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1 Appied Cay Science, 5 ( 1990) Esevie Science Pubishes B.V., Amstedam 165 Effects of vaiation in wate content, cay faction and sodium cabonate additions on the synthetic mouding popeties of gbokoda cay and siica sand C.A. Loto* 1 and H. Adebayo Depatment of Metaugica and Mateias Engineeing, Obafemi Awoowo Univesity, e-fe (Nigeia) (Received Januay 23, 1989; accepted afte evision Febuay 9, 1990) ABSTRACT Loto, C.A. and Adebayo, H., Effects of vaiation in wate content, cay faction and sodium cabonate additions on the synthetic mouding popeties of gbokoda cay and siica sand. App. Cay Sci., 5: n this investigation, the gbokoda pue siica sand is chaacteised and used as a base sand fo the gbokoda cay- sand mixtue in an attempt to deveop an efficient synthetic mouding sand. The mechanica popeties of the cay-sand-wate mixtue wee detemined. The effect of additions ofna 2 C0 3 to the mouding sand was examined with paticua attention to its infuence on mechanica popeties of the synthetic mouding sand. The fineness numbe, sceen buk faction, tota coase faction and the tota fine faction of gbokoda siica sand wee found to be within the ange that coud give good moudabe popeties. The vaues obtained fo the geen compessive stength, the dy compessive stength, the geen and dy shea stengths, coapsibiity and toughness indicate that gbokoda cay has good vaues as a binde fo synthetic mouding sand. n genea, the addition of Na 2 C0 3 gives impoved popeties to the mouding sand though with a tendency towads impaied coapsibiity vaues. NTRODUCTON Deveopment of mouding sand and techniques of its testing has been a subject of investigation fo a vey ong time. Cays fom diffeent deposits have been chaacteised and aso the base siica sands used in synthetic mouding sands. Compehensive investigations have been caied out on vaious aspects of mouding sand deveopment and testing (Gim and Cuthbet, 1945; Schubet, 1958; Lawence, 1961 ). * 1 Pesent addess: Depatment of Mechanica Engin.eeing, Univesity of Lagos, Akoka, Yaba, Lagos (Nigeia) /90/$ Esevie Science Pubishes B. V.

2 . " c 166 C.A. LOTO AND H. ADEBAYO The vaious wok of Sandes and Doeman ( 1967, 1968, 1969) on duabiity of bonding cays ae paticuay significant in this espect. The individua eseach wok of these investigatos coud not be sepaatey eviewed hee due to ack of space. n a pevious study (Loto and Omotosho, 1990 ), cay obtained fom the gbokoda deposit was chaacteised and its synthetic mouding sand popeties when subangua agoon sand was used as the base sand wee detemined. The pesent wok is a continuation of the pevious one and is undetaken to ook into the effect of sodium cabonate additions on the synthetic mouding sand popeties, using a high-quaity pue white base siica sand ( 98% pue). The gbokoda siica sand used as the base sand in this investigation is cuenty being used fo age-scae gass manufactuing. An attempt to futhe utiise the sand in the foundy industy is one of the aims of this wok. Sodium cabonate addition to this mouding sand is undetaken as an activation teatment fo the cay (Sandes and Doeman, 1967, 1968, 1969). t has been peviousy shown that gbokoda cay is kaoinitic in stuctue and its wate etention o sweing capacity is ow. This contibuted to its owe geen and dy compessive stengths when compaed with a bentonite cay. An activation pocess which wi invove the epacement of Cain the cay with Na ions is expected to enhance moe fee wate adsoption of the cay and hence gives impoved stength popeties. n addition, gbokoda cay is acidic (ph 4.2). Thee is theefoe a tendency towads foccuation of the cay pateets due to its high viscosity when mixed with wate (Finn, 1963). Addition of sodium cabonate wi povide Na + which is expected to make the cay at east sighty akaine. This wi enhance optimum distibution of cay in the sand mixtue and thus gives impoved mouding popeties. EXPERMENTAL PROCEDURES Sepaation of cay fom sand The as-eceived unteated cay contained a ot of coase gain patices, mainy sand. The sepaation of the aw cay into two factions, above and beow 4 mesh size (cay and sit wi pass though a 4-mesh sceen whie the siica sand wi not) was theefoe consideed necessay. Gavity sedimentation was used to sepaate the quatz coase patices fom the cay. The as-eceived wet cay was mixed with wate and thooughy dispesed with 1.5 g/dm 3 cagon (sodium hexametaphosphate). Afte stiing fo about 20 min, the ja's content was aowed to sette fo about 5 min. The sand sediment and the cay patices in suspension wee sepaated by decantation. The sediment consisting of quatz was discaded whie the cay suspension was etained fo subsequent sepaation teatment. Due to the finess of the cay patices, a faste sedimentation technique, ] 1 : < ] ' t L!!...; :i t "b L L!

