Sciknow Publications Ltd.

JMIR 2013, 1(1):27-32

Journal of Mechanics & Industry Research DOI: 10.12966/jmir.05.06.2013
©Attribution 3.0 Unported (CC BY 3.0)

Characteristics of Zircon Sand and the Effect on Foundry

Casting
L. O. Asuquo1, E N Bassey2 and A.P. Ihom1,*
1
Department of Mechanical Engineering, University of Uyo, Nigeria
2
Department of Chemical Engineering, Akwa Ibom State University, Nigeria

*Corresponding author (paulihom@yahoo.co.uk)

Abstract – The characteristics of zircon sand and how they affect foundry castings have been studied with respect to their
surface finish, mechanical properties and the microstructure. Local and imported zircon sand was employed in the work and
it was found that imported zircon sand showed better performance than the local zircon sand. From the study it was evident
that the local zircon sand could be upgraded to make it suitable for castings under extreme temperature conditions.
Keywords – Special Sands, Characteristics, Foundry, Casting, Zircon, Properties

with exceptional refractoriness, volume stability and me-

1. Introduction
Metal casting or founding is one of the most important
technologies used throughout the world in the engineering
industries on which the growth of any national economy
largely depends [3]. The production of sound, dimensio-
nally accurate castings is dependent on the quality charac-
teristics of the sand used as mould materials. Thus its se-
lection and testing constitute one of the steps in founding [6,
7, 8]. In the past few decades, designers and material en-
gineers have been faced with the problem of developing
engineering materials that can cope with the challenges
associated with tribology, resistance to wear, dimensional
stability etc. However on account of new and emerging
technological processes several versatile High Performance
Engineering (HPE) materials such as toughened zirconia,
silicon carbide and other advanced ceramics have been
developed [2]. These materials are currently playing posi-
tive and increasing role in the world industries.
Nigeria is endowed with enormous mineral raw mate-
rials that have a wide range of applications in the production
of these expensive HPE materials, but unfortunately they
are either neglected or under-tapped. One example of such
materials is the local zircon sand useful for the production
of high performance zirconia [2].
Zircon sand occurs in many parts of Nigeria such as
Kano State and Plateau State predominantly in Udegi area
where it is associated with alluvial tin deposits. The zircon
sand is produced as a bye- product during tin mining. It is
from the natural zircon sand that the pure oxide zirconia
(ZrO2) is obtained. Zirconia may further be processed with
addition of alumina to a toughened zirconia which
represents the high performance engineering material.
It is also well known that the manufacture of very heavy
castings requires service conditions which call for materials
chanical strength. Although silica sand is the most univer-
sally available material suitable for foundry mould, other
refractory materials are known to be better suited to extreme
conditions.
In this respect zircon sand has been found to be the most
notable of the materials with high refractoriness, free from
sudden volume changes unlike the case of silica which
undergoes α-β quartz phase transformation at elevated
temperature [4]. Zircon sand is also suitable for resistance
to slag reaction in the casting of high manganese steels.
Other qualities include good heat conduction, high strength
and not easily welded to casting surface.
In this paper, the utilization of zircon sand (local and
imported) as mould materials in foundry casting is reported.
The main focus of the work is to study how the characte-
ristics of the sand as mould materials affect the quality of
the cast products.
2. Materials and Methods
2.1. Sample Collection
The sand samples used for this research work were obtained
from Idah in Kogi State, Nigeria. The local zircon sand was
from Associated Tin Mining (ATMN), Jos while the im-
ported zircon sand was from Australia.
2.2. Sieve Analysis
200 grams of sand sample was weighed out from a stock
spread in a thin layer and heated between 105 – 110 0C for
one hour. The sample was then placed in the top bowl of a
series of sieves with apertures in ascending order of fine-
ness down to the collection pan at the bottom. The sand was
screened on a sieve shaker where shaking proceeded for 15
minutes. Thereafter the zircon sand grains retained on each
28 Journal of Mechanics & Industry Research (2013) 27-32

