• Author / Uploaded
• Onat

Citation preview

(

)

Mold&Core Test Handbook 3rd Edition

American Foundry Society www.afsinc.org

Mold & Core Test Handbook Third Edition

Put?lished and distributed bythe

American Foundry Society Des Plaines, lllinois 60016-8399 www.afsinc.org

) Copyright 2001 ISBN 0-87433-228-1

Printed in the Unlted States of America

AII rights reserved. No part ot this book may be reproduced in any tonn or by any means, electronic, mechanical, photo-copying, recording or otherwlse, without prior pennission of the publisher. The American Foundry Society as a body, is not responsible tor the statements and opinlons advanced in this publication. Nothing contained in any publication of the Society Is to be construed as granting right, by implication or otherwlse, tor manufacture, sale or use in connection wlth any method, apparatus or product covered by letters patent, nor as lnsuring anyone against liability tor infringement of letters patent

AIIEIIICAII FOUNOIIY .ocllTY

Contents Preface ...................................... P-1 Procedure for Submission of New AFS Mold & Core Test Handbook Documents ........................ P-1 Format for AFS Mold & Core Test Handbook Documents ........•...... P-2 Standard Process for Procedure Stıbmission and Approval ............... P-7 lntermediate Status Designation During Review Process ................ P-8 How to Use This Book ..............•............................ P-9 How to Use Glossary .....................................•..... P-10 Acknowledgınents .•.................•....................•...... P-10

Testing Procedures Sectlon 1: 1000 Serles Foundry Aggregates AFS 1100-00-S Saınpling and Reduction of Sand Flow Chart .......... 1-1 AFS 1101-00-S Saınpling of Sand ................................ 1-3 AFS 1104-00-S Saınpling ofBagged Sand ......................... 1-5 AFS 1105-00-S Sieve Analysis (Partide Size Determination of Sand) ........................... 1-7 AFS 1106-00-S Grain Fineness Number, AFS GFN, Calculation ..•.... 1-11 AFS 1107-00-S Grain Shape Classification .......•......•...•..... 1-13 AFS 1108-00-S Surface Area, Measured, ofa Sand .•............... 1-15 AFS 1109-00-S Surface Area, Calculated, ofa Sand ................. 1-19 AFS 1114-00-S Acid Demand Value (ADV) of Sand ................ 1-21 AFS 1116-00-S Specific Gravity of Sand ....•...........••.•••... 1-23 AFS 1117-00-A Specific Gravity of Sand, Alternate ...........•..... 1-25 AFS 1119-00-S Permeability, Base .........................•.... 1-27 AFS 1120-00-S Reduction of Dry Sand Sample, Gate Splitter ....••... 1-29 AFS 1121-00-A Reduction ofDry Sand Sample, Chute Splitter ..•..•.. 1-31 AFS 1122-00-A Reduction of Dry Sand Sample, 16:1 Reducer ........ 1-33 AFS 1123-00-A Reduction of Sand Saınple, Coning and Quartering •... 1-35 AFS 1125-00-S Drying Sand Saınples ............................ 1-37 AFS 1126-00-S Angularity, Coefficient of ...•...•..........•.••.. 1-39 AFS 1130-00-S Bulk Density, Untapped, ofDry Sand .........•••... 1-41 AFS 1131-00-S BulkDensity, Tapped, Dry Sand •..............•... 1-43 Sectlon 2: 2000 Serles Clay Bonded Sands AFS 2110-00-S Clay, AFS Method ..............• ; ......•...•.... 2-1 AFS 2111-00-S Clay, 25 Micron Method ........••..........•••... 2-5 . AFS 2201-00-S Sand Mixture Preparation, Clay Bonded .......••••... 2-7 AFS 2204-00-S Shear Strength, Green or Dried ..•.•.....•.•..••...• 2-9 AFS 2205-00-S Tensile Strength, Green ......••..•.........•••... 2-11 AFS 2206-00-S Tensile, Wet, Moldiıig Sand .•..•.....•..••••...••. 2-13 AFS 2207-00-S Splitting Strength, Green ....•.•...•...•.•..•••... 2-15 Mold & Core Test Handbook

ili

Testing Procedures, continued AFS 2209-00-S AFS 2210-00-S AFS 2211-00-S AFS 2213-00-S AFS 2216-00-S AFS 2217-00-S AFS 2218-00-S AFS 2219-00-S AFS 2220-00-S AFS 2221-00-S AFS 2230-00-S AFS 2245-00-S AFS 2246-00-S AFS 2247-00-S AFS 2248-00-S AFS 2249-00-S AFS 2250-00-S AFS 2251-00-S