3 / SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND TABLE Chemica composition ofgbokoda cay gbokoda cay 167 i K+(ppm) (%) Na+ (ppm) (%) Ca2+ ppm) (%) Fe (ppm) (%) J f t' L L "centifuga sepaation", was used. This is an extension of gavity sepaation, as the setting ates of patices ae inceased unde the infuence of centifuga foce. A aboatoy centifuge consisting of fou 55-cm 3 tubes adiay aanged and taces of 70 mm adius when otating was used fo the sepaation. The tubes wee fied with the suy obtained fom the gavity sepaation suspension, and aowed to otate unde the centifuga foce of 1.9 KN at 15,000.p.m. fo 30 min. The cea wate suspension obtained was discaded and the cay sediment emoved fo futhe use. The composition of the cay (Tabe ) has eaie been detemined (Loto and Omotosho, 1990).,.!:>The obtained fine cay sediment was oven-died using a aboatoy Gaenkamp oven at a tempeatue of 50 o C fo 15 h. ph measuement. 10 g of the fine cay mateia was dissoved in 50 cm 3 of distied wate contained in a beake and thooughy stied. ts ph was measued by a ph mete and ecoded as 4.2. S.E.M. anaysis. A scanning eecton micoscope ( SEM) equipped with an enegy dispesive spectophotomete (EDS) was used to anayse quaitativey the chemica composition of the cay (Fig. 1) and a micogaph of the cay patice (Fig. 2) was made. Pepaation of the base siica sand The base siica sand used was washed sevea times with wate and died in the sun fo ten days. The size and distibution of the sand gains was detemined by the sieve anaysis test method of the A.F.S. (Ameican Foundyman Society ). A died 50-g sampe of the sand was used. The sampe was paced on top of a seies ofbss 410 sieves and shaken with the vibating sieve shake fo 15 min. The sand etained on each sieve afte shaking and that on the bottom pan was weighed. ts pecentage of the tota sampe was detemined (Tabe ). Additive. The additive used was sodium cabonate (Na 2 C0 3 10H 2 0).

4 168 C. A. LOTO AND H. ADEBA YO Fig.. SEM/EDS quaitative chemica anaysis of gbokoda Cay: MG=magnesium; AL=auminium; S/=siicon; P = phosphous; S=suphu; K= potassium CA =cacium; T/ =titanium; FE= ion., Pepaation of test sampes The base siica sand, vaying amounts of cay by dy weight pecent and known amounts of tempeing wate wee mechanicay mixed by a muing appaatus. Afte mixing, the sampe was stoed in poyethyene bags to pevent ai-dying. Cyindica test specimens confoming to A.F.S. standad specimens wee pepaed and used fo the mechanica tests. An amount of sand mixtues adequate to fom standad 50-mm diamete and 50-mm high test specimens afte thee ams wee detemined and measued out. n a the expeiments, the dy sampe weight used anged fom 150 to 170 g depending on the dy sand-cay atio. The amming device was secuey mounted, the sand poued into the specimen tube and ammed by impact with thee bows of 6,500 g weight. By the manuay opeated amming device the weight was dopped fom a height of 50 mm ± Thee ams nomay poduce a specimen of 50 mm ± in height povided the pope weight of sand was put in the specimen tube. Gauge maks ae shown at the top of the amme od to measue the specimen height. The specimen was emoved fom the tube by means of a stipping post. "( " 1 J J u T! u i, ' :!

