Development of low cost block mold for copper alloy casting

Siti Zaleha Mohd Nor, Romzee Ismail, Sahrim Ahmad, Ahmad Salihin Samsudin, Mohd Ikmar Nizam Mohamad Isa

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

Suitable block mold formulations for copper alloy casting have been developed and the formulations used were 25% plaster of paris (POP), 75% silica sand and 31-37% water. Silica sand with a grain size of 106-212 µm was added into dilute suspension of POP and the mixing process was continued until a thick slurry (mixture) was obtained. It has been found that the mixing time of molding materials was highly depended on the type of plaster and optimum slurry viscosity around the diameter of 7.7 – 9.6 cm (slump test) was essential to ensure that the wax pattern could be fully invested. In the dewaxing process, the mold was subjected to the temperature of 170°C for 3 hours and burnout process was effectively achieved by heating the molds at 750°C for 5 hours. The pouring process was successfully carried out without any leakage and it was found that all molds can be easily broken under a force of a hammer. The developed mold also able to produce fully formed of casting without any major defects such as misrun, fin or flash and rat tail, which can be associated with inadequate mold temperature, mold cracks and the separation of mold’s material respectively.

Original languageEnglish
Pages (from-to)27-33
Number of pages7
JournalJurnal Teknologi
Volume78
Issue number6-6
DOIs
Publication statusPublished - 2016
Externally publishedYes

Fingerprint

Plaster
Copper alloys
Molds
Silica sand
Casting
Dewaxing
Costs
Hammers
Waxes
Molding
Rats
Viscosity
Cracks
Heating
Temperature
Defects
Water

Keywords

  • Block mold
  • Copper alloy casting
  • Silica sand
  • Wax pattern

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Mohd Nor, S. Z., Ismail, R., Ahmad, S., Samsudin, A. S., & Isa, M. I. N. M. (2016). Development of low cost block mold for copper alloy casting. Jurnal Teknologi, 78(6-6), 27-33. https://doi.org/10.11113/jt.v78.9017

Development of low cost block mold for copper alloy casting. / Mohd Nor, Siti Zaleha; Ismail, Romzee; Ahmad, Sahrim; Samsudin, Ahmad Salihin; Isa, Mohd Ikmar Nizam Mohamad.

In: Jurnal Teknologi, Vol. 78, No. 6-6, 2016, p. 27-33.

Research output: Contribution to journalArticle

Mohd Nor, SZ, Ismail, R, Ahmad, S, Samsudin, AS & Isa, MINM 2016, 'Development of low cost block mold for copper alloy casting', Jurnal Teknologi, vol. 78, no. 6-6, pp. 27-33. https://doi.org/10.11113/jt.v78.9017
Mohd Nor, Siti Zaleha ; Ismail, Romzee ; Ahmad, Sahrim ; Samsudin, Ahmad Salihin ; Isa, Mohd Ikmar Nizam Mohamad. / Development of low cost block mold for copper alloy casting. In: Jurnal Teknologi. 2016 ; Vol. 78, No. 6-6. pp. 27-33.
@article{72d48571fc274800b5255deab953a8db,
title = "Development of low cost block mold for copper alloy casting",
abstract = "Suitable block mold formulations for copper alloy casting have been developed and the formulations used were 25{\%} plaster of paris (POP), 75{\%} silica sand and 31-37{\%} water. Silica sand with a grain size of 106-212 µm was added into dilute suspension of POP and the mixing process was continued until a thick slurry (mixture) was obtained. It has been found that the mixing time of molding materials was highly depended on the type of plaster and optimum slurry viscosity around the diameter of 7.7 – 9.6 cm (slump test) was essential to ensure that the wax pattern could be fully invested. In the dewaxing process, the mold was subjected to the temperature of 170°C for 3 hours and burnout process was effectively achieved by heating the molds at 750°C for 5 hours. The pouring process was successfully carried out without any leakage and it was found that all molds can be easily broken under a force of a hammer. The developed mold also able to produce fully formed of casting without any major defects such as misrun, fin or flash and rat tail, which can be associated with inadequate mold temperature, mold cracks and the separation of mold’s material respectively.",
keywords = "Block mold, Copper alloy casting, Silica sand, Wax pattern",
author = "{Mohd Nor}, {Siti Zaleha} and Romzee Ismail and Sahrim Ahmad and Samsudin, {Ahmad Salihin} and Isa, {Mohd Ikmar Nizam Mohamad}",
year = "2016",
doi = "10.11113/jt.v78.9017",
language = "English",
volume = "78",
pages = "27--33",
journal = "Jurnal Teknologi",
issn = "0127-9696",
publisher = "Penerbit Universiti Teknologi Malaysia",
number = "6-6",

}

TY - JOUR

T1 - Development of low cost block mold for copper alloy casting

AU - Mohd Nor, Siti Zaleha

AU - Ismail, Romzee

AU - Ahmad, Sahrim

AU - Samsudin, Ahmad Salihin

AU - Isa, Mohd Ikmar Nizam Mohamad

PY - 2016

Y1 - 2016

N2 - Suitable block mold formulations for copper alloy casting have been developed and the formulations used were 25% plaster of paris (POP), 75% silica sand and 31-37% water. Silica sand with a grain size of 106-212 µm was added into dilute suspension of POP and the mixing process was continued until a thick slurry (mixture) was obtained. It has been found that the mixing time of molding materials was highly depended on the type of plaster and optimum slurry viscosity around the diameter of 7.7 – 9.6 cm (slump test) was essential to ensure that the wax pattern could be fully invested. In the dewaxing process, the mold was subjected to the temperature of 170°C for 3 hours and burnout process was effectively achieved by heating the molds at 750°C for 5 hours. The pouring process was successfully carried out without any leakage and it was found that all molds can be easily broken under a force of a hammer. The developed mold also able to produce fully formed of casting without any major defects such as misrun, fin or flash and rat tail, which can be associated with inadequate mold temperature, mold cracks and the separation of mold’s material respectively.

AB - Suitable block mold formulations for copper alloy casting have been developed and the formulations used were 25% plaster of paris (POP), 75% silica sand and 31-37% water. Silica sand with a grain size of 106-212 µm was added into dilute suspension of POP and the mixing process was continued until a thick slurry (mixture) was obtained. It has been found that the mixing time of molding materials was highly depended on the type of plaster and optimum slurry viscosity around the diameter of 7.7 – 9.6 cm (slump test) was essential to ensure that the wax pattern could be fully invested. In the dewaxing process, the mold was subjected to the temperature of 170°C for 3 hours and burnout process was effectively achieved by heating the molds at 750°C for 5 hours. The pouring process was successfully carried out without any leakage and it was found that all molds can be easily broken under a force of a hammer. The developed mold also able to produce fully formed of casting without any major defects such as misrun, fin or flash and rat tail, which can be associated with inadequate mold temperature, mold cracks and the separation of mold’s material respectively.

KW - Block mold

KW - Copper alloy casting

KW - Silica sand

KW - Wax pattern

UR - http://www.scopus.com/inward/record.url?scp=84975080936&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84975080936&partnerID=8YFLogxK

U2 - 10.11113/jt.v78.9017

DO - 10.11113/jt.v78.9017

M3 - Article

VL - 78

SP - 27

EP - 33

JO - Jurnal Teknologi

JF - Jurnal Teknologi

SN - 0127-9696

IS - 6-6

ER -