Moulding sand, also known as foundry sand, is a type of sand used to create moulds for metal casting. It is composed mainly of silica sand along with water and clay as binders. Moulding sand comes in different varieties depending on its composition and properties, including green sand, dry sand, loam sand, and others used for specific purposes like facing, backing, or creating cores. The key properties moulding sand requires are porosity to allow gas escape, adhesiveness, collapsibility after solidification, flowability to take the mould shape, sufficient refractoriness to withstand heat without melting, and cohesiveness for the sand particles to stick together.

1. What is Moulding sand?
Moulding sand, also known as foundries sand, is a kind of sand that is widely
used to manufacture all sorts of moulds regardless of whether they are
employed for producing casting of ferrous or nonferrous metals. Although silica
sand of superior grade is also mined, the natural sand found on the banks and
beds of rivers provides a greater source.
Silica sand is utilized in the majority of sand casting procedures. Because of the
simplicity of the materials employed, sand casting was one of the earliest kinds
of casting undertaken. Because of its simplicity, it is still one of the most
affordable metal casting procedures. A combination of water and clay holds the
sand required to make a mould for a casting procedure. Engineers frequently
compress, heat, and damp moulding sands to produce a particular shape. A
typical blend maybe 89 percent sand. 4 percent water, and 7 percent clay.

2. Types of Moulding Sand
There are various types of moulding sand depending upon the chemical
composition of the sand. The main moulding material in the foundry shop is
sand. It can withstand hot molten metal. Moulding sand does not chemically
react with the moulding sand. This analysis specifically covered the main
varieties of moulding sands and their qualities. The different varieties of
moulding sands are as follows:
Green Sand
Dry Sand
Loam Sand
Facing Sand
Backing Sand
Parting Sand
Core Sand
System Sand

3. Green Sand
Moulding sand or sandstone that is green
in colour is known as green sand. It
contains silica sand, 18 to 30 per cent clay,
and 6 to 8 per cent water overall. It is
porous, light, and soft, and the binding
between the green sand grains is provided
by clay and water. When pressed by hand,
it feels slightly moist in green sand. Under
pressure, it can retain its shape and
impression. The green sand is inexpensive
and easily accessible. This moulding sand
is used to create a mould that is known as
a green sand mould. Castings made of
ferrous and non-ferrous metals are
frequently produced using it.

4. Dry Sand
The kind of green sand that has removed
moisture is dry sand. In a good oven, the
mould created from the green sand is baked or
dried to create dry sand. Clay and silica make
about 15% to 20% of the dry sand's
composition. This Moulding sand is stronger,
more thermally stable, and more rigid.

5. Loam Sand
Loam sand is clay-rich and dries hard. This
is specifically used for moulding loam. For
large castings like bells, rollers, and
pulleys, typically. It has silica, graphite,
water, clay, fireclay, and gainster in it.
Loams are sandy, wet, and readily absorb
water. The texture and richness of loam
soil make it easier to work across a large
area.
Facing Sand
Sand that forms the mould's face is
referred to as facing sand. This sand is
known as "facing sand" because
manufacturers primarily utilize it to make
the face upon which they pour molten
metal. Sea coal makes about 5% of the
facing sand, and iron makes up 25%. It is
positioned as the pattern's next surface to
contact the hot, molten metal.

6. Backing Sand
The Backing sand, also known as the floor
sand, supports the face sand. It is ancient
and widely used moulding sand that is
used for the backing. Due to the addition of
coal dust and burning from coming into
touch with molten metal, it is occasionally
referred to as black sand.
Parting Sand
To create a non-sticky pattern, parting sand
(dry sand without the binder) is used. Pure
silica makes up parting sand. The parting
mould is created using parting sand. Often,
the pattern is taken out of the mould. The
mould is then used to adhere. Therefore,
since the mould does not stick, parting
sand is utilized. Such parting sand is used
to sprinkle on the mould before connecting
it to the pattern. Parting sand is sprinkled
over the drag, cope surface, and cheek to
prevent sticking.

7. Core Sand
The sand used to create cores is known as
core sand. Since it contains both silica
sand and core oil, it is also known as oil
sand. Linseed oil, resin, light mineral oil,
and other binders are all included in core
oil. Mixing pitch, wheat, and water can
make large cores economically.
System Sand
The entire flask is filled with system sand in
a Mechanical casting where machine
moulding is used. This sand mould has a
high level of strength, permeability, and
refractivity.

8. Properties of Moulding Sand
Moulding sand is used in the foundry
industry for mould preparation during metal
casting. The properties of the moulding
sand improve the casting metal's quality.
When adequate sand is used, casting
faults that may occur during the mould
preparation and casting process is
considerably reduced. Here, we will go
over all of the properties that moulding
sand must have to prepare an effective
mould cavity.
•Porosity
•Adhesiveness
•Collapsibility
•Flowability
•Refractoriness
•Cohesiveness
Porosity

9. Porosity
Porosity, often known as permeability, is the
most important characteristic of moulding
sand. It refers to the moulding sand's capacity
to enable gases to pass through. During the
pouring of molten metal into the sand hole,
gases and steam are produced. This property is
affected not only by the form and size of the
sand particles but also by the amount of clay,
binding substance, and moisture in the
combination.
Adhesiveness
The ability of sand particles to adhere to
another body is called adhesiveness. Sand's
adhesiveness causes sand particles to adhere
to the sides of the moulding box. Sand
adhesion allows for properly lifting the cope
together with the sand.

10. Collapsibility
Collapsibility refers to the capacity of the
moulding sand to collapse after the molten
metal has solidified. When the casting is
withdrawn from the mould, it should
disintegrate into small particles of moulding
sand with minimal force.
Flowability
Flowability or plasticity is the ability of sand
to adapt to the moulding process by
flowing all around the pattern and taking
the right mould shape when rammed.
Moulding sand must have good plasticity to
have a good impression of the pattern in
the mould. Fine-grained sand is generally
more plastic.

11. Refractoriness
The moulding sand's capacity to survive
the molten metal's high temperature
without melting into it is referred to as
refractoriness. The moulding sand must
have sufficient refractoriness to produce a
high-quality, defect-free casting. Sand with
low refractoriness melts and fuses in the
casting, lowering the quality of the cast
metal. The refractoriness of sand is a
measure of its sinter point, not its melting
point.
Cohesiveness
Cohesiveness refers to the capacity of
sand particles to cling together. The sand's
strength is determined by how cohesive
the sand particles are. The sand should be
strong enough to hold its shape throughout
carrying, twisting, closing, and pouring. If it
is not of sufficient strength, it will be unable
to keep its shape, and the mould may be
damaged during the pouring of molten
metal.