sieve and the collection pan were weighed and arranged
against their respective sieve mesh number and converted to
the nominal aperture size in micro meter (µm)[13].
2.3. Sintering Point
The test material was poured into a combustion boat of
80mm in length and 12mm width. The combustion boat was
introduced carefully into the already heated sintering fur-
nace to avoid its bursting. Several combustion boats were
filled with the sand samples and the first test started at about
115OC. The test material was exposed to the first chosen
temperature for 3 minutes. After the removal of this sample
from the sintering furnace, it was left to cool and then de-
termined under the microscope whether the temperature had
caused changes on the test materials. By slightly increasing
the temperature by 50 OC, it was easy to determine at what
temperature the sticking together, sintering and glazing
began.
2.4. Permeability Test
The permeability was determined by measuring the rate of
air flow through a compacted specimen under standard
conditions. The standard test specimens for permeability
were transferred immediately to the electric permmeter
made by Ridsdale and Co. Ltd with serial No. 872 for the
determination of the permeability of the sand.
The specimens were mounted on the device, while still
inside the specimen tube. The machine was switched on and
the test lever adjusted to test. The result was displayed on
the dial of the machine.
2.5. Compression Test
The sand sample weighing 2000 grams was thoroughly
mixed with water, bentonite and swelling binder for a total
time of 8 minutes according to the scheme in Table1.

Table 1. Test Mixture for Local and Imported Zircon Sand

Components Percent, % Measure Mixing Nos Mixing Time

Zircon Sand 100 2000g 1

1+2 (2mins)
Bentonite 3.0 60g 3 1+2+3 (1min)
Swelling Binder 0.8 16g 4 1+2+3+4 (5mins)
Total = 8mins
Water 2.3 46ml 2

Using standard rammer, the mixture was compacted to a two sand samples using Monsanto tensometer. The standard
bulk density similar to that encountered in a well rammed shapes were obtained from lathe machine based on standard
mould. The test sample was then removed from the ramming procedures which were strictly followed.
tube and put in between the compression inserts of a uni-
versal strength machine shown in Figure 1. Therefore, by
turning the hand wheel a load was applied to the specimen
until fracture occurred. The compression strength was fi-
nally shown by the maximum indicator pointer. The test was
carried out immediately as green, after 3 hours, 5 hours and
24 hours for 3 times each and the average value of each was
taken.
The surface of the entire rod specimen cast from the sand
sample was prepared metallographically to 600 grit and
slightly polished. Having assembled the compression at-
tachment in the machine and one compression die and the
Brinell Ball bolster inserted and then the mercury level
adjusted to zero, the polished surface was placed against the
Brinell ball and the load applied with the quick-acting han-
dle. The handle was turned until the mercury reached 750kg
graduation and kept up for 5 seconds. Having obtained the
desired impression, the specimen was moved from the ma-
chine and the diameter of the impression measured with the
Brinell reading microscope with the corresponding Brinell
Figure1.Schematic Diagram of Universal Strength
Machine
hardness number noted.
Note: 1.Compression Insert 2.Main Piston 3.Low Pressure Gauge
4.Pressure Piston 5.Hand Wheel
2.6. Tensile Test
Tensile tests were carried out using the rods cast from the
 L. O. Asuquo et al.: Characteristics of Zircon Sand and the Effect on Foundry Casting 29

Variable
100
%(Local Zircon)
% (Imported Zircon)

80

Percent Pass (%)

60

40

20

0.0 0.1 0.2 0.3 0.4 0.5

Sieve Size, mm

Figure 2. Matching Grain Size Distribution of Local and Imported Zircon Sand
zircon sand. The results of the comparative physi-
3. Results of Tests co-chemical characteristics of the local and imported zircon
sand are shown in Table 3. In Tables 4 and 5 are shown the
Table 2 gives the grain size distribution of the local and results for compression test for the sand moulds while Table
imported zircon sand while Figure 2 shows a match be- 6 gives the results of the mechanical tests.
tween the grain size distribution of the local and imported
Table 2. Screen Analysis showing Grain Size Distribution of Local and Imported Zircon Sand

Sieve Size, mm Local Zircon, % Imported Zircon, %

Retained Pass Retained Pass

0.71 - - 0.005 99.71

0.50 0.06 100 0.10 99.705

0.355 1.91 99.95 0.67 99.605

0.250 35.14 98.04 27.625 98.935

0.180 42.09 62.90 58.135 71.31

0.125 16.82 20.81 12.59 13.175

0.090 3.37 3.99 0.515 0.585

0.063 0.61 0.62 0.07 0.07

Table 3. Comparative Analysis of Physico – Chemical Properties of Local and Imported Zircon Sand

