Eliminating Flange-Casting Sand Fusion with Lustron HPL

Goal

Eliminate Sand Fusion on Heavy Flange Castings Across a Mixed Molding-Line Operation

Operating Disamatic high-pressure lines alongside ARPA conventional and resin-bonded hand molding, the foundry needed a solution that would perform consistently across its mixed process base while addressing fusion specifically on heavy flange components.

Challenge

• Sand fusion observed on the bottom/drag side of casting, particularly on heavy flange castings
• Excessive shot blasting time
• The need for a measurable reduction in sand-related rejections

Outcome

Lustron HPL, specified to VM 40±5%, Ash ≤7%, and 80% minimum passing at 0.212mm, was introduced:

• Foundry-stage rejection reduced by 22.18%
• Second-stage shot blasting eliminated entirely (100% reduction)
• Rework on flange-type casting components reduced by 100%
• Significant improvement in casting surface finish
• Faster casting turnaround and improved productivity
• Lower shot consumption, reducing electricity usage and improving energy efficiency
• Sand LOI increased from 4.8% to 5.2%, resulting in sand-fusion-free castings
• ₹5.5 lakh per month in savings generated across 640 MT of output