5 n,m SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND 169 t! : ' E. J \.!..),..,... / '1 c L L f Fig. 2. SEM micogaph ofgbokoda cay patice showing the suface stuctue and the patice shape ( x 1000). Geen compession test The geen compession test was caied out to detemine the compessive stess in kn/m 2 necessay to cause uptue of the standad cyindica specimen using a Univesa sand stength testing machine. Geen compessive stength tests wee pefomed immediatey afte the specimen was stipped fom the tube to pvent any incease in geen stength due to ai-dying with incease in exposue time. The compessive stength was detemined by axiay oading the cyindica specimen though the fat faced hodes of the compession testing machine. The ate of oading was standadised by keeping it constant to pevent o minimise ceep of geen sand unde oading. The esuts obtained ae pesented in Figs. 3 and 8. Detais of the tests, testing

6 ' ' 170 C.A. LOTOAND H. ADEBAYO TABLE AFS sieve anaysis ofgbokoda siica sand Sieve numbe Amount of 50-g sampe etained on sieve Mutipie Poduct (g) (%) PAN :o \) Tota Aveage gain fineness: 'E 90 ' c % 60 V (\ 50 c 40,..," 30 E ; (\_!J ON,,' t' a Pecent tempeing wate in mouding sand Fig. 3. Vaiation of geen stength with cay and pecent of tempeing wate fo gbokoda-caybonded siica sand.

7 , ', SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND 171 pocedues and equipment ae given in the Foundy Sand Handbook (Ameican Foundymen Society, 1963). c! : t,, ' : t- Geen shea test The geen shea test was caied out on the univesa testing machine. This was achieved by changing the oading sufaces on the testing machine fom compession to shea pates. The specimen then uptued in shea aong its ongitudina axis when sufficienty oaded. Dy compession and shea tests These tests foowed the same pocedues as fo the geen compession and geen shea tests (Ameican F oundymen Society, ). The dy compession and shea tests wee caied out by dying the specimen in an oven at 100-OoC fo 2 h befoe testing. Since dy compession ;stength is usuay much geate than geen stength, highe oads wee equied on the univesa test machine. Shatte,index tests J; ' The shatte index tests wee caied out in a shatte index teste which is designed to dop a ammed specimen of moud sand fom a height of 1.85 m onto a stee anvi. To detemine the shatte index of the mouding sand, an A.F.S. standad test specimen was pepaed without stipping. The tube containing the ammed specimen was seated in position in the top casing beow the punge. The specimen was ejected fom its tubua moud by genty puing down the hande. The fagments wee coected in a 12.5-mm mesh sieve. Basicay, the shatte index vaue was used to detemine the toughness and coapsibiity of the mouding sand. Fo toughness detemination: Shatte index= X 100 Fo coapsibiity:. Shatte index W W 1. whee W is weight of specimen, and W 1 is weight of sand emaining on the s1eve.