Physico-Chemical Properties Local Zircon Imported Zircon

ZrO2 50.7 % 64.4 %

SiO2 25.4 % 31.4 %

30 Journal of Mechanics & Industry Research (2013) 27-32

Al2O3 8.2 % 3.2 % *

LOI 9.22 % 1.83 %

Sintering Point 1350 oC 1550 oC

Sticking Temperature 1200-1250 oC 12 50-1300 oC

Particle Size Distribution >90% 0.240 - 0.500 mm 0.245 – 0.500 mm

Average grain Size 0.165 mm 0.170mm

ZrO2 : SiO2 Ratio 2.0 :1 2.05 :1

*Al2O3+ Ti O2

Table 4. Compression Test Result for Local Zircon Sand (Permeability = 77.1)
Compression Strength (N/cm2)

Immediately After 3 Hrs After 5 Hrs After 24 Hrs

8.6 20.2 21.5 29.3

9.1 19.6 20.6 30.0

8.9 19.4 21.0 31.2

Average Value 8.6 19.73 21 30.16

(N/cm2)

Table 5. Compression Test Result for Imported Zircon Sand (Permeability =83.5)
Compression Strength (N/cm2)

Immediately After 3 Hrs After 5 Hrs After 24 Hrs

10.2 21.2 23.1 32.0

9.8 20.4 20.9 32.0

9.2 20.8 21.8 32.2

Average Value 10.0 21.0 21.6 32.0

(N/cm2)

Table 6 . Results of Mechanical Tests on Cast Materials

Zircon Sand Type Hardness Test (BHN) Tensile Stress (N/mm) Percent Elongation (%)

