Ceramic fused sand (also known as ceramic sand or ceramic proppant sand) is an advanced molding material used in foundry casting. It offers several advantages over traditional silica sand and other molding materials, making it increasingly popular in precision casting applications. Here are the key advantages:
1. High Refractoriness & Thermal Stability
Ceramic fused sand has a much higher melting point (~1,800°C) compared to silica sand (~1,470°C), making it suitable for high-temperature alloy castings (e.g., steel, stainless steel, and high-chromium iron).
Reduces burn-on defects and improves surface finish.
2. Excellent Flowability & Compactability
The spherical shape of ceramic sand particles ensures better flowability, allowing for uniform compaction in molds and cores.
Reduces voids and improves dimensional accuracy in castings.
3. Low Thermal Expansion & Reduced Veining Defects
Unlike silica sand, which expands significantly when heated, ceramic sand has minimal thermal expansion (~0.13% vs. ~1.5% for silica sand).
Minimizes veining, cracking, and metal penetration defects in castings.
4. Superior Reusability & Cost Efficiency
Ceramic sand is highly durable and can be reused 50-100 times (compared to 5-10 times for silica sand), reducing waste and material costs.
Lower binder consumption due to better bonding properties.
5. Better Collapsibility & Easy Shakeout
After casting, ceramic sand molds break down more easily, reducing residual stresses and improving shakeout efficiency.
Beneficial for complex and thin-walled castings.
6. Improved Surface Finish & Dimensional Accuracy
The smooth, spherical grains reduce surface roughness, leading to finer casting finishes.
Minimizes machining requirements, saving post-processing costs.
7. Chemically Inert & Reduced Gas Defects
Ceramic sand does not react with molten metal, preventing gas-related defects (e.g., pinholes, blowholes).
No silica dust generation, improving workplace safety (no risk of silicosis).
8. Environmentally Friendly
Lower binder usage reduces harmful emissions.
Reusability decreases landfill waste compared to silica sand.
Applications:
Ideal for steel, alloy steel, high-chromium iron, and non-ferrous castings.
Used in shell molding, no-bake, and cold-box processes.
Suitable for investment casting as a filler or stucco material.