396 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
© P. PUSPITASARI, J.W. DIKA, 2019
https://doi.org/10.15407/ufm.20.03.396
P. PUSPITASARI and J.W. DIKA
Mechanical Engineering Department, State University of Malang, 
5 Semarang Str., 65145 Malang, East Java, Indonesia
CASTING QUALITY ENHANCEMENT 
USING NEW BINDERS ON SAND CASTING 
AND HIGH-PRESSURE RHEO-DIE CASTING
Casting quality is a perfection factor for measuring the success of the metal casting. 
One of efforts to obtain high-quality casting product is identifying the quality of 
sand moulding used. Identification of the sand-moulding quality is defined by the 
hardness, shear strength, tensile, and permeability. This article reviews the expla-
nations of the strength of sand moulding with composition variation of binder type: 
(1) sand moulding, bentonite, fly ash, and water; (2) sand of mount Kelud eruption, 
bentonite, and water; (3) sand of mount Kelud eruption, Sidoarjo mud, and water; 
(4) sand of mount Kelud eruption, Portland cement, and water; (5) sand moulding, 
volcanic ash, and water; (6) green sand, bentonite, fly ash, and water; (7) sand of 
Malang, bentonite, tapioca flour, and sago flour; (8) sand moulding, bentonite, 
Portland cement, and water. High-pressure rheo-die casting commonly known in the 
literature as rheo-high-pressure die casting (rheo-HPDC) is a novel casting tech-
nique in producing good-quality cast products. Escalating market demand drives the 
development of new technology, with which casts with excellent mechanical proper-
ties, good microstructure, and minor casting defects can be produced. As an ad-
vanced version of HPDC, rheo-HPDC can be regarded as a smart manufacture tech-
nique, since it integrates the semi-solid metal technology that considers the proper 
preparation of slurry. The slurry-making process has been continuously developed, 
and the latest preparation method is the self-inoculation method. This review article 
discusses the procedure, mechanism, development, and product quality of sand cast-
ing with new binders as well as rheo-HPDC technique.Keywords: diffusion, marten-
site, austenite, radioisotope, dislocation, stack-ing fault defect.
Keywords: casting quality, moulding sand, binders, rheo-HPDC, smart mechanism, 
aluminium.
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 397
1. Introduction
The ever-increasing amount of engineering process in the field of tech-
nology is primarily an effort to optimise the use of natural resources 
effectively and efficiently for the benefit of human life [1]. Casting is 
an engineering process in the branch of production engineering, in 
which Indonesia requires to redouble more serious efforts to improve its 
product quality, production system, and production cost, hence more 
internationally competitive cast products. Training programmes are 
highly suggested by experts in casting, foundry operations in Indonesia, 
and industrial development [2]. Of all casting techniques, sand casting, 
as a casting process that utilises sand moulds, is the oldest known in 
existence. The sand casting process involves designing pattern, making 
moulding sand, forming a mould cavity, melting metals, pouring molten 
metal into the mould, breaking up the mould and removing the casting, 
and cleaning the casting [3].
Sand and metal are two types of mould media commonly used in 
casting processes. Due to its superior heat dissipation capability, a met-
al mould can rapidly solidify cast alloys and thereby enhance dendritic 
cells. Cast components produced in metal moulds typically exhibit high-
er ductility than in sand moulds [4]. Despite many new advanced tech-
nologies for metal casting, sand casting remains the most widely used 
technique due to its low-cost feedstock, varying sizes and compositions, 
and reusable moulding sand [5]. In fact, sand casting is by far the oldest 
and most common manufacturing method [6, 7] for over 70% of all 
castings [8–10]. The two statements above suggest that good castings 
can be manufactured through metal casting. This technique is preferred 
because mass production of castings can be done over a short span of 
time, hence lower production costs than the sand casting process.
In sand casting, mould making is a critical stage, which must be 
performed for each casting. The composition of moulding materials af-
fects the bonding strength of the sand. A sand mould is formed by com-
pacting the moulding sand. The types of sand commonly used for mould-
ing are natural sand and artificial sand-clay mixtures [11]. Some 
determining factors in producing good-quality cast products are raw 
materials, material composition, moulding sand quality, smelting sys-
tem, pouring system, and casting finishing process [3].
Several primary requirements of moulding sand are formability, 
easy to manufacture and capable of holding the mould shape once mol-
ten metal is poured into the mould cavity, permeability, determining 
how much gas in the mould or molten metal is able to pass through dur-
ing casting, and grain-size distribution, which affects formability and 
permeability [12]. Moreover, moulding sand should have thermal stabil-
ity (i.e. the ability to withstand heat damage such as cracking and dis-
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
398 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
P. Puspitasari and J.W. Dika
tortion), reusability (i.e. the ability to be recycled for future use for 
environmental and economic significance) [8], and collapsibility (i.e. the 
ability to compress or collapse during casting solidification).
