Development of Foundry shop for Aluminum sand casting

The Green Foundry project has as a main objective the decrease of the European foundry industry environmental impact by introducing novel technologies for sand molding systems. In particular the use of inorganic binders in ferrous foundries applied in sand molding systems improves the environmental

Project Title

Development of Foundry shop for Aluminum sand casting

Project Area of Specialization

Mechanical Engineering

Project Summary

The Green Foundry project has as a main objective the decrease of the European foundry industry environmental impact by introducing novel technologies for sand molding systems. In particular the use of inorganic binders in ferrous foundries applied in sand molding systems improves the environmental and economic impact leading to increased competitiveness of the industry. Replacing the currently used organic binders with new inorganic binders, one goal of the project is the reduction of hazardous air emissions, casting fumes and fine particles like binder aerosols from the casting process. The indoor air quality is improved. Moreover the use of inorganic binders would allow foundries to use the foundry sand more efficiently, improving the use of natural resources. The Green Foundry Project aims to demonstrate different methods for purification and re-use of surplus sand. As a further objective the project has the role of being an example for other foundries: introducing the inorganic systems in iron and steel foundries, the project aims to provide encouraging examples for the industry on an EU level, producing the necessary practical and information tools that will allow a systemic use of inorganic binders and technologies in ferrous foundries.

Project Objectives

1. Decrease hazardous air emissions from the casting process the project aims to replace the currently used organic binders with new inorganic binders.
2. Improve the indoor air quality for a safer work environment  organic binders emit hazardous casting fumes and fine particles like binder aerosols.
3. Improve the use of natural resources – using inorganic binders would allow foundries to use the foundry sand more efficiently. Project aims to demonstrate different methods for purification and re-use of surplus sand.
4. Provide encouraging examples for the industry on an EU level by implementing the new inorganic sand moulding systems in iron and steel pilot foundries.

Project Implementation Method

Sand casting also known as sand molding is a metal manufacturing process categorized by utilizing sand as an aggregate material for making the mold . The sand-casting process encompasses, moulding, metal melting, solidification, shake out and fettling . The mold is a cavity where the molten metal is poured into and allowed to solidify. During the sand-casting process, the sand is rammed around the pattern to produce the mould cavity . A pattern is a reproduction of the final casting . The mould must have adequate strength to carry the metal during casting and it must be permeable enough to allow gases to pass through during solidification . After solidification, the casting is removed from the mould and the sand is reused again in the process . Sustainability in manufacturing is driven by cleaner and more efficient productions . Sustainable manufacturing involves a variety of concepts that encompasses profit, environmental impact, product life cycle, operator knowledge and recyclability . In addition, the sand-casting process is a sustainable method in that, the refractory sand is recycled during the process after its separation from the final casting. The recycling of the sand is made to reduce the cost of the process and as well as to prevent environmental pollution caused by dumping of the sand. As such, sand casting is one of the most popular and efficient casting methods for small and medium parts since it gives good properties of parts.

Benefits of the Project

In today’s global completion, it is important for foundries to focus on process improvement to increase competitive advantage. Competitive advantage for sand casting foundries means improved production process, improved plant maintenance processes, improved product quality and proper utilization of resources, especially scarce resources. Process knowledge could be very critical for sand casting foundries to alleviate its limitations compared to other metal manufacturing techniques the biggest benefit of this is that all students in our university can experiments on it and create something desired shape like IC ENGINE parts and other etc. the current era is evolving. If we have a foundry, we can design anything we want, we don’t have to go out to market.

Technical Details of Final Deliverable

Green sand is a mixture primarily of sand, clay, and water. Other additives may be used to impart specific properties to the sand. The process of green sand moulding is easily automated so it is capable of high production volumes, particularly for small and medium sized castings. The sand is readily recycled with only small additions of new clay and water. Green sand has low compressive strength, offering little resistance to contraction, so hot tearing risk is minimized.

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Education

Core Technology

Others

Other Technologies

Shared Economy

Sustainable Development Goals

Good Health and Well-Being for People, Decent Work and Economic Growth, Climate Action

Required Resources

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