Foseco India Limited Gat Nos.

922 & 923 Sanaswadi Taluka Shirur District Pune 412 208 Tel +91 (0)2137 668100 Fax +91 (0)2137 668160

TEST PROCEDURES FOR TESTING GREEN SAND, RETURN SAND, NEW SAND & BENTONITE AFS CLAY : Take 50 gms of sand (moisture free) in 500 BSS test sieve. Add 2-3 drops of 50% NaOH solution. Hold under running tap water till all the clay particles are washed away. Dry under infra red lamp. Cool and weigh again. (Loss in Weight)*2 is expressed as total/ AFS clay in percentage. AFS Clay % = (Loss in Weight)*2

ACTIVE CLAY IN MOULDING & RETURN SAND : A ) Preparation of standard 0.01 M Methylene Blue (MB) Solution :(Using Methylene Blue powder with molecular weight of 409.93.) Dissolve 4.0993 gm of Methylene Blue powder in distilled water and dilute to 1000 ml so that the concentration will be 0.01 M. B ) Methylene Blue Calibration Graph :Blend 5 gm of new 5 gm of new 5 gm of new 5 gm of new Equivalent to 8 % Bentonite 6 % Bentonite 4 % Bentonite 2 % Bentonite

silica sand + 0.4 gm Bentonite silica sand + 0.3 gm Bentonite silica sand + 0.2 gm Bentonite silica sand + 0.1 gm Bentonite

These blends are titrated against 0.01 M MB Solution. The blend is taken in 600 ml glass beaker. Add 100-150 ml of distilled water. Warm to 800C. Cool. Add 2.5 ml of 0.5 N H2SO4 and titrate against 0.01 M MB solution. End point is appearance of Blue hallow on the filter paper.

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Plot the Calibration graph as shown below : CALIBRATION GRAPH :

C) Active clay in moulding and return sand :1.

Take 5 gm sand (moisture free) in 600 ml glass beaker. Add 100-150 ml distilled water. Warm upto 80 0C and cool. Add 2.5 ml of 0.5 N H2SO4. Titrate against 0.01 M Methylene Blue solution. End point is appearance of Blue hallow on the filter paper. Using the calibration graph already plotted, calculate the active clay present in the sample.

2.

DEAD CLAY : Refer to procedure in determining AFS clay & Active clay of moulding and return sand. After determining both of the above, the dead clay is calculated as follows : Dead clay = AFS clay - Active clay

VOLATILE MATTER : Weigh out exactly 1 gm of sample for which Volatile Matter is to be tested, in a V.M. crucible. Take the weight of crucible with sample as W1. Keep this crucible in a muffle furnace at 920!20 0 C for 7 min. After 7 min. take out the crucible and cool it to room temperature. Weigh the same and take this weight as W2. VOLATILE MATTER (in %) = (W1-W2) * 100 LOS ON IGNITION : Weigh out sample for which loss on ignition is to be tested in a crucible or in a Platinum Dish. Take the weight of the crucible + sample weight (generally 1 gm) as W1. Keep this crucible in a muffle furnace at 920!200C till there is no further loss in weight. Take out the crucible and cool it in a dessicator at room temperature. Weigh the crucible. Note down this weight as W2. % Loss on Ignition (L.O.I.) = (W1 - W2) * 100

Note : For samples where exact weighing is difficult, take any amount of sample and calculate the percentage of L.O.I. accordingly.

SIVE GRADING :
1.

Arrange the sieves set in such a way that the pan will be at the bottom. Minimum mesh number sieve will be at the top and maximum mesh number sieve just above the pan. Order to be followed for mesh number, i.e., top to bottom in the ascending order. Weigh out known weight of sample and transfer it into the top mesh of the set. Shake the whole system for 10 minutes using sieve shaker . Weigh the portion of material retained in each sieve. Retained portion is noted as + or plus or passed portion noted as - or minus. It is expressed in terms of percentage.

2. 3. 4.

Note : Sample weight is to be considered on its density. For low density material, minimum sample weight is preferred and vice versa. In case of too fine and water insoluble materials, wet sieve analysis is preferred from 100 mesh onwards in the ascending order. Instead of manually shaking the sieve set, water can be passed through the set. Dry each sieve and weigh them. Portion retained on each sieve is noted as plus portion.

MOISTURE CONTENT :
1. 2.

Weight of empty petri dish : W1 Weight of petri dish + Sample : W2 (5 gm of sample is enough) Keep under IR lamp at 105-110 0C Cool it in a dessicator. Weigh in an analytical balance : W3 Repeat process 3 to 5 till W3 is constant. % of Moisture = W2 - W3 * 100 W2 - W1

3. 4. 5. 6.