CO2 Molding

Introduction:

Co2 Casting is a kind of sand casting process. In this process the sand molding
mixture is hardened by blowing gas over over the mold. This
process is favoured by hobby metal casters because a lot of
cost cutting can be done. In addition, one can be sure of getting
dimensionally accurate castings with fine surface finish. But,
this process is not economical than green sand casting
process.

Process:

The Mold for Co2 Casting is made of a mixture of sand and liquid silicate binder
which is hardened by passing Co2 gas over the mold.
The equipment of the molding process include Co2 cylinder, regulator, hoses and
hand held applicator gun or nozzle. Carbon di oxide molding deliver great accuracy in
production.

Any existing pattern can be used for the molding purpose which can be placed in the
mold before the mold is hardened. This method helps in producing strong mold and
cores that can be used for high end applications. If the process is carefully executed
then casting can be as precise as produced by the shell casting method.

Carbon di oxide casting is favored both by the commercial foundrymen and hobbyist
for a number of reasons. In commercial operations, foundrymen can assure
customers of affordable castings which require less machining. The molding process
which can be fully automated is generally used for casting process that require speed,
high production runs and flexibility. In home foundries this is one of the simplest
process that improves the casting quality .

Applications: Co2 casting process is ideal where speed and flexibility is the prime
requirement. molds and cores of a varied sizes and shapes can be molded by this
process.

Advantages: This process has many advantages in

comparison to other forms of castings some of them are as
follows:

Compared to other casting methods cores and molds are

strong

Reduces fuel cost since gas is used instead of to other costly heating
generating elements

Reduces large requirement for number of mold boxes and core dryers

Provides great dimensional tolerance and accuracy in production

Moisture is completely eliminated from the molding sand

This process can be fully automated.

LOAM MOULDING:
Loam is one type of clay which is made with sand mixed with water to form a thin
plastic mixture from which moulds are made. Loam sand also contains ganisters or fire
clay. The loam must be sufficiently adhesive so that it can cling to the vertical surface. It
always requires special provision to secure adequate ventilation. The object is opened
out pores in the otherwise compact, closely knit mass, by artificial means. There are
various kinds of organic matter such as chopped straw, and particularly horse manure,
is mixed up with the sand, a typical loam sand mixture is given below :

1.

Silica Sand

22 vol.

2.

Clay

3.

Coke

10 percent

4.

Moisture

18-20 vol.

vol.

This applied as plaster to the rough structure of the mould usually made of brick
work and the exact shape is given by a rotating sweep around a central spindle. Cast
iron plates and bars are used to reinforce the brick work which retains the moulding
material. Loam moulds also be prepared by the use of skeleton pattern made of wood.
The surfaces of loams are blackened and are dried before being assembled.

Loam moulds are employed chiefly in the making of large casting for which it
would be expensive to use full pattern and ordinary flasks equipment. Objects such as
large cylinders, chemical pans, large gears, round bottoms, kettles and other machining
parts are produces in the loam moulding.

IN NUTSHELL :

Loam is a molding sand containing about 50 per cent sand grains and 50 per cent clay.

Loam molding was much used in the past for making large bronze castings and is still
practiced in some shops, particularly in making huge manganese- bronze propellers.

In this method a substrate is made of bricks, wood and other material to the approximate
contour of the casting. A very viscous slurry of water, clay and sand is daubed over the
framework and worked to proper shape with sweeps. The mold is dried by forced hot air or
torches.

No pattern is required, as sheet-steel sweeps are so shaped that they generate proper
casting contour as the sweep arm is moved back and forth over a fixed spindle.

Such sweeps are used occasionally in making molds for large rolling-mill rolls where
ordinary molding sand is used instead of a slurry.

The chief advantages of this process are savings in pattern cost and storage; pattern
storage alone is an important and expensive item in most foundries.

Loam molding is slow and laborious, and special molders are required; all work must be
done by hand as the process is very much an art.