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<p>Bentonite clay is commonly used as a binder in the green sand mold casting process. The chemical composition of bentonite clay and fly ash is similar. Therefore, the present investigation focuses on the effect of different&#xa0;wt.% of fly ash-modified bentonite clay on the properties of green sand mold and as-cast A356 alloy. It was observed that up to 30&#xa0;wt.% of fly ash can be used to replace bentonite clay in the total clay content without compromising the properties of green sand molds. Furthermore, A356 alloy casting trial was taken in the laboratory using fly ash-modified bentonite clay as a binder (Type M) and pure bentonite clay as a binder (Type B). The A356 alloy casting quality, such as surface roughness, hardness, and microstructures, produced using molds with the Type M binder was benchmarked against the Type B binder, and found to have a good agreement (≈&#xa0;95%) between them. This study creates an opportunity to use fly ash in foundry industries as a partial replacement in bentonite clay.</p>

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Design and Development of Fly Ash-Modified Bentonite Clay in Green Sand Mold Casting Process for A356 Alloy Casting

  • 期刊论文

  • 发表日期：

    2025年4月22日

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  • Dheerendra Singh Patel,
  • Ramesh Kumar Nayak

摘要

Bentonite clay is commonly used as a binder in the green sand mold casting process. The chemical composition of bentonite clay and fly ash is similar. Therefore, the present investigation focuses on the effect of different wt.% of fly ash-modified bentonite clay on the properties of green sand mold and as-cast A356 alloy. It was observed that up to 30 wt.% of fly ash can be used to replace bentonite clay in the total clay content without compromising the properties of green sand molds. Furthermore, A356 alloy casting trial was taken in the laboratory using fly ash-modified bentonite clay as a binder (Type M) and pure bentonite clay as a binder (Type B). The A356 alloy casting quality, such as surface roughness, hardness, and microstructures, produced using molds with the Type M binder was benchmarked against the Type B binder, and found to have a good agreement (≈ 95%) between them. This study creates an opportunity to use fly ash in foundry industries as a partial replacement in bentonite clay.