Category:

Description

 Introduction:

AFCICOAL is a carbonaceous, low ash green sand additive, an excellent substitute developed to overcome the following shortcomings of conventional coal dust: –

  1. Serious problems like contamination of Iron Pyrites slate & other minerals, which are injurious to casting finish, are eliminated by use of AFCICOAL.
  2. Ash content is maintained at minimum level to avoid reduction in permeability and refractoriness of Sand usually faced due to coal dust.
  3. Inconsistency in volatile matter content in coal dust is eliminated.
  4. It is a free flowing powder & disperses easily with minimum mixing effort.

Function:

AFCICOAL’s high carbon producing ability forms a protective non – wetting barrier between the sand & the metal, resulting in castings free from surface imperfections. It also acts as a buffer between sand grains, allowing the sand to expand, thereby improving permeability, reducing expansion defects & blow-hole formation.

Application:

Add AFCICOAL 1.2% in initial stages where 100% new sand is used & generally for   10% new sand addition, 0.3 to 0.8% by weight of AFCICOAL is used. However actual percentage addition will vary from foundry to foundry & additions of new sand.

Further addition of AFCICOAL will go on reducing with the use of reclaimed sand. Proper monitoring and sand control will considerably reduce further addition rates. However, this reduction further depends upon individual foundry practice, efficiency of sand mixer, and sand to metal ratio, sand mix temperature, moisture requirements, quality of new sand used, nature of clays, volatile matter & fixed carbon. Carbon is adjusted to suit the different mould pressure that gives consistent strength and compactness.

Mixing Procedure – (For New Sand System)

AFCICOAL is used for Green Sand Moulding System. To ensure good results, dry mulling for about 2-3 minutes with AFCICOAL is recommended.

Green Moulding sand is prepared as follows:

  1. Add (60 – 75) AFS silica sand in muller mixer.
  2. Add Bentonite – 5 to 6% of sand, mix for 2 minutes.
  3. Add AFCICOAL – 1.2% of sand.
  4. Mix for about 2 /3 Minutes.
  5. Add Water – 3 to 4% of sand.
  6. Mix for another 3/5 minutes.
  7. Above mixed sand is used for moulding.

Advantages:

  1. Imparts very good surface finish & excellent casting Peel.
  2. Improves Sand flow ability.
  3. Reduce total gas in the system.
  4. Gives much cleaner draw.
  5. Reduces friability of Mould surface.
  6. Acts as an excellent anti – scabbing agent.
  7. Allows sand to breathe better.
  8. Reduces Metal penetration and avoids sand fusion.

Special features:

  1. Gives better life to sand & reduces addition of new sand.
  2. Good refractoriness & is highly economical due to low addition.
  3. Does not fume or smell, hence non – hazardous & safe to use.
  4. Keeps very clean atmosphere in the foundry.
  5. Elimates use of Coal Dust, reducing dust pollution & prevents fire hazards.
  6. Imparts very good Anti-Fusion & Anti – Finning Properties.

 

Standard Packing:  40 Kg HDPE Bag

Storage:  Preferably store in cool dry place & in covered condition.

Precautions:

  1. It is non – poisonous & safe to use.
  2. Keep away from heat or flame.
  3. Use of hand gloves is recommended.

AFCICOAL SERIES OF PRODUCT S WITH SPECIFICATIONS :

SR.NO. PRODUCTS NAME SPECIFICATION

 

 RECOMANDED FOR FERROUS CASTINGS
1. AFCICOAL-30 VM   : 45 – 50 %

FC    : 45 – 50 %

LOI  :  95% MIN.

ASH :   5 % MAX.

High pressure Moulding line for Mould pressure up to 900
3. AFCICOAL-31 VM  : 50 – 55 %

FC   : 40– 45%

LOI : 95% MIN.

ASH : 5 % MAX.

High Pressure Moulding line for Mould pressure up to 450 – 900
4. AFCICOAL-32 VM  : 55 – 60 %

FC   : 35 – 40 %

LOI : 95 % MIN.

ASH : 5 % MAX.

High Pressure Moulding line for Mould pressure up to 450
5. AFCICOAL – 32 M VM  : 55 – 60 %

FC   : 35 – 40 %

LOI : 95 % MIN.

ASH : 5 % MAX.

High Pressure Moulding line for Mould pressure up to 450
6. AFCICOAL-33 VM  : 60 –65 %

FC   : 30 – 35 %

LOI  : 95 % MIN.

ASH : 5 % MAX.

Medium Pressure Moulding line
7. AFCICOAL-34 VM : 65 – 70 %

FC  : 25 – 30 %

LOI : 95 % MIN.

ASH : 5 % MAX.

Low Pressure Moulding line

 

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