8 172 C.A. LOTO AND H. ADEBAYO Additions of sodium cabonate Sodium cabonate (Na 2 C0 3 10H 2 0) was added to the dy siica sand/cay mixtue. The effects of this additive on the popeties of the synthetic mouding sand wee detemined by adding vaied amounts of it to the siica sandcay-wate system. 13% by dy weight of cay content and 3 wt% of tempeing wate wee used. The vaious tests eaie descibed in this wok wee caied out on the mouding sand with vaied amounts of added sodium cabonate. The amounts of sodium cabonate added to the dy mouding sand anged fom 0.5 to 3 wt%. c RESULTS AND DSCUSSON Sieve anaysis Tabe gives the esuts of sieve anaysis (A.F.S. standad) of the base siica sand used fo the synthetic mouding sand. Sieving is done to detemine the fineness numbe of the sand gains. The finess numbe is essentiay the aveage gain size of the siica sand and it coesponds to the sieve numbe whose openings coud just et pass a the sand gains if a wee of the same size. The second coumn of Tabe shows both the numbe of gams and pecentages of the 50-g sand sampe etained on each sieve. The pecentage etained on each sieve was mutipied by a facto given in coumn 3 of Tabe. The facto is the size of the peceding sieve. Coumn 4 gives the poduct obtained by mutipication of each pecentage etained on each sieve and the facto. The aveage gain fineness was detemined by dividing the tota sum of the afoementioned poducts by the tota pecentage of sand gains etained in the sieve set and pan. Tabe aso gives the aveage gain fineness. Sieve anaysis of the gbokoda white siica sand gave its aveage gain fineness numbe as 36 ( 36.40). The buk faction of the siica sand is epesented by the vaue in the midde potion oftabe. The sieve anaysis indicated that the gbokoda siica sand is a 4-sceen buk faction sand. A sceen faction is abitaiy defined as etaining moe than 10% of the sand; that is, it is one of fou succeeding sceens on which the buk of the sand is etained, each sceen having moe than 10% etained on it. n geen sand mouding, 3-, 4-, 5- and 6-sceen buk factions ae being commony used, but the 4-sceen type seems to be most vesatie ove a wide ange of conditions. The c oas faction of the sieve anaysis is composed of the tota pecentage of sand gains etained on the sceens, coase than those of the buk faction and in amounts of ess than 10%. The sieve anaysis esut (Tabe ) indi- : i '

9 \ SYNTHETC MOULDNG PROPERTES OF G BOKODA CLAY AND SL CA SAND 173 c ( cated that the tota coase faction by dy weight of gbokoda siica sand is 3.00 (2. 72 )%. The tota coase faction must be imited to amounts usuay ess than 4% fo sand of the 4-sceen distibution type. This imitation is necessay since an excess of coase patices contibutes to a poo casting suface finish. The fine faction of the sieve anaysis is composed of the tota pecentage of sand gains etained on sceens fine than those of the buk faction and in amounts of ess than 10%. The esut of the sieve anaysis showed that the tota fine faction (by weight) ofgbokoda siica sand is 2.38%. The tota fine faction must be imited in amount, usuay to ess than about 5% by weight fo a sand of the 4-sceen type. This imitation is necessay since an excess of fine patices causes baing to occu duing muing. Mouding popeties of test sampes without sodium cabonate additions Figs. 3-7 show the esuts of tests obtained fo the mouding popeties of the gbokoda-cay-bonded siica sand. The effect of vaious pecentages of cay and tempeing wate on the geen compession stength of the mouding sand is pesented in Fig. 3. The cuve fo the geen shea stengths aso foows the same tend. t is shown in Fig. 3 that fo each of the vaious pecentages of cay content, and with inceasing pecent of tempeing wate, geen compession stength inceased steadiy fom a eativey ow vaue to an optimum vaue. Afte eaching the optimum vaue, the stength deceased to a minimum vaue as the tempeing wate inceased. This phenomenon is appaenty due to the fact that inadequate wate fais to deveop adequate stength and that too much wate causes excessive pasticity and weakness in the cay-siica-wate bond stength. The poa chaacteistics of cay enabe it to adsob stong poa moecues such as wate, and the adsoption esuts in the fomation of a thin wate aye aound the cay patices, thus enhancing the cay's pasticity. Fig. 4 shows the infuence of the cay binde content on the stength of the synthetic mouding sand. The cuve of Fig. 4a was obtained by potting the peak (optimum) points of cuves in Fig. 3 against thei coesponding pecent cay content. This cuve was used to detemine the optimum cay content fo the mouding sand and it shows that the geen stength of the mouding sand inceased gaduay fom 3% cay content up to 7% cay content by weight, afte which the situation changes to a apid incease of the geen stength fom 7% cay up to 13% cay content by weight. Afte eaching 13% cay content, the incease in geen stength became eativey vey sma with futhe incease in cay content. Since the stength of the cay-siica-wate bond is paty a function of the numbe and aea of contacts of sand gains (Lawence, 1968; Dape, 1968), this behaviou was not unexpected. As the binde ayes become continuous and then pogessivey thicken, popotionatey ess

