Modeling of gas evolution during sand mold castings is one of the most important technical and environmental issues facing the metal casting industry. This article focuses on describing the capability of numerically predicting gas evolution for the furan binder/silica sand system. It illustrates numerical modeling to study the gas evolution from furan binder/silica sand mold aggregate for aluminum, cast iron, and steel alloy cast components. The article discusses simulation results and experimental validation for aluminum alloys, cast iron castings, and steel alloys, as well as a parametric study that investigated the effects of various variables. It concludes with information on the application of 3-D modeling methodology to investigate gas emissions in furan binder/silica sand castings for steel 4140 and aluminum A356 alloys.

This article reviews the basic types of mold aggregates and bonding methods for expendable molds and coremaking. It provides an overview of mold media and the basic types of sands and their properties. The most significant clays used in green sand operations, such as bentonites, are discussed. The article describes the methods of sand bonding with inorganic compounds. It provides a description of resin-bonded sand systems: no-bake binder systems, heat-cured binder systems, and cold box binder systems. The article concludes with a discussion on the media used for expendable molds, namely, ceramic shells and rammed graphite, for casting reactive metals such as titanium or zirconium.