Use of Mull to Energy- Stable power techniques for improving Green Sand System performance

Advisor: Dr Robert Voigt rcv2@psu.edu The production of green sand systems in iron foundries can be improved by controlling batch -to- batch mulling energy instead of controlling the mulling time. In this study, sand data from 4 foundries was evaluated before and after the transitioning from conventional mull-to-time (MTT) to mull-to-energy stable power mulling strategies (MTESP). Unnecessary over-mulling was eliminated with MTESP strategies; which significantly brought down the time by 75% thus increasing the mulling output. In the process, sand properties were not adversely impacted, However in terms of scrap, there was a 50% reduction in sand-related scrap after MTESP implementation.