Coal Dust for Ferrous Foundries and Green Sand Moulding

Coal dust is a vital component in ferrous foundries, particularly in green sand moulding processes. Its unique properties enhance casting quality, making it indispensable for producing high-integrity iron castings.

Role of Coal Dust in Green Sand Moulding

In green sand moulding, a mixture of sand, clay, water, and additives like coal dust forms the mould into which molten metal is poured. Coal dust serves several critical functions:

Surface Finish Enhancement: During casting, coal dust decomposes to produce a reducing atmosphere, preventing oxidation and ensuring a smooth, lustrous surface on the final product.
Defect Prevention: It minimises defects such as metal penetration and sand fusion by creating a protective barrier between the molten metal and the sand mould.
Mould Integrity: The addition of coal dust improves the mould’s strength and collapsibility, facilitating easier shakeout and reducing the likelihood of casting defects.

James Cumming & Sons’ Superior Coal Dust

James Cumming & Sons, an Australian family-owned company with over 115 years of expertise, specialises in manufacturing high-performance industrial coal dust tailored for iron foundries. Their product is distinguished by:

High Fixed Carbon Content
Low Sulphur Levels
Consistent Volatile Matter
Minimal Ash Content
Optimal Particle Sizing

These characteristics make their coal dust highly reliable and effective in enhancing casting quality.

To meet diverse operational needs, James Cumming & Sons offers flexible packaging solutions:

Bulk Bags: One metric tonne woven polypropylene bags for large-scale operations.
Pneumatic Tankers: Deliveries ranging from 8 to 40 metric tonnes for seamless integration into automated systems.
Smaller Sacks: 20 kg multiwall paper or woven polypropylene sacks, shrink-wrapped on pallets, suitable for smaller foundries or precise applications.

Custom packaging options are also available upon request to cater to specific requirements.

Green Sand-Casting Process Overview

Green sand casting is a widely used method in ferrous foundries due to its versatility and cost-effectiveness. The process involves creating a mould from a mixture of sand, clay, water, and additives like coal dust. Molten metal is then poured into the mould to form the desired casting. The presence of coal dust in the moulding sand plays a crucial role in preventing defects and ensuring a high-quality surface finish on the castings.

Incorporating high-quality coal dust into green sand moulding processes is essential for producing superior iron castings. James Cumming & Sons’ commitment to quality and their extensive experience make them a trusted supplier for foundries seeking to enhance their casting operations. Their superior coal dust product not only improves casting quality but also contributes to more efficient and reliable foundry processes.

For more information request a quote or visit our Industrial Coal Dust page.