10 174 C.A. LOTO AND H. ADEBAYO a :z 120.s:: g. 100 "' 80 c:.q 60 "' c.. e 40 8 c QJ 20 QJ N e 25.s:: g. 20 "'.. QJ.s:: Pecent cay in mouding sand Pecent cay in mouding sand "' c: QJ en e :::>.E c b Fig. 4a. Vaiation of optimum geen compession stength with pecent cay content fo the gbokoda-cay-bonded siica sand. b. Vaiation of optimum geen shea stength with pecent cay content fo the gbokoda-caybonded siica sand. \. advantage is to be gained fom futhe binde aye addition (Finn, 1963 ). At a paticua cay content the geen sand is consideed to be cay-satuated. A cay-satuated geen sand is one containing a high enough pecentage of cay so that any futhe incease in cay content wi not cause an incease in maximum geen compession stength of the aggegate. Fig. 4 shows that the gbokoda-cay-bonded gbokoda siica sand, did not become cay satuated within the pecentage of cay content used in the expeiment. Thee was an incease in geen compession stength with incease in cay content up to the 21 wt% imit of cay used. This suggests that at east up to 21% cay can sti be used to give an incease in geen compession stength. A cay-satuated sand has about the same compessive stength as the cay by itsef. The specific pecentage of cay equied fo satuation depends on the puity and the type of cay, base sand, and on the additives. t is known that in most cases about 8 to 12 wt% of bentonites (eithe sodium o cacium bentonites) and about 2"0 to 25 wt% of fie cay ae sufficient to poduce a satuated mixtue with a sand fineness AFS numbe of 60 to 100 (Heine et a., 1977). The aveage fineness numbe fo gbokoda siica sand is detemined to be The effects of inceasing the pecentage of cay content on the dy stength L ;!

11 SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND :z 175 -""' c 100 "' 75 i:' :-;h: t en!th Pecent c ay in mouding sand Fig. S. Dy stength (compession and shea) at points of optimum geen compession stength vs. pecent cay content. of the mouding sand is shown in Fig. 5. The cuves wee obtained by potting the espective vaue of dy compession and shea stengths (obtained fo vaying pecentage of tempeing wate with maximum vaues of geen stength) against the coesponding pecentage of cay content. t can be seen fom Fig. 5 that both the dy compessive and the shea stengths incease gaduay with inceasing cay content fom 3 to 13% by weight. This is foowed by shap incease with futhe inceasing cay content. This tend wi be due to the attainment of an impoved binde distibution and highe buk densities. t coud aso be due to the effect of the suface tension of the wate suounding the cay and sand-cay patices and fiing the capiay intestices, paticuay intestices of the cay patices. The suface tension is caused by the suface ayes of wate acting on a stetched membane, focing the patices togethe. As the wate aye becomes thinne by dying, the foces hoding the patices togethe incease (Tayo et a., 1966). Fig. 6 shows the effects of a vaying pecentage of cay contents on the coapsibiity of the mouding sand, and it was obtained by potting the vaues of coapsibiity (obtained with vaious pecentages of tempeing wate that deveoped maximum geen compession stength) against pecentage of cay contents. t is aso shown in Fig. 6 that coapsibiity of the mouding sand deceases steadiy fom a maximum vaue at 3 wt% of cay to a eativey ow vaue at 11 wt% with inceasing cay content fom 11 to 15 wt% the decease in coapsibiity is sow and sma. Fig. 7 shows the effect of a changing am:ount of cay on the toughness of the mouding sand. The cuve shows that the toughness (of the synthetic moud-

