GILSONITE IN FOUNDRY

Natural Asphalt in Foundry Industry

Gilsonite, also known as natural asphalt or uintaite, is a unique natural resource that has various industrial applications, including use in the foundry industry. Foundries play a crucial role in metal casting processes, and the addition of certain materials, like Gilsonite, can enhance the efficiency and properties of foundry products.

Here’s how Gilsonite is commonly used in the foundry industry:

Binder and Additive:

Binder: Gilsonite can act as a binder in foundry sand mixtures. When mixed with sand, it forms a strong bond, helping to hold the sand particles together. This is crucial in the creation of molds for metal casting.
Additive: Gilsonite is often added to foundry sand formulations to improve the quality and properties of the molds. It enhances the resistance of the molds to high temperatures and can contribute to the overall strength of the mold.

Thermal Properties:

Gilsonite has excellent thermal stability. In foundry applications, where molten metal is poured into molds, materials with good thermal resistance are essential. Gilsonite can withstand high temperatures, making it suitable for use in foundry sand.

Reduction of Veining Defects:

Veining defects in casting refer to the formation of veins or cracks on the surface of the metal casting. Gilsonite, when added to foundry sand, has been reported to reduce or eliminate veining defects. This can lead to improved casting quality.

Reduced Gas Emission:

Gilsonite can contribute to reduced gas emission during the casting process. This is important in foundry operations where controlling the release of gases is critical for producing high-quality castings.

Surface Finish:

The addition of Gilsonite can contribute to a smoother surface finish on castings. This is desirable in many applications, especially in industries where aesthetics or the appearance of the final product is important.

Cost-Effective Solution:

Gilsonite is a naturally occurring material, and its use in foundry applications can be a cost-effective solution compared to synthetic alternatives. Its availability and natural properties make it an attractive option for certain foundry operations.

When incorporating Gilsonite in foundry processes, it’s important to consider the specific requirements of the casting operation, the type of metal being cast, and the desired properties of the final product. Additionally, proper testing and optimization of formulations are typically conducted to ensure that the use of Gilsonite meets the specific needs of the foundry industry. Foundry, the technology of melting metals and shaping alloys, relies on high-performance materials. Gilsonite stands out for superior properties, ensuring top-notch iron castings with a fine finish and fewer defects. Recognized globally for its efficacy in molten iron environments, Gilsonite surpasses other carbon additives, generating less gas and fostering a reductive atmosphere for improved mold release and fewer imperfections. When combined with coal, Gilsonite enhances foundry sands, reducing gas evolution, and improving ventilation. Its use results in casting finishes equal to sea coal, contributing to smoother plates on gray iron castings. Notably, Gilsonite increases hot resistance, pure resistance, reduces penetration, and enhances mold hardness, offering a compelling alternative or addition to traditional carbonated additives in foundry processes.

Foundry Sand, predominantly sourced as specialized silica sand in limited Iranian regions, serves a pivotal role in casting various steel components, both small and large. While this sand finds utility in diverse applications like water treatment, over 80% of its extraction is dedicated to the casting industry. In sandblasting, a mixture of clay and water is employed, featuring a composition of 90% sand, 7% clay, and 3% water. Additional adhesives include organic dressings like phenolic resins, inorganic binders such as sodium silicate and phosphate, and other alternatives, selectively employed to enhance strength and disintegration resistance as needed. This versatile material plays a crucial role in shaping the form and appearance of castings in the steel industry.

KEY ROLES OF SPECIALIZE FOUNDRY SAND IN STEEL CASTING PROCESSES

FOUNDRY SAND PERFORMANCE WITH GILSONITE

Gilsonite stands out as a pivotal additive in foundry sand, fostering strong adhesion between sand and other materials. As the mold is filled, Gilsonite’s sublimation induces gassing, facilitating mold separation from the casting material while maintaining a polished mold surface.

This versatile substance significantly improves sand density, water requirements, and strength at various stages (green, dry, baked, and hot). Gas evolution curves reveal Gilsonite’s rapid volatilization compared to sea coal, achieving the same total volatiles with only a third of the additive level.

During pouring, carbonaceous additives release gases forming a protective film, preventing direct metal contact with sand grains. This minimizes sand-metal contact, reducing burn-on risk. When heated, these additives produce hydrocarbon gases, forming a lustrous carbon layer that acts as a barrier to iron silicate formation, inhibiting burn-on and penetration.

1. Burn-on: Firm bonding of sand grains to casting.
2. Burn-off: Rough, sandy appearance on the casting surface.
3. Metal penetration: Molten metal infiltrates voids, creating a fused mass that complicates casting removal.
4. Pinholes: Caused by high nitrogen content, impacting casting quality.

ADVANTAGES OF GILSONITE FOUNDRY SAND IN METAL CASTING

Embracing Gilsonite in foundry sand yields numerous benefits:

Reduced Imperfections: Mitigates imperfections by impeding the swift reaction between the silica sand mold and the oxidized surface of molten iron.
Enhanced Shakeout Performance: Improves the ease of sand peel from castings during the shakeout process.
Smoother, Cleaner Casting Surface: Results in a casting surface characterized by enhanced smoothness and cleanliness.
Minimized Imperfections and Scrap: Drastically reduces casting imperfections, losses, and scrap, contributing to overall efficiency.

In the foundry and refractories sector, especially for molding high-value metals, meticulous attention to finishing is paramount. Gilsonite emerges as a superior carbon additive, surpassing traditional Sea Coal in carbonic value and overall performance.

Key Features of Gilsonite Include:

Greater Gas Generation: Three times the gas generation of sea coal, leading to improved mold release.
High Lustrous Carbon: Contributes to a superior finish on castings.
Reductive Atmosphere: Fosters a reductive atmosphere, minimizing reactions between the mold and casting and reducing imperfections.

PACKING OF FOUNDRY GILSONITE NATURAL ASPHALT LUMP AND POWDER FORM

Gilsonite in lump form like rock packed in the 500~1000 kg jumbo bag
Gilsonite 200 mesh packed in the 500~1000 kg jumbo bag
Gilsonite 300 mesh packed in the 500~1000 kg jumbo bag
Gilsonite 30-40 mesh packed in the 500~1000 kg jumbo bag
Gilsonite 100 mesh packed in the 500~1000 kg jumbo bag
Gilsonite 300 mesh packed in 25 kg pp bag
Gilsonite 200 mesh packed the 25 kg multi-paper bag
Gilsonite 200 mesh packed the 50 lbs multi-paper bag
Gilsonite 30-40 mesh packed pp bag on the pallet
Bulk on vessel

TECHNICAL DATA SHEET OF GILSONITE FOUNDRY

NO	TEST	RESULT	TEST METHOD
1	ASH CONTENT,WT%	10	ASTM-D3174
2	MOISTURE CONTENT,WT%	0.5%	ASTM-D3173
3	VOLATILE MATTER,WT%	64	ASTM-D3175
4	SOLUBILITY IS CS2,WT%	78	ASTM-D4
5	SPECIFIC GRAVITY @25C	1.11	ASTM-D3289
6	NORMAL NEPTHAN INSOLUBLES,WT%	79	ASTM-D3279
7	COLOR IS MASS	BLACK	———————–
8	COLOR IN STREAK OR POWDER	BLACK	———————–
9	SOFTENING POINT,C	150	ASTM-D36
10	PENETRATION @25C	0	ASTM-D5