Mold Strength ...................•............•. 2-17 Methylene Blue Clay Test, Ultrasonic Method, Molding Sand ...••...•....•.•.. 2-19 Methylene Blue Clay Test, Boiling Method, Molding Sand ..•...........•...•• 2-23 Volatile Material at 900F (482C) or 1200F (649C) ....• 2-27 Moisture, Infrared, Determination in Molding Sand ••.• 2-29 Moisture, Calciuın CarbideMethod ..•...........•.. 2-31 Moisture Dete~tion, Forced Hot Air Method .....• 2-33 Moisture Detennination, Oven Method ........••.... 2-35 Compactability of Molding Sand Mixtures, Rammer Method ..............•••............••. 2-37 Compactability of Molding Sand Mixtures, Squeezer Method i ••..••.•••••••••••...••••••... 2-39 Hardness, Mold (Hardness, Green Surface) .....•..•.• 2-41 Calcium, S(;)luble, in Bentonite ................•.•.• 2-43 Nitrogen, Arnmoniacal, Molding Sand, Dietert Method ...•.•......•....•••.........•... 2-47 Nitrogen, Arnmoniacal, Molding Sand, Modified Tecator Determination ....•.............. 2-49 Friability ............•......•...•.........••.•. 2-51 Cone Jolt Toughness ...•......•..•••........•...• 2-53 Sulfur, Determination in Molding Sand ..........•... 2-55 Riddling, Molding Sand ............•..........••. 2-59

Sectlon 3: 3000 Serles Chemlcally Bonded Sands AFS 3180-00-S Work Time/Strip Time, No Bake Sand Mixture, Hardness Method .................•............•. 3-1 AFS 3185-00-S Work Time/Strip Time, No Bake Sand Mixture, Strength Method ..••.............•.............•. 3-3 AFS 318~00-S Bench Life (Work Life), Cold Box/Hot Box/Warın Box, Tensile Method .....••. 3-5 AFS 3202-00-S Compression Strength, Green Core Sand Mixtures ...••. 3-7 AFS 3236-00-S Collapsibility, Elevated Temperature, 1-1/8 in. Dia. x 2 in. Test Specimen ..•.•...•....•••.• 3-9 AFS 3301-00-S Tensile Strength, 1 in. Thick Tensile Specimen ...•.•• 3-11 AFS 3306-00-S Transverse Strength, 1/4 in. x 1 in. x 4 in., Shell .....•• 3-13 AFS 3307-00-S Tensile Strength, 1/4 in. Thick Tensile Specimen, Shell ..........••••• 3-15 AFS 3308-00-S Specimen Preparation, 1/4 in. Thick Tensile Specimen, Shell, Duınp and Strike-Off . ~ ........•••. 3-17 AFS 3309-00-S Specimen Preparation, 1/4 in. Thick Tensile Specimen, Shell, Blown Method ••.••...........•.• 3-19 AFS 3310-00-S Specimen Preparation, 1/4 in. x 1 in. x 4 in. Transverse Specimen, Shell, Duınp and Strike-Off Method ..•......•..•.•.•..•• 3-21 AFS 3311-00-S Specimen Preparation, 1/4 in. x 1 in. x 4 in. Transverse Specimen, Shell, Blown Method ......•.•. 3-23

iv

Mold & Core Test Handbook

Testing Procedures, continued APS 3312-00-S APS 3313-00-S APS 3315-00-S APS 3317-00-S APS 3318-00-S APS 3320-00-S APS 3321-00-S APS 3324-00-S APS 3326-00-S APS 3329-00-S APS 3330-00-S

APS 3331-00-S APS 3332-00-S APS 3333-00-S APS 3334-00-S APS 3335-00-S APS 3336-00-S APS 3337-00-S APS 3338-00-S APS 3339-00-S APS 3340-00-S APS 3341-00-S APS 3342-00-S APS 3343-00-S APS 3344-00-S APS 3345-00-S APS 3346-00-S

