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<p>The measurement of active clay in foundry green sand is an essential component in the control of the metal casting process. The methylene blue (MB) test is the current AFS standard to measure active clay. Currently, there are two standard AFS tests for determining MB content. One test uses a boiling method, and the most commonly used test uses an ultrasonic scrubber and tetrasodium pyrophosphate (TSPP). While the ultrasonic test was determined to be safer for the operators, it continues to be time-consuming (25-30 minutes per test), qualitative in nature in regard to reading the halo, and dependent on operator judgment and bias effects. A new spectrophotometric test has been developed that offers a faster, quantitative (digital) measurement for active clay in green sands and does not require extensive training or experience. In this study, this new alternative test is optimized and evaluated at three foundries to determine viability as an alternative measurement of active clay in working foundry green sand systems. The trials were conducted and optimized over two rounds of foundry testing. The variance of the optimized methods has been reviewed relative to the standard MB test using a comparison within each foundry and a gage repeatability and reproducibility test. This analysis confirms that the new test has similar variability compared to the standard AFS MB test performed by experienced operators. Furthermore, the new test offers a quantitative measurement as an alternative to the standard MB test.</p>

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Digital Active Clay Measurement by Spectrophotometric Method in Green Sand Foundries

  • 期刊论文

  • 发表日期：

    2025年6月2日

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  • James R. Springstead,
  • Piao Jian Tan,
  • Sam Ramrattan,
  • Brian Rachwitz,
  • Michelle Ring,
  • Steve Neltner,
  • Tom Arenholz,
  • Scott Outman,
  • Jay Morrison

摘要

The measurement of active clay in foundry green sand is an essential component in the control of the metal casting process. The methylene blue (MB) test is the current AFS standard to measure active clay. Currently, there are two standard AFS tests for determining MB content. One test uses a boiling method, and the most commonly used test uses an ultrasonic scrubber and tetrasodium pyrophosphate (TSPP). While the ultrasonic test was determined to be safer for the operators, it continues to be time-consuming (25-30 minutes per test), qualitative in nature in regard to reading the halo, and dependent on operator judgment and bias effects. A new spectrophotometric test has been developed that offers a faster, quantitative (digital) measurement for active clay in green sands and does not require extensive training or experience. In this study, this new alternative test is optimized and evaluated at three foundries to determine viability as an alternative measurement of active clay in working foundry green sand systems. The trials were conducted and optimized over two rounds of foundry testing. The variance of the optimized methods has been reviewed relative to the standard MB test using a comparison within each foundry and a gage repeatability and reproducibility test. This analysis confirms that the new test has similar variability compared to the standard AFS MB test performed by experienced operators. Furthermore, the new test offers a quantitative measurement as an alternative to the standard MB test.