Local 159.17 347.13 0.15

Imported 167.55 509.55 8

surface finish of the casting. In Table 2 which gives the

4. Discussion of Results sieve analysis of the sand, it is seen that the grain size dis-
tribution of both local and imported sand range from
4.1. Grain Size Distribution and Chemical Characteris-
0.063mm – 0.50mm. The matching of the sieve seizes of the
tics of Zircon Sand
two sands in Figure 2, shows some similarity in the shape of
The grain size and its distribution of the zircon sand play a
the graphs but with the sieves of imported sand falling on a
significant role in determining the quality of the mould
more narrow range of between 0.1mm and 0.15mm than that
mixture especially with respect to permeability and the
 L. O. Asuquo et al.: Characteristics of Zircon Sand and the Effect on Foundry Casting
of the local sand at between 0.1 and 0.25mm.
As may be observed from Table2, it is found that the
average grain size of the two grades of the sand are almost
the same at 0.165mm for local sand and 0.175mm for im-
ported sand.
Further observation of the grain size distribution in Ta-
ble 2 shows that the range below 0.1mm is 4.61% in the
local zircon and o.66% for the imported zircon sand indi-
cating higher fines content in the local zircon sand than in
the imported zircon. The higher fines level must have been
responsible for the lower permeability of 77.1 as against
83.5 for the imported zircon sand.
Also the percentage of the size range between 0.1mm –
0.25mm is 94.05% for the local zircon sand and 98.35% for
the imported zircon sand. It is therefore not surprising that
the zirconia content in the imported zircon sand is 64.4%
while that in the local zircon sand is lower at 50.7%. These
tend to support some observations in an earlier study [12]
where >60% of zirconia was found in the size range of
0.1mm – 0.25mm of zircon sand and that as the percentage
of < 0.1mm grain size increased so did the content of zir-
conia decrease.
From the various tests carried out in this study it was
found that the above stated grain-size distribution and the
chemical characteristics had a great level of influence on the
performance of the zircon sand
4.2. Sintering Point
4.2.1. Effect of Zirconia Content
The zirconia content of the imported zircon sand was found
as 64.4% as against 50.7% for the local zircon sand while
the corresponding sintering points were 1550 oC and 1350
o
C respectively. These results show that the higher zirconia
content in the imported zircon sand must have impacted
positively on its refractoriness as represented by the sinter-
ing point.
4.2.2. Effect of Silica Content
From the comparative chemical composition of the two
grades of zircon sand in Table 3, it may be seen that the
silica (SiO2) contents are 25.4 % and 31.4 % for the local
and the imported zircon sand respectively. As was observed
in some studies [1,5] increased level of silica in the zircon
sand results in the formation of low melting fluxes which
tend to lower the sintering point of the mould material. From
this stand point it would have been expected that higher
silica content in the imported zircon sand would give rise to
a lower sintering point than that of the local zircon sand. As
shown from the results above that was not so. However it is
understood that zircon sand with a satisfactory level of free
31
silica is a measure zirconia to silica in the zircon sand which
should not be < 2 .0 : 1.0 [12]. In this work this ratio was
found as 2.0 : 1.0 for local zircon sand and about 2.0 : 1.1 for
the imported zircon sand. Correspondingly, as seen in Table
3, the sticking temperature range was also found to be
slightly higher for imported zircon sand at 1250-1300 OC as
against 1200 - 1250OC for the local sand.
4.3. Permeability
The results of the permeability test for the two zircon sand
shown in Table 4 give the values as 77.1 and 83.5 for the
local and imported zircon sand respectively. Although when
compared with published standards [9], the performance
was satisfactory for grey iron castings yet it was evident that
the local zircon sand had a greater tendency for gas pene-
tration defects than the imported zircon sand.
4.4. Green Compressive Strength
The compression test results given in Tables 4 and 5 for the
two sand samples showed that the compression strengths
increased with time. For the local zircon sand, the average
green compression strength varied from 8.6 N/cm2 (imme-
diately after sample preparation) to 30.16 N/cm2 (after
24hrs). The imported zircon sand gave corresponding fig-
ures of 10 N/cm2 to 32 N/cm2, which were slightly higher.
4.5. Surface Finish
The effect of the zircon sand on the surface finish was eva-
luated using a flexowell bearing cover casting. The result
showed that some defects were observed with the local
zircon sand arising from erosion of some mould materials
caused by metal stream and adhesion of a crust of sand unto
the surface of the casting. Unlike the case of the local zircon
sand, the surface of the casting using the imported zircon
sand was smooth.
4.6. Mechanical Properties
The mechanical properties of the cast materials were tested
on basis of their ability to carry loads (a measure of hardness
test) and withstand compressive forces (a measure of tensile
stress). According to the results of the tests shown in Table 6,
the mechanical properties of the casing from imported zir-
con sand are better than those from the local zircon sand.
From the Table 6, the comparative values hardness, tensile
stress and percent elongation are 159.17BHN, 347.13
N/mm2 and 0.15% respectively for the casting from local
zircon sand mould. For the casting from imported zircon
sand mould the respective values are 167.55, 509.55 and 8%.
The lower mechanical properties shown by the products
from local zircon sand could be attributed weaknesses
caused by some defects such as blow holes present in the
32 Journal of Mechanics & Industry Research (2013) 27-32
casting.
4.7. Micro-Structures
In the micrographs shown in Figures 3 and 4 there is evi-
dence of different levels of carbide precipitation at the grain
boundaries occasioned by the rate of cooling within the
mould. The heat conduction was believed to be influenced
basically by the content of zirconia in the zircon sand. In the
micrograph of the casting from local zircon sand mould in
Figure 3, it was noticed that on account of low heat con-
duction only a little dispersion of carbide within the grain
occurred but there was much of somewhat delayed precipi-
tation and solidification at the grain boundaries. However
with respect to the casting from imported zircon sand in
Figure 4, due to a faster rate of heat conduction within the
mould, the carbide in the metal had little time to precipitate
and so remained in solid solution during solidification. This
resulted in finer grain structure when compared with mi-
crograph in Figure 3.
Figure 3. Micrograph of Local Zircon Sand ×100
Figure 4. Micrograph of Imported Zircon Sand ×100
5. Conclusion and Recommendation
From the study, the effect of the characteristics of zircon
sand on foundry castings using local and imported zircon
sand was established. It was found that imported zircon sand
showed better performance than the local zircon sand and
this was attributed to the higher zirconia content in the im-
ported zircon sand as well as the lower content of fines i.e.
below 0.10mm grain size in it. It was therefore considered
that for an improved performance of the local zircon sand it
might be inexpensively beneficiated to limit the grain size to
between 0.100 mm and 0.215 mm. This would be in line
with the results of earlier studies[10, 11 ,12] which showed
the positive effect of analysis and of grain size restriction of
sand on the quality of steel castings.
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