12 ' 176 C.A. LOTO AND H. ADEBAYO 6 2 O_L Pecent cay in mouding sand Fig. 6. Coapsibiity at point of optimum geen compession stength vs. pecent cay content ;; 90 )-80 :a 70 QJ c: -5, 60 ::J 50 i\ "' 6j 10 o Pecent cay in mouding sand Fig. 7. Toughness at points of optimum geen compession stength vs. pecent cay content. ing sand) foows an inceasing tend as the cay content inceases. With a cay content between 3 and 19 wt% the incease in toughness gives an amost inea eationship. Figs. 6 and 7 togethe ae a measue of defomation o pasticity of a mouding sand. Defomation duing the geen compession test gives evidence of the "toughness" of a sand. t is detemined fom the decease in ength of the cyindica specimen duing the geen compession test and can be measued by means of a dia gauge attached to the geen sand testing head. The poduct of defomation and geen stength is used as an index of toughness (Beey, 1982). Mouding sand toughness is cacuated by dxsx 100, whee d=defomation (.un) and s=geen compession stength (kn/m).... 1

13 i f t! j! SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND 177 A ow toughness vaue indicates fiabiity in patten withdawa and subsequent handing opeations. Too high a vaue may indicate unsatisfactoy mouding quaities esuting fom excessive cay o wate content. Vaues of have been quoted by Davies ( 1950) as epesenting a moudabe ange. The gbokoda-cay-bonded gbokoda siica sand, with 13 wt% cay content and 3 wt% tempeing wate, gave a toughness vaue of 64, which fas within the moudabe ange. Effects of sodium cabonate additions The effects of sodium cabonate additions on the geen compession and shea stengths of the synthetic mouding sand ae pesented in Fig. 8. Both stengths inceased by addition of up to 0.5 wt% sodium cabonate. Beyond this 0.5 wt% the geen compession and shea stengths began to decease. The fa in both geen compession and shea stengths continued steadiy as the sodium cabonate content was futhe inceased. Fig. 9 shows the effects of sodium cabonate addition on the dy compession and shea stengths of the synthetic mouding sand. The dy compession stength inceased popotionay with inceasing sodium cabonate addition. The dy shea stength aso inceased steadiy with inceasing sodium cabonate addition but not popotionay. Fig. 1 0 shows the effects of sodium cabonate addition on the coapsibiity of the synthetic mouding sand. The coapsibiity deceased steadiy with sodium cabonate addition of up to 2.0 wt%. Beyond this 2% addition the coapsibiity became faiy constant. The effects of sodium cabonate addition on the toughness of the synthetic ( 'E g' 0 QJ 30 c OL {) {) 35 Pecent sodium cabonate added to mouding sand Fig. 8. Vaiation of geen stength with pecent sodium cabonate content fo the gbokodacay-bonded siica sand.

14 178 C.A. LOTO AND H. ADEBAYO '.: 350 z :;; D y Compession Dy Shea Pecent sodium cabonate added to mouding sand Fig. 9. Dy stength (compession and shea) vs. pecent sodium cabonate content fo the gbokoda-cay-bonded siica sand. 1-6 _1-4 -f 1-2.?:: O :is 08 "iii E" o t Pecent sand sodium cabonate added to mouding Fig. 10. Coapsibiity vs. pecent sodium cabonate content fo the gbokoda-cay-bonded siica sand. mouding sand is shown in Fig. 11. The toughness inceased steadiy with inceasing sodium cabonate addition of up to 2 wt%. The toughness became amost constant when the sodium cabonate addition futhe inceased beyond 2.0%. A the above esuts show, in genea, an impovement of the popeties of the synthetic mouding sand up to cetain amounts of sodium cabonate addition, except fo the dy compession stength, which inceased popotionay with inceasing sodium cabonate addition, the same as fo the dy shea stength, though this incease was not popotiona.

