.-Y. Chang, and J.-C. Chang, International Journal of Cast Metals Research, 14, 43–52 (2001).
I. Narasimha Murthy, N. Arun Babu, and J. Babu Rao, Mater Today Proc 5, 161 (2018).
R.K. Nayak, J. Sadarang, Feasibility Study of Stone-Dust as an Alternative Material to Silica Sand for Al–Si (A356) Alloy Casting. Inter Metalcast (2021). https://doi.org/10.1007/s40962-021-00695-4
Funding
The authors would like to express their sincere thanks to the 'Advanced Manufacturing Technology program of Department of Science and Technology, Govt. of India,' for the financial support to carry out this work (Grant No. DST/TDT/AMT/2017/173). Special thanks to RSB Metaltech, Pvt. Ltd, Cuttack, India, for their support as an industrial partner to develop an alternate source of silica sand for Indian foundry industries.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Nayak, R.K., Sadarang, J. A Study on the Suitability of Mahanadi Riverbed Sand as an Alternative to Silica Sand for Indian Foundry Industries. Trans Indian Inst Met 75, 1169–1179 (2022). https://doi.org/10.1007/s12666-021-02472-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12666-021-02472-7