Tensile Strength, Hot, 1/4 in. Thick Tensile Specimen, Shell, Dump and Strike-Off Method ....... 3-25 Melt Point, Shell •..............•..........•..•.. 3-27 Specimen Preparation, 1 in. Thick Specimen, Hot Box, Warm Box/Cold Box .....•.............. 3-29 Post Cure, 1 in. Thick Tensile Specimen ....•.....•.. 3-31 Hardness, Scratch •.........•..........•......•.. 3-33 Tensile Strength, Hot, 1 in. Thick Tenı;ile Specimen ...•.•................ 3-35 Preparation and Tensile Strength, Hot, 1 in. Thick Tensile Specimen .................. 3-37 Penetration, lmpact .............................. 3-39 Hot Distortion ......•........................... 3-41 Specimen Preparıition, 1 in. Thick Tensile Specimen, Core Oil ....•............•..... 3-43 Sand Miıcture Preparation, Alkaline Phenolic Ester, Cured Cold Box (Methyl Formate) •.........••.........•....•.•.. 3-45 Sand Mixture Preparation, Epoxy Acrylic, Cold Box (SO2) ....•..•............ 3-47 Sand Mixture Preparation, Alkyd Oil Urethane, No Bake ................•.... 3-49 Sand Mixture Preparation, Acid Cured, No Bake (Furan, Phenolic) ..•........•............ 3-51 Sand Mixture Preparation, Furan Binder, Cold Box (SO2) ..................... 3-53 Sand Mixture Preparation, Alkaline Phenolic Ester Cured, No Bake ............. 3-55 Sand Mixture Preparation, Inorganic Phosphate, No Bake •............••..........••.. 3-57 Sand Mixture Preparation, Sodium Silicate Ester Cured, No Bake .........•.•.. 3-59 Sand Mixture Preparation, Sodium Silicate, Cold Box (CO2) ..............•... 3-61 Sand Mixture Preparation, Core Oil •.............••. 3-63 Specimen Preparation, APS 2 in. Dia. x 2 in. Cylinder Core, Cold Box, No Bake, Blown .......•... 3-65 Specimen Preparation, APS 2 in. Dia. x 2 in., Cylinder Core, Core Oil, No Bake, Rammed •.....••.. 3-67 Specimen Preparation, 1 in. Thick Tensile Specimen, Multi-Cavity Core Box, No Bake .......... 3-69 Specimen Preparation, 50 mm x 8 mm Disc, Blown, Cold Box, Warm Box/Hot Box ...•..•.. 3-71 Disc Transverse Strength, 50 mm x 8 mm Disc Specimen .........••..•.••..•............. 3-73 Sand Mixture Preparation, Hot Box/Warm Box ..••.•. 3-75 Sand Mixture Preparation, Phenolic Urethane, ColdBox (Amine) •......•....••.•.....•..•.••.. 3-77

Mold & Core Test Handbook

V

Testing Procedures, continued Sectlon 4: 4000 Serles Mold & Core Coatlngs AFS 4403-00-S Thickness, Wet, Refractory Coatings ...........••.••. 4-1 AFS 4404-00-S Thickness, Dry, Refractory Coatings ...•......•...... 4-3 AFS 4405-00-S Solids Content, Total, Refractory Coatings ........•.•. 4-5 AFS 4406-00-S Sag/Settle Test, Refractory Coatings ..............•.. 4-7 AFS 4407-00-S Viscosity, Brookfield Method, Refractory Coatings •.••. 4-9 AFS 4408-00-S Viscosity, Zahn Method, Refractory Coatings ....•.••. 4-13 AFS 4409-00-S Specific Gravity, maume Hydrometer Method, Refractory Coatings •..•................•. 4-15 AFS 4410-00-S Specific Gravity, Gravimetric Method, Refractory Coatings •........................••.. 4-17 AFS 4411-00-S Specific Gravity, Mud Balance Method, Refractory Coating~ ..........•...•............•. 4-19 Sectlon 5: 5000 Serles Mlscellaneous Test Procedures AFS 5100-00-S Loss On lgnition, LOI ............•......•........ 5-1 AFS 5101-00-S Magnetic Material, Removal and Determination ......•. 5-3 AFS 5112-00-S Temperature ofFoundry Sands .............•...•.•. 5-5 AFS 5113-00-S pH of Sand ..................................... 5-7 AFS 5202-00-S Compression Strength, Green or Dried ............... 5-9 AFS 5214-00-S Density, Bulk, Dry Additives ...•.........•....•••. 5-13 AFS 5215-00-S Dry Fineness Test for Seacoal and Other Ground or Pulverized Materials .................... 5-15 AFS 5220-00-S AFS 2 in. Dia. x 2 in. Specinıen Preparation, Squeezer Method ...•.•..........•.........•...• 5-19 AFS 5221-00-S AFS 2 in. Dia. x 2 in. Specinıen Preparation, Rammer Method, Using a Density Indicator .........• 5-21 AFS 5222-00-S AFS 2 in. Dia. x 2 in. Specinıen Preparation, Rammer Method ...........................•.... 5-23 AFS 5223-00-S Permeability, Mold and Core •........•........••.. 5-25 AFS 5224-00-S Permeability, Standard AFS 2 in. Dia. x 2 in. Test Specimen .•.............•..•...........•••. 5-27 AFS 5232-00-S AFS 1-1/8 in. Dia. x 2 in. Solid Specimen Preparation, Squeezer Method .....•............••. 5-29 AFS 5233-00-S AFS 1-1/8 in. Dia. x 2 in. Solid Specimen Preparation, Rammer Method ......•......•..••... 5-31 AFS 5234-00-S Compressive Strength, Hot 1-1/8 in. Dia. x 2 in. Test Specimen .......•••.........•.... 5-33 AFS 5235-00-S Deformation, Hot ...........•..•.••.........•••• 5-37 AFS 5237-00-S Expansion, Shock Load, Recorder Method .......•.•• 5-39 AFS 5239-00-S Compressive Strength, Retained ..••......••....••. 5-41 AFS 5240-00-S Specimen Preparation, Hollow Confined Test ..•..•.•• 5-43 AFS 5241-00-S Expansion, Hollow Confined, Shock .•.........••••• 5-45 AFS 5242-00-S Expansion, Hollow Confined, Equilibrium ...•....••. 5-47