15 t SYNTHET C MOULDNG PROPERTES OF GBOKODA CLAY AN D SLCA SAN D 179 ' j j i i f i t 1 ( ( n ' ;; 70 )t :? 60 so ] O 0 O.S 10 S S Pecent sodium cabonate added to mouding sand Fig.. Toughness vs. pecent sodium cabonate content fo the gbokoda-cay-bonded siica sand. The addition of Na 2 C0 3 to the synthetic mouding sand is an activation pocess. t has been expained that by mass action the sodium dispaces the cacium (content of cay) which combines with the cabonate to fom CaC0 3 (Sandes and Doeman, 1967, 1968). n the base exchange chemisty the Na + is inceased and the Ca 2 + educed. The esutant CaC0 3 is amost insoube in wate and is not invoved futhe in the base exchange chemisty but is pesent as an accessoy minea (Sandes and Doeman, 1968, 1969), i.e., it pecipitates as a cacium sat (Finn, 1963 ). The natue of the pecipitate was not detemined. This teatment has ateed the stuctue of the cay minea and it has vaious effects on the popeties of the synthetic mouding sand. Fist, the adsoption ofna +by base exchange has made the cay moe akaine, inceasing its ph fom its oigina 4.2 to a basic condition (not measued) and thus enhancing optimum distibution of cay in the sand mixtue (Finn, 1963). The Na + gets adsobed to the boken bonds at the edge of kaoinite cysta ayes. A mechanism expaining how the adsoption makes the mixtue moe akaine (Finn, 1963) is that at ow ph the excess H + o othe ions ae bonded to the cay. Unde acid conditions (ow ph) such as with the cay used hee, the viscosity is high. This is because the attactive foces between the cay patice ae appaenty highe at a ow ph, thus eading to foccuation of the cay pateets (Finn, 1963 ). Optimum cay distibution in the sand mixtue wi enhance the impoved popeties of the geen and dy compessive stengths, geen and dy shea stengths, coapsibiity and toughness such as obtained by Na 2 C0 3 addition in this wok. gbokoda cay contains Na+ and Ca2+ as indicated by chemica anaysis. t aso contains some montmoionite mineas, though the minea content p 1 i

16 C.A. LOTO AND H. ADEBA YO 1'' seems to be dominated by kaoinite as indicated by X-ay diffaction anaysis (Loto and Omotosho, 1990). The esuts (Fig. 8) show that an addition of about 0.5 wt% ofna 2 C0 3 gave the gbokoda cay an optimum geen stength. This addition is substantia when compaed with the 0.17 wt% of the ion in the cay o the 0.02 wt% in about 13 wt% of the sand. A steady and continued fa in both geen compession and shea stengths with inceasing sodium cabonate content was obseved (Fig. 8) beyond the optimum vaue of 0.5% Na 2 C0 3 addition to the mouding sand. The eason fo this is difficut to expain. Howeve, it coud be attibuted to a eduction in pasticity o igidity of the cay esuting fom too much wate adsoption caused by the Na + exchange. Fee wate can be moe easiy adsobed when the weake monovaent Na + pedominates ove the divaent Ca 2 + cation (Sandes and Doeman, 1967 ). With inceasing Na 2 C0 3 addition, moe fee wate wi be adsobed, which beyond the optimum imit, that is beyond the iquid imit of the cay (Sandes and Doeman, 1967), coud cause the weakening of the bond stength. Liquid imit measues the wate-hoding capacity of a cay. The inea incease in dy compessive stength was not unexpected. The oosey bonded " mechanicay hed" wate has been eiminated and ony the tighty bonded wate in the cay- wate-siica bond emains. Unde basic conditions, Na + ions ae bonded to the cay; at ow ph vaues, the excess H+ ions ae bonded to the cay patices instead. The esidua bonding foces of the Na +-to-wate combination (fo the dy bonds) ae evidenty quite high. The optimum distibution of cay due to its basic natue by the addition ofna 2 C0 3 has an enomous effect on its dy compessive and shea stengths.. ] CONCLUSONS - ( 1) gbokoda siica sand is a 4-sceen buk faction sand. t possesses modeate amounts of coase and fine factions as is evident fom the esut of sieve anaysis of the sand. The coase faction is 2. 72% and fine faction is 2.38% by weight. The puity of the siica sand (:::::! 98% ) and its aveage fineness numbe of suggest that it coud be vey suitabe in situations whee maximum efactoiness is equied, fo exampe in stee mouding sands. ( 2 ) The gbokoda-cay-bonded gbokoda siica sand exhibits optimum geen compession and shea stengths at the addition of 1 3 wt% cay and 3 wt% tempeing wate. The dy compession and shea stengths vaues of the synthetic mouding sand ae aso easonaby good though eativey owe than the typica dy coin pession and shea stengths of typica geen sands (the westen and southen bentonites of the U.S.A.). ( 3 ) The cay-bonded siica sand with an optimum cay content at 3 wt% of tempeing wate exhibits a modeate toughness and coapsibiity vaues which fa within.the moudabe ange.

