Posts by amirosengren
Digital Active Clay Measurement by Spectrophotometric Method in Green Sand Foundries
Originally published in Modern Casting: March 2025 In this study, a new test is optimized and evaluated at three foundries to determine viability as an alternative measurement of active clay in working foundry green sand systems. J.R. SPRINGSTEAD, P.J. TAN, S. RAMRATTAN, WESTERN MICHIGAN UNIVERSITY, KALAMAZOO, MICHIGAN; B. RACHWITZ, EJ, EAST JORDAN, MICHIGAN; M. RING,…
Read MoreWhen Dust Collection Becomes a Strategic Advantage in Foundry Sand Systems
When Dust Collection Becomes a Strategic Advantage in Foundry Sand Systems By Jay M. Morrison – Carpenter Brothers, Inc. Walk into any foundry and you’ll see dust everywhere—around shakeout decks, along sand conveyors, in the sand tower, and hanging in the air above a busy muller floor. Foundries move, reclaim, and cool tens of thousands…
Read MoreSilica Sand for Making Molds and Cores
Silica Sand Silica sand has long been the backbone of the foundry industry, serving as the primary material for producing molds and cores. Its unique properties make it a reliable and cost-effective choice for creating high-quality castings across a wide range of metals and industries. Why Silica Sand? Silica sand, composed primarily of quartz (SiO₂),…
Read MoreHow Standard & Calcined Zircon Sand Improve Your Metal Castings
STANDARD & CALCINED ZIRCON SAND Choosing the right sand is critical if you want to produce cleaner, more precise castings. At Carpenter Brothers, Inc., we supply both standard zircon sand and calcined zircon sand — each designed to help foundries cast high-value parts with fewer defects and better surface quality. Below, we break down how…
Read MoreAluminum Fluxes 101
Basics of Furnace Cleaning, Dross Handling and Wall Cleaning JOHN REYNOLDS | Originally published Fall 2022 Casting defects, energy usage, metal recovery, ergonomics, and labor are cost variables addressed by properly identifying and applying fluxes for the aluminum casting operation. Proper selection and application are especially important to realize the benefits that flux can provide.…
Read MoreThe Smarter Way to Mix: What You Need to Know About The SandMASTER™ Mulling Mixer by Mixer Systems, Inc.
Mulling Mixer: Innovative Solution for Sand Mixing When it comes to industrial mixing, performance, reliability, and efficiency aren’t just nice to have — they’re essential. Whether you’re running a green sand foundry or producing high-performance precast materials, the equipment you choose sets the tone for everything that follows. At Mixer Systems, they engineer standout solutions…
Read MoreThe Why’s and How’s of Fluxing Aluminum
FLUXING ALUMINUM Casting of Aluminum 101: Types of Melting Furnaces There are several types of furnaces that are used to melt aluminum. The most popular are: 1) Gas fired crucible furnaces 2) Reverberatory furnaces 3) Electric resistance furnaces. Schematic diagrams of these furnaces are shown below. There are a multitude of electric furnaces used to…
Read MoreManaging Coreless Induction Furnace Slag Build-Up
Coreless induction furnace fluxing will eliminate build-up on sidewalls, improve slag fluidity, improve electrical efficiency, keep furnace volumes and ladles constant, and extend refractory life. By Rod Naro In the past 60 years, melting methods of ferrous charge metals in coreless induction furnaces have changed dramatically. In today’s foundry industry, a major economic driver is…
Read MoreSpecialty Sands
Specialty Sands The use of silica sand as a molding and/or core aggregate is very economical. However, there are occasions where the use of silica sand with conventional binders and additives does not give satisfactory casting results. When expansion defect problems such as veining occur, or if you are experiencing burn-on, metal penetration, or poor…
Read MoreCombustible Dust Management
Managing Your Plant’s Combustible Dust Combustible dusts are fine particles that present an explosion hazard when suspended in air under certain conditions. Dust explosions can cause destruction of property, injuries, and loss of life. The Federal Government has updated the National Fire Protection Association (NFPA-68) regulation from a guideline to a standard in 2008. The…
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