LAB REPORT # 04

INSTITUTE OF SPACE AND TECHNOLOGY

LAB REPORT #04

SUBMITTED TO:
SIR ZEESHAN

SUBMITTED BY:
MUHAMMED AHMED (210301026)
SAAD AHMED (210301029)
MUHAMMED AHMED (210301035)
MAARIJ ALI (210301031)
MAAZ SHAHID (210301033)
SAMI ULLAH BABAR (210301024)

SECTION:
MAT-14(B)
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1. Abstract.......................................................................................3
2. Materials......................................................................................3
3. Procedure....................................................................................4
4. Metal Melting using Natural Gas-Fired Clay Oven:..............5
5. Metal Pouring and Solidification:.............................................5
6. Casting Retrieval:.......................................................................6
7. Observations and Discussion:....................................................6
8. Discussion....................................................................................7
9. Conclusion...................................................................................7
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Lab Report: Preparation of Mold for Sand Casting of I-

Shape Aluminum Sample using Jaggery Water Binder
and Natural Gas-Fired Cylindrical Clay Oven
1. Abstract
This experiment aimed to explore an alternative casting method by creating a sand mold for
casting an I-shaped aluminum sample. Jaggery water, a non-standard binder, was used
alongside sand to prepare the mold. A unique aspect of this experiment involved melting the
aluminum using a cylindrical clay oven fueled by natural gas instead of a conventional
electric furnace. The process incorporated a gating system for proper metal flow. Molten
aluminum was then poured into the mold, allowed to solidify, and the casting retrieved after
cooling.

2. Materials
 Foundry sand
 Metal Mold Box
 I-shaped pattern (material: thermocol)
 Rammer tool (for compacting sand)
 Spru pin/rod
 Parting compound (used to prevent sticking between mold halves)
 Safety equipment (gloves, safety glasses, heat shield, respirator for clay oven)
 Aluminum sample
 Cylindrical clay oven
 Natural gas burner
 Crucible (clay or ceramic, capable of withstanding high temperatures)
 Tongs or heat-resistant gloves (for handling crucible)
 Pouring ladle

3. Procedure
1. Mold Preparation:

Metal mold box was separated, and a parting compound was applied on the contact
surfaces to prevent sticking during mold opening.

o Pattern Placement: The I-shaped pattern, made of thermocol (packing

peanuts), was placed in the drag (bottom box) of the mold. The thermocol
pattern served as a sacrificial element to create the desired cavity in the sand
mold.
o Sand Mixing: Dry sand was used to ensure even distribution throughout a
mixing bucket. Jagger water solution was gradually added to the sand while
mixing thoroughly in a sand mixer to achieve a consistent and moldable damp
sand mixture.
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Figure 1: Sand Preparation

Figure 2: Sand Mixture

o Sand Ramming:

The sand mixed with Jaggery water binder was placed around the I-shaped
thermocol pattern in the drag. The sand was rammed evenly using the rammer tool
to achieve uniform density throughout the mold (around 70% packing density).
Careful ramming around the pattern was necessary to ensure complete
encapsulation and avoid voids in the cavity.

4. Metal Melting using Natural Gas-Fired Clay Oven:

o Clay Oven Construction: The cylindrical clay oven was a homemade
design, constructed from firebricks.
o Fuel System: A natural gas burner compatible with the clay oven design
was used for heating. The burner was positioned to create a directed flame
towards the crucible placed inside the oven.
o Melting Process:
 The crucible was placed inside the clay oven.
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 Aluminum ingots were placed within the crucible.
 The natural gas burner was ignited, and the flame was adjusted to
achieve a temperature sufficient to melt the aluminum. The
temperature could be monitored visually based on the color of the
glowing crucible and the furnace interior.

Important Note: Melting aluminum using a clay oven, even with natural gas, requires
extreme caution due to the high temperatures. Proper ventilation and use of a respirator are
essential to avoid inhaling harmful fumes.

5. Metal Pouring and Solidification:

o Once the aluminum was judged molten based on visual observation (molten
aluminum has a shiny, reflective surface), the crucible was carefully removed
from the oven using tongs while wearing heat-resistant gloves.
o The molten aluminum was poured into the mold sprue hole, ensuring the mold
cavity filled completely. Observation was made to avoid overflows or spillage.
o The filled mold was allowed to cool for several hours (approximately 4 hours
for the given aluminum volume) to allow for complete solidification. During
cooling, the thermocol pattern decomposes due to the heat, leaving behind the
desired I-shaped cavity in the sand.

6. Casting Retrieval:
o Once cooled, the clamps were removed, and the mold box was broken open
carefully. The solidified aluminum casting, replicating the I-shape, was
retrieved. Any remaining.

7. Observations and Discussion:

Figure 3: Casted Sample

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Figure 4: Casted Sample

 The quality of the sand mold was visually inspected. Minor cracks were observed on
the mold surface, possibly due to the challenges of using Jaggery water as a binder
compared to standard options. The use of thermocol as a pattern also presented
limitations, as complete decomposition during solidification might leave residual
traces or affect the surface finish of the casting.
 During pouring, a small amount of molten aluminum spilled from the sprue hole. This
could be attributed to factors like:
o Incomplete mold filling: The sand mixture with Jaggery water binder
might have exhibited lower strength or permeability compared to standard
binders, potentially affecting the mold's ability to retain the molten metal.
o Gating system issues: The size or design of the sprue, runners, and risers
might not have been optimal for smooth metal flow and proper filling of the
cavity.
 The final aluminum casting was retrieved and inspected. Dimensional accuracy was
measured using calipers or a ruler to compare with the original thermocol pattern
dimensions. The surface finish of the casting was also observed, noting any
imperfections or irregularities.

8. Discussion
The experiment successfully explored the creation of a sand mold for I-shaped aluminum
casting using Jaggery water as a binder and a natural gas-fired clay oven for melting.
However, limitations were encountered due to the non-standard materials and methods.

 Jaggery water binder: Compared to established clay or oil-based binders,

Jaggery water might not offer the same level of strength and consistency in the mold.
This could have contributed to the observed cracks and potential leakage during
pouring.
 Thermocol pattern: While thermocol is a readily available and inexpensive
pattern material, it decomposes during casting, potentially leaving behind residue and
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affecting the casting surface finish. Additionally, achieving complex shapes with
thermocol might be challenging.
 Natural gas-fired clay oven: Melting aluminum using a clay oven, even with
natural gas, offers less precise temperature control compared to an electric furnace.
This could have resulted in challenges in achieving the optimal pouring temperature
for the aluminum.

Further studies could explore:

 Utilizing established clay or oil-based binders to assess the impact on mold strength
and casting quality.
 Employing more durable and reusable pattern materials like wood or metal for
intricate shapes and improved surface finish.
 Refining the design and operation of the natural gas-fired clay oven for more
consistent temperature control during aluminum melting.

9. Conclusion
This experiment served as a preliminary exploration of alternative materials and methods for
sand casting. While a functional I-shaped aluminum casting was achieved, the limitations of
Jaggery water as a binder and the use of thermocol patterns became evident. Future research
should focus on utilizing established casting practices and materials for more reliable and
predictable results.