17 J \! f i i SYNTHETC MOULDNG PROPERTES OF GBOKODA CLAY AND SLCA SAND 181 ( 4) The geen compession and shea stengths of the synthetic mouding sand ae impoved by addition ofupto 0.5 wt% of sodium cabonate. ( 5) The dy compessive stengths of the synthetic mouding sand inceased popotionay with inceasing sodium cabonate addition, whie the dy shea stength aso impoves consideaby. ( 6) The toughness of the synthetic mouding sand is impoved by sodium cabonate addition, whie the coapsibiity is impaied. ( 7) gbokoda cay demonstates easonabe cation exchange with sodium ion in the activation teatment with sodium cabonate, as evidenced by the impoved popeties obtained. ACKNOWLEDGEMENTS!,',, t ] u ' i u ] ]1 J 1 J...J The authos acknowedge the co-opeation of the Depatment of Metaugica and Mateias Engineeing, Obafemi Awoowo Univesity, e-fe, Nigeia and the Depatment of Mechanica Engineeing, Univesity of Lagos, Nigeia, fo making avaiabe the eseach faciities used in this investigation. Pemission to use the SEM/EDS equipment fo the quaitative anaysis of the cay by the Depatment of Engineeing Metas, Chames Univesity of Technoogy, Gothenbug, Sweden, is aso acknowedged. REFERENCES Ameican Foundymen Society, Foundy Sand Handbook, 7th ed. Des Paines,. Beey, P.R., Foundy Technoogy. Buthewoth Scientific, London, 146 pp. Davies, W., Foundy Sand Conto. The United Stee Co. Ltd., Sheffied. Dape, A. B., Geen compession stength as a function of coating thickness and points of contact. AFS Tans., 76: Finn, R.A., Fundamentas of Meta Casting. Addison Wesey Pubishing Co. nc., Reading, Mass., pp Gim, R.E. and Cuthbet, F.L., The bonding action of cays. Cays in Geen Mouding Sands, inois State Geo. Suv. Rept., 102: Heine, R.W., Lope, C.R. and Rosentha, P.C., Pincipes of Meta Casting. TMH edition, New Dehi, 110 pp. Lawence, W.G., Factos infuencing mouding sand popeties. Foundy, pp (Oct ). Loto, C. A. and Omotosho, E.O., Anaysis and deveopment of gbokoda cay as a binde fo synthetic mouding sand. App. Cay Sci., 5: Sandes, C. A. and Doeman, R.L., The Duabiity of bonding cays, Pats, and. AFS Tans., 7.5: Sandes, C.A. and Doeman, R.L., Duabiity of bonding cays. Pat V, and: Duabiity of twenty-nine commecia cays. AFS Tans., 76: Sandes, C.A. and Doeman, R.L., Cay technoogy, duabiity of bonding cays, Pats V X. AFS Tans., 77: Schubet, C.E., Effects of gain size on physica popeties of synthetic mouding sands. Foundy, pp (Mach, 1958). Tayo, F.H., Feminas, M.C. and Wuff, J., Foundy Engineeing. Wiey, New Yok, N.Y.

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