10 Description of defects: Burnt-on sand 11 Description of defects: Burnt-on sand

Burnt-on sand

Assistance for decisions ➝ P. 124

Sand control ➝ P. 176

Characteristic features Possible causes

Thin sand crusts firmly adhering to the casting. The defect occurs Clay-bonded sand
to a greater extent in the case of thick-walled castings and at high • Lustrous carbon content too low
temperatures. • Proportion of low-melting-point substances too high
• Oolitization too high
Incidence of the defect
Moulding plant
Where there is a heavy-section casting, but also in the proximity
• Uneven mould compaction
of the gate and at high casting temperatures, the moulding sand
sinters on the casting in the form of a thin crust due to low ther- Gating and pouring practice
mal resistance. The tendency of the molten metal to penetrate • Uneven distribution of inflowing metal with resultant over-
into the sand pores results in the firm adherence of the crust to heating
the surface of the casting. It is difficult to remove, even by shot- • Temperature of liquid metal too high
blasting, and usually has to be ground off.
Remedies
Explanations
Clay-bonded sand
The high temperature to which the sand is subjected causes sinter- • Increase proportion of lustrous carbon producer. This in-
ing of the bentonite and silicate components. In addition, the creases the amount of coke as well as the amount of
always present iron oxides combine with the low-melting-point lustrous carbon, which then results in positive separation
silicates to form iron silicates, thereby further reducing the sinter between mould and metal.
point of the sand. Sintering and melting of the impurities in the • Use purer silica sands or, if necessary, add new sand. Reduce
moulding sand enable the molten iron to penetrate even faster, dust content. If necessary, reduce the amount of bentonite.
these layers then frequently and firmly adhering to the casting • Reduce oolitization by adding new sand.
surface.
Moulding plant
• Ensure uniform compaction. If necessary, increase heat
removal from the moulds.

Gating and pouring practice

Fig. 1: Sand grains on the surface of a grey iron casting with insufficient lustrous carbon. • Even out incoming metal flow
Scale: 10 mm = 0.08 mm • Reduce pouring rate
• Reduce liquid metal temperature
Fig. 2: Thin-wall grey iron casting with closely adhering sand layer.
Scale: 10 mm = 8.1 mm
12 Description of defects: Burnt-on sand 13 Description of defects: Burnt-on sand

Background information References

Adhering sand layers primarily form when the lustrous carbon- Russian authors report that, when pouring molten steel into sodi- 1 Wirkung von Sorption und Glanzkohlenstoffbildung ton- ➝ Onillon, M.; Rebaudieres, J.
producing capacity of the moulding sand is too low. With grey um silicate bonded moulds, burning-on is drastically reduced where gebundener Formstoffe auf Gußstückeigenschaften Physikalische und chemische Vererzung bei Gußeisen
iron castings, the lustrous carbon content in the sand should lie the surface tension is increased through the use of additives. Institut für Gießereitechnik GmbH, Abschlußbericht zum Fonderie 31, 1976, P. 209 – 216 (French)
between 0.2 and 0.6 %, according to other authors between Boosting the AFS number by using finer new sands similarly AIF-Forschungsvorhaben Nr. 5405, April 1985
➝ Paskeev, I.
0.2 and 0.4 % .1 Due to the difficulty in precisely determining reduces adherence of sintered crusts because the casting surface
2 Winterhalter, J.; Siefer, W. Untersuchungsverfahren zur Bildung von Anbrennungen an
the lustrous carbon in the sand, the “active carbon content” is is smoother.
Zur Wirkung von Feinanteilen und Glanzkohlenstfoffbildnern Gußstücken
measured and should be between 0.35 and 0.65 %. The moulds should be well and uniformly compacted. There is
im Formstoff auf die Gußstückeigenschaften Litejnoe proizvodstvo 1977, P. 26 – 28 (Russian)
If sand adherence is experienced, this can be eliminated either a greater risk of metal penetration at locations where compaction
Gießerei 74, 1987, P. 633 – 639
by using a higher proportion of or a more “active” lustrous carbon is low, and thus of the formation of adhering crusts. ➝ Aymard, J.-P.; Leger, M.-T.; Lageal, B.
producer. Additional references Metall-Formstoff-Reaktionen von Manganhartstahlguß
Improved coke formation will likewise reduce the formation of (12 % Mn) und Chromstahlguß (13 bis 25 % Cr)
➝ Grochalski, R.
adhering crusts, but not as much as increasing lustrous carbon Fonderie 31, 1976, P. 265 – 273 (French)
Gießereiformstoffe, 1955, P. 22
production.
➝ Ivanov, N. Ch.; Skljarova, V. N.
It is important to limit impurities in the moulding sand. Silicates ➝ Disamatic-Application “Gußfehler”, P. 78 – 84
Formstoffmischungen mit Dibutylphthalat zur Herstellung
and oxides can lead to excess consumption of lustrous carbon
➝ Berndt, H. von penetrationsfreien Gußstücken aus Gußeisen
producers due to oxidation.2 Lowering the sinter point of the sand
Die Überwachung von Verschleißerscheinungen an einem Litejnoe proizvodstvo 1976, P. 18 – 19 (Russian)
also increases the risk of burning-on, with simultaneous penetra-
Sandumlaufsystem
tion of metal into the adhering layer. ➝ Sarma, A. K. D.
Gießerei 55, 1968, P. 441 – 453
Likewise, intensified burning of sand onto grey iron castings Vererzen von Formsanden
has been observed with the use of more highly oolitized moulding ➝ VDG-Merkblatt F 252, Indian Foundry J. 18, 1972, P. 167 – 170
sands. It is therefore recommended to add an appropriate amount “Bestimmung der Anschnittelemente”
➝ Kleimann, W.
of new sand to that in circulation. According to our previous expe-
➝ Holzmüller; Kucharcik Einsatz von Bentoniten und C-Trägern in modernen Form-
rience, the added amount should not significantly exceed 100 kg
Atlas der Anschnitt- und Speisertechnik für Gußeisen 2. Aufl. sanden.
of new sand per t of molten iron.
1975, P. 17 Giesserei-Erfahrungsaustausch 7, P. 315 – 320, 1997

➝ Boenisch, D.; Lorenz

Modellversuche über das Formkastenfüllen von Naßguß-
sanden, Dissertation 1988, TH Aachen