Products

NAIGAI CERABEADS® 60

Features

  • The selected raw materials to make CERABEADS® artificial sand are fired at a high temperature, making the structure dense.
  • CERABEADS® artificial sand is made of mullite crystals with an extremely stable quality.
  • It is made by firing spherical granules, not by crushing.
  • CERABEADS® artificial sand has the following advantageous chemical and physical properties:
    • Uniform component composition
    • Stable grain size distribution and air permeability
    • High refractoriness (SK37, 1825°C)
    • High resistance to wear, crush and thermal shock
    • Little thermal expansion
    • Excellent fluidity and filling efficiency owing to being spherical

Features

  • As foundry sand
  • Sand for loop system
  • As spot sand, face sand for sand casting
  • Sand for applications where high accuracy in dimension and surface smoothness are required
  • As reusable lime sand
  • Sand for rapid prototyping and Additive Manufacturing (AM)
  • As setter for high-temperature furnaces
  • As media for fluidized bed
  • As ceramic filters
  • Others

Product lineup

NAIGAI CERABEADS® 60 #400

#400

NAIGAI CERABEADS® 60 #650

#650

NAIGAI CERABEADS® 60 #750

#750

NAIGAI CERABEADS® 60 #1450

#1450

Product information

Grain size composition and grain size distribution

Representative value
mesh 36 50 70 100 140 200 280 PAN AFS GFN
μm 425 300 212 150 106 75 53 -53
Product
No.		 #400 9.1 72.6 17.5 0.8         41.1
#500 4.1 37.8 28.6 25.0 4.2 0.3     52.7
#550 3.2 29.8 30.3 30.8 5.5 0.4     55.7
#650   3.5 39.2 48.3 8.4 0.6     64.0
#750   2.5 27.1 37.2 25.6 7.2 0.5   77.2
#850   2.5 22.4 29.9 30.2 12.4 2.5 0.2 86.1
#950   1.4 14.1 21.4 42.9 19.3 0.9   94.3
#1450       5.2 69.5 23.5 1.7   109.6
#1700         2.6 73.9 21.8 1.6 154.6

Comparison with other casting sands

  CERABEADS® Zircon Chromite Quartz sand
(Flattery sand)
Powder bulk density
(g/cm3)		 1.69 2.99 2.81 1.58
Refractoriness SK37
(1825 °C)		 SK37
(1825 °C)		 SK39
(1880 °C)		 SK33
(1730 °C)
Coefficient of thermal
expansion (%)
* At 1000 °C,
after 300 sec		 -0.03 0.18 0.26 1.50
Coefficient of heat transfer * R.T.
(W/(m·k))		 0.24 0.53 0.29 0.30
Specific heat * R.T.
(MJ/(m3·K))		 1.16 0.60 1.54 0.97
Main chemical components Al2O3 61 %
SiO2 36 %		 ZrO2 66 %
SiO2 32 %		 Cr2O3 45 %
Fe2O3 25 %
Al2O3 15 %
MgO 10 %		 ≧SiO2 99 %
(1) Powder bulk density As CERABEADS® artificial sand is about half as light as zircon and chromite, it can turn out about twice the number of molds per unit weight. It can also be handled very easily, saving labor and transfer power costs. However, attention should be given to the amount of binder addition.
(2) Refractoriness Having high refractoriness (SK37, 1825°C), CERABEADS® artificial sand can be used for casting various materials. There is also no need to use different sand type according to material.
(3) Coefficient of
thermal expansion		 Owing to little thermal expansion, CERABEADS® artificial sand is excellent in dimensional precision.
(4) Coefficient
of heat transfer		 As CERABEADS® artificial sand is smaller in thermal transfer compared with other sands, special attention and arrangements should be made when it is used in cases where a high coefficient of thermal transfer is required.
(5) Specific heat Although CERABEADS® artificial sand is higher in specific heat compared with other sands, it may be evaluated differently depending on the mold making method or casting method.
Regeneration test

Casting sand is regenerated and reused over and over by undergoing heating and cooling processes. We have looked into various differences in the crushability of casting sand through the crushability test (S-6) and variations in explosive thermal expansion through the repeated explosive thermal expansion test according to The Japan Foundry Society, Inc.

(1) Crushability test

This test shows clearly that CERABEADS® artificial sand has a higher resistance to crushability compared with other general casting sands. CERABEADS® artificial sand also demonstrated its excellence in resistance to wear, crush and thermal shock, while also showing a high yield ratio when it is used repeatedly as a casting sand.

≪Test method≫

1) Sample
The sand volume was adjusted to CERABEADS® 600g to make a test sample.
2) Method of heating to explosive heat temperature
The test sample adjusted to room-temperature was put into an electric furnace heated to 1300°C. After heating for an hour, the test sample was take out from the furnace quickly, and cooled to room temperature.
3) Crushing method
The test sample heated by explosive heat and cooled to room temperature was loaded into a magnetic ball mill (5L volume) together with 40 pcs of alumina balls of Ø20 mm each and crushed for 20 mins. After crushing, the grain size distribution was measured and the grain fineness number (AFS GFN) was obtained by calculation. The steps 2) and 3) were repeated 3 times to measure the crushability.
4) Crushability index calculation method
Crushability (%) = (AFS GFN after crushing / AFS GFN of base sand)×100

Crushability test result

(2) Repeated explosive thermal expansion test

The little thermal expansion of CERABEADS® artificial sand is evident in comparison with quartz sand.
When collected, regenerated and reused, CERABEADS® artificial sand little thermal expansion is maintained with practically no change even after repeated use. This indicates its stable quality to meet the requirements of strict dimensional precision.

Coefficient of thermal expansion

Click here for Loop System Application

If you have any questions or inquiries,
please contact the following

[CERABEADS® Sales Sec.]
12-8, Shiokusa-cho, Seto-shi, Aichi 489-0895, Japan
Tel: +81-561-21-3715  Fax: +81-561-21-4141

→For the inquiry form, click here.

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