Adding special binders is one way to improve the bonding capacity 
of moulding sand. Several materials that can be used as binders are 
water-glass, resin, cement, flour, and others; these binding materials 
can hold shape and certainly affect the quality of cast products [11]. 
The most widely used binding material for sand casting is bentonite [13, 
14]. Bentonite is preferable because it produces excellent binding 
strength and becomes plastic when wet and hard when dry [15]. Ben-
tonite is a kind of clay produced from the alteration of volcanic ash, 
containing primarily montmorillonite. Bentonite consists of plate-sili-
cate minerals and is categorised into a group of minerals called alumi-
nosilicates [16].
A feasible core binder is the key element to optimal sand with high 
strength and intended performance, and thus, it has a major impact on 
production technology and casting production costs [17–18]. The devel-
opment of binding materials over time is illustrated in Fig. 1.
2. Properties of Sand Moulds with Fly Ash
High-quality sand moulds in the casting industry are those composed of 
sand containing high silica content. Silica is heat-resistant, absorbent, 
thermally conductive, and sufficiently permeable to allow the escape of 
gas that forms during casting and, consequently, prevent casting de-
fects [19]. The greatest difficulty in using fly ash in casting is its dif-
ferent composition since it is produced from the burning of coal. Thus, 
its physical properties and chemical composition are also determined by 
the criteria of the combustion process [20]. A study on the use of fly ash 
as a binder in sand mould production.
Fig. 1. The sequence of research development of binder compositions for sand mould-
ing to optimise casting quality (2009–2017)
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
Figure 2 shows the research scheme to determine the compressive 
test with a variety of binder compositions. The binder uses bentonite 
and fly ash. The research found that the addition of fly ash in the 
moulding sand mixture had an effect on the compressive strength of the 
sand mould [21].
Figure 3 shows among the other three compositions, the fourth 
moulding sand composition had the lowest compressive strength. The 
addition of 2% fly ash in the moulding sand mixture increased the 
compressive strength by 11.4% compared to the one without fly ash; it 
was due to the occurrence of a complete pozzolanic reaction [21]. The 
pozzolanic reaction is a reaction between calcium and silicates or alu-
minates to form cementing agents (CaSiO2H2O and CaAl2O3H2O), as 
shown below:
CaO + H2O → Ca (OH)2;
Ca (OH)2 → Ca2+ + 2 (OH)−;
Ca2+ + 2 (OH)− + SiO2 → CaSiO2H2O;
Ca2+ + 2 (OH)− + Al2O3 → CaAl2O3H2O.
Fig. 2. The study sche-
me of moulding sand 
compositions with fly 
ash [21]
Fig. 3. The compressive strength 
graph for moulding sand added 
with fly ash [21]
400 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
P. Puspitasari and J.W. Dika
The addition of 2% fly ash to the mould composition increased the 
hardness of the sand mould by 82.6%. A pozzolanic reaction occurred 
completely in the specimen, in which the cementing agents hardened 
and bound sand grains. The strong bond shortened the distances be-
tween grains so that the sand mould got solid.
3. Properties of Sand Moulds 
with Bentonite, Sidoarjo Mud, Portland Cement
The study of combining bentonite, Sidoarjo mud, and Portland cement 
as a binding agent for sand moulding is described as follows.
Figure 4 shows the research procedure for optimising casting qual-
ity through the addition of different binders, i.e. bentonite, Sidoarjo 
mud, and Portland cement. Compressive, shear, and tensile tests were 
carried out on sand moulds both in dry and wet conditions. These re-
searches found that the addition of bentonite in moulding sand mixture 
with dry condition had an effect on the compressive strength and shear 
strength of the sand mould, while the addition of Sidoarjo mud had an 
effect on the tensile strength [22].
As shown in Fig. 5, the mixture of moulding sand and bentonite 
in dry condition had the highest compressive strength, followed by the 
moulding sand-Sidoarjo mud mixture, while the moulding sand added 
with Portland cement in wet state had the lowest compressive 
strength [22].
Fig. 4. The study scheme of moulding sand compositions with bentonite, Sidoarjo 
mud, and Portland cement [22]
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
According to Fig. 6, the mixture of moulding sand and bentonite in 
dry condition had the highest shear strength compared to those with the 
other binders under study (Sidoarjo mud and Portland cement), while 
the moulding sand-Portland cement mixture in wet condition had the 
lowest shear strength [22].
Fig. 7. Tensile strength (N/cm2) 
comparison of moulding sand spe-
cimens mixed with bentonite, Si-
do arjo mud, and Portland cement 
[22]
Fig. 6. Shear strength (N/cm2) 
comparison of moulding sand spe-
cimens mixed with bentonite, Si-
doa rjo mud, and Portland cement 
[22]
Fig. 5. Compressive strength (N/
cm2) comparison of moulding sand 
specimens mixed with bentonite, 
Sidoarjo mud, and Portland ce-
ment [22]
402 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
P. Puspitasari and J.W. Dika
As shown in Fig. 7, the results of the tensile testing showed that the 
mixture of moulding sand and Sidoarjo mud used in dry condition had 
the highest tensile strength, followed by that with bentonite in dry con-
dition and the lowest tensile strength was found in the moulding sand 
mixed with the Sidoarjo mud in wet condition [22].
Under wet condition, the moulding sand added with 15% bentonite 
had the highest compressive strength of 8.7 N/cm2. The mixture with 
the highest shear strength was that with moulding sand and 15% ben-
tonite (5.03 N/cm2). The highest tensile strength of 0.7 N/cm2 belonged 
to the mixture of moulding sand, 15% bentonite, and 15% Portland ce-
ment. In wet condition, the highest compressive strength of 14.55 N/
cm2 belonged to the mixture of moulding sand and 15% bentonite. The 
highest shear strength was 6.5 N/cm2 and found in moulding sand con-
taining 15% bentonite. The highest tensile strength of 1.3 N/cm2 be-
longed to the moulding sand mixed with 15% Sidoarjo mud.
4. Properties of Sand Moulds 
with Mount Kelud’s Volcanic Ash
Mount Kelud erupted in 2014. The sound of the blast was so powerful 
that it was heard across the city of Yogyakarta (200 km away) and even 
Purbalingga (300 km away) [23]. During this eruption, mount Kelud 
ejected many kinds of volcanic material such as volcanic ash. Volcanic 
ash or volcanic sand contains major elements (aluminium, silica, potas-
sium, and iron), minor elements (iodine, magnesium, manganese, atri-
um, phosphor, sulphur, and titanium), and trace levels (aurum, asbes-
tos, barium, cobalt, chrome, copper, nickel, plumbum, sulphur, stibium, 
stannum, strontium, vanadium, zirconium, and zinc). Five elements 
Fig. 8. The study scheme of moulding sand compositions with volcanic ash [25]
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 403
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
with the highest concentrations in volcanic ash are silicon dioxide 
(55%), aluminium oxide (18%), iron oxide (18%), calcium oxide (8%), 
and magnesium oxide (2.5%) [24].
Despite the disaster it creates, volcanic ash also brings benefits to 
the agricultural and casting industry [25]. One of the research on the 
use of volcanic ash as a binder in sand mould production.
Figure 8 shows the research procedure in which the samples of 
moulding sand were added with varying amounts of volcanic ash as a 
binder, i.e. 5% (moulding sand I), 10% (moulding sand II), and 15% 
(moulding sand III). Each mixture was tested for its compressive and 
shear strengths. The results of the tests are represented in Figs. 9 and 10.
As shown in Fig. 9, the moulding sand III containing 81% moulding 
sand, 15% volcanic ash, and 4% water had the highest compressive 
strength. The lowest compressive strength belonged to the moulding 
sand I composed of 91% moulding sand, 5% volcanic ash, and 4% water.
Figure 10 represents the results of shear testing which are not far 
different from the compressive test results. The moulding sand III, 
which consisted of 81% moulding sand, 15% volcanic ash, and 4% water, 
had the highest shear strength, whereas the moulding sand I con tai -
ning 91% moulding sand, 5% volcanic ash, and 4% water had the 
lowest. Thus, it can be seen that the increasing amount of volcanic ash 
resulting the increasing value of compressive strength and shear 
strength [25].
Fig. 10. Compressive shear (N/cm2) 
comparison of moulding sand spec-
imens with 5%, 10%, and 15% 
volcanic ash [25]
Fig. 9. Compressive strength (N/cm2) 
comparison of moulding sand spec-
imens with 5%, 10% and 15% vol-
canic ash [25]
404 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
5. Properties of Sand Moulds 
with a Mixture of Fly Ash and Bentonite
The following research involved a mixture of fly ash and bentonite as a 
binder in sand mould production.
As shown in Fig. 2 and 11, the two research schemes are similar. In 
this research, the amount of fly ash was increased to 2%, 4%, and 6% 
[26]. This research aimed to investigate the compressive strength and 
permeability of the mixtures. The results of the tests are as follows.
As presented in Fig. 12, the moulding sand with 6% fly ash had the 
greatest permeability, while the lowest belonged to the one with 4% fly 
ash. As shown in Fig. 13, the highest compressive strength was found 
in the mixture with 2% fly ash, while the lowest belonged to that with 
6% fly ash. Based on Fig. 12 and 13, the mixture with 2% of fly ash 
has the best permeability and compressive strength [26].
6. Properties of Sand Mould with a Mixture 
of Bentonite, Tapioca Flour, and Sago Flour
The following research studied bentonite, Sidoarjo mud, and Portland 
cement as binding materials in the production of sand moulds.
One can see in Fig. 14 three types of binders used to make sand 
moulds, i.e. bentonite, tapioca flour, and sago flour. The research exam-
ined each binding material and a mixture of the three. Compressive, 
tensile and shear tests were performed on each moulding sand specimen 
both in wet and dry conditions. This research found that the addition of 
tapioca flour in moulding sand mixture with dry condition had an effect 
P. Puspitasari and J.W. Dika
Fig. 11. The study scheme of moulding sand compositions with fly 
ash [26]
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 405
Fig. 12. Permeability (cm3/min) 
comparison of moulding sand 
specimens with 2%, 4%, and 6% 
fly ash [26]
Fig. 13. Compressive strength (N/
cm2) comparison of moulding sand 
specimens with 2%, 4%, and 6% 
fly ash [26]
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
on the shear strength and tensile strength of sand mould, while the ad-
dition of sago flour in moulding sand mixture with dry condition had an 
effect on the compressive strength [27]. The findings of the research 
scheme are shown in Table 1.
The moulding sand added with sago flour as a binder and used in 
dry condition had the highest compressive strength, as shown in Table 
Fig. 14. The study scheme of moulding sand compositions with bentonite, tapioca 
flour, and sago flour [27]
406 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
1. However, the moulding sand added with sago flour in wet conditions 
had the lowest compressive strength.
As shown in Table 2, the highest shear strength was found in the 
moulding sand, which was in dry condition and added with tapioca flour. 
On the other hand, the lowest shear strength belonged to the moulding 
sand, which was in wet state and mixed with several binding materials 
(5% bentonite, 2.5% sago flour, and 2.5% tapioca flour).
In dry state, the moulding sand mixed with tapioca flour had the 
highest tensile strength, as shown in Table 3. The lowest tensile strength 
belonged to the moulding sand containing 2% bentonite, 4% sago flour, 
and 4% tapioca flour in wet condition.
P. Puspitasari and J.W. Dika
Table 1. Comparison of wet and dry compressive strengths [27]
Binder
Wet compressive 
strengths, N/cm2
Dry compressive 
strengths, N/cm2
Bentonite (B) 11.83 12.16
Tapioca Flour (TF) 05.06 25.16
Sago Flour (SF) 04.90 28.60
B (5%) + SF (5%) + TF (5%) 06.30 06.51
B (5%) + SF (2.5%) + TF (2.5%) 06.70 07.51
B (2%) + SF (4%) + TF (4%) 05.50 09.71
Table 2. Comparison of wet and dry shear strengths [27]
Binder
Wet shear strengths,
 N/cm2
Dry shear strengths, 
N/cm2
Bentonite (B) 3.16 05.86
Tapioca Flour (TF) 2.13 18.16
Sago Flour (SF) 2.18 06.90
B (5%) + SF (5%) 2.53 03.10
B (5%) + TF (5%) 2.36 07.83
B (5%) + SF (2.5%) + TF (2.5%) 1.90 06.78
Table 3. Comparison of wet and dry tensile strengths [27]
Binder Wet tensile strengths, N/cm2
Dry tensile 
strengths, N/cm2
Bentonite (B) 0.7 0.75
Tapioca Flour (TF) 0.85 1.73
Sago Flour (SF) 0.52 0.53
B (5%) + SF (5%) 0.48 0.6
B (5%) + TF (5%) 0.45 0.65
B (2%) + SF (2.5%) + TF (2.5%) 0.58 1.03
B (2%) + SF (4%) + TF (4%) 0.35 1
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
Therefore, the best conditions for sand moulding to obtain compres-
sive strengths, shear strengths, and tensile strengths are in dry condi-
tions [27].
7. Properties of Sand Mould 
with a Mixture of Bentonite and Portland Cement
The study procedure for producing moulding sand binders formulated 