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Refractory Coated Surface Characterization for Steel using Disk-Shaped Chemically Bonded Sand Specimens—Part II

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Abstract

Chemically bonded sand systems are an important part of foundry technology and their interactions at the mold-steel interface are of great interest. With today’s emphasis on near-net-shape steel castings and more stringent dimensional requirements, there is a need to characterize as-cast surface quality. Part I of this two-part paper focused on surface quality at uncoated as-cast steel/chemically bonded sand interfaces. The results of Part I suggest that refractory coating (wash) technologies may be required. Therefore, Part II focuses on studying the effects of refractory coating, metal, and chemically bonded sand system on as-cast surface quality. Refractory coatings, designed for steel castings, were applied to disk-shaped specimens by four industrial partners using normal production techniques. A small and practical casting trial, using disk-shaped specimen cores, was developed at Western Michigan University. This trial allows several core specimens to be wetted simultaneously from a known head pressure, temperature, and steel alloy. The casting trials were conducted at Saginaw Valley State University. The results show that various combinations of refractory coatings and chemically bonded sand systems provide different as-cast surface quality. Also, a new refractory coating technology (sol–gel) may provide a superior as-cast surface quality with silica and ceramic sands in a steel casting. Traditional refractory coatings, while still better than no coating, performed worse. Finally, the refractory coatings can affect the shakeout/collapsibility of a chemically bonded sand system. Overall, this indicates that more engineering of these coatings may be required for steel.

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Acknowledgments

The authors thank the metal casting students at SVSU (H. Towalski, K. Konwinski, and I. Portice) and WMU (A. Patel, M. Patel, K. Pathak, and K. Shenoy) for their support with casting trials and laboratory testing.

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Authors and Affiliations

  1. Saginaw Valley State University, University Center, USA

    R. Tuttle

  2. Western Michigan University, Kalamazoo, USA

    S. Ramrattan & L. Wells

  3. University of Ljubljana, Ljubljana, Slovenia

    J. Medved

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  1. R. Tuttle
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  2. S. Ramrattan
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  3. L. Wells
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  4. J. Medved
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Correspondence to R. Tuttle.

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Tuttle, R., Ramrattan, S., Wells, L. et al. Refractory Coated Surface Characterization for Steel using Disk-Shaped Chemically Bonded Sand Specimens—Part II. Inter Metalcast 16, 493–501 (2022). https://doi.org/10.1007/s40962-021-00618-3

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  • DOI: https://doi.org/10.1007/s40962-021-00618-3

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