vl

Mold & Core Test Handbook

) .. ·

--). _

Testing Procedures, continued APS 5243-00-S APS 5244-00-S APS 5300-00-S APS 5301-00-S

Expansion, Free, Equilibrium .••...•........••..•.. 5-49 Expansion, Free, Shock ....•..........•.......... 5-51 Gas Evolution ...••..........•.......•......•... 5-53 MQI (Mold Quality Indicator) •.•.............••... 5-55

Safety ....................................... 6-1 General Requirements ..•.............•...•.....•..........•...... 6-1 General Laboratory Precautions , ....•.•....•.....••............•... 6-1 General Laboratory Programs •.•...........•...............•....... 6-3 Physical Hazards ..................•..........•................. 6-4

Traceability and Calibration . . . . . . . . . . . . . . . . . . . . . 7-1 Traceability Calibration

.

.•..............•.........•............••...... 7-1 ...... •,• ••.•.......................•...••...... 7-1

Gage R&R and Measurement System Variability .... 8-1 Definition of Key Terms .............•........................•... 8-1 Performing R&R Studies ...•...............•...••.........•..••.. 8-3

Appendices .................................. 9-1 Abbreviations and Symbols .................................•..... 9-3 Conversion Factors and Tables •.....•.........................•.... 9-5 Example Laboratory Report Forms ..............••................. 9-7

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Mold & Core Test Handbook

vii

41/S

.

AllfallCAII FOUIIDRY SOCIIETY Mold & Core Test Handbook, J'd_ EditionUpdates Item # GM0004A This packet contains updates to the Mold & Corf! Test Handbook, J:d_ Edition. Remove the old page(s) from your copy and replace them with the new ones listed below:

• • • • • • • • • )

Copyright page (update) Preface ( update) Contents (update) Index (update) AFS 1114-00-S (correction) AFS 1100.-03-S (update) AFS 1101-03-S (update) AFS 1104-03-S (update) AFS 3180-03-S ( update)

• • • • • • • •

AFS 3185-03-S (update) AFS 3186-03-S (update) AFS 4403-03-S (update) AFS 4404-03-S (update) AFS 5112-03-S (update) AFS 5223-03-S (update) AFS 5224-03-S (updafo) AFS 5302-04-S (new)

/

Price: Corporate Member Individual Member List Price

$10.00 $15.00 $20.00

GH0004R

)

AMERICAN FOUNDRY SOCIETY

Mold & Core Test Handbook, 3rd Edition Updates Item # GM0004B This packet contains updates to the Mold & Core Test Handbook, 3"' Edition. Remove the old page(s) from your copy and replace them with the new updated procedures listed below:

•

• • •

• •

• • • • •

• • • • •

Copyright page (update) Contents (update) AFS 1120-05-S (update) AFS l 121-05-A (update) AFS l 122-05-A (update) AFS l 123-05-A (update) AFS 2110-04-S (update) AFS 21 l 1-04-S (update) AFS 2245-04-S (update) AFS 3330-04-S (update) AFS 3331-04-S (update) AFS 3332-04-S (update) AFS 3333-04-S (update) AFS 3334-04-S (update) AFS 3335-04-S (update) AFS 3336-04-S (update)

• •

• • • • •

• • • • •

• • •

AFS 3337-04-S (update) AFS 3338-04-S (update) AFS 3339-04-S (update) AFS 3345-04-S (update) AFS 3346-04-S (update) AFS 4409-05-S (update) AFS 4410-05-S (update) AFS 4411-05-S (update) AFS 5215-05-S (update) AFS 5220-05-S (update) AFS 5221-05-S (update) AFS 5222-05-S (update) AFS 5232-05-S (update) AFS 5233-05-S (update) AFS 5240-05-S.(update)

Price: Corporate Member $10.00 lndividual Member $15.00 List Price $20.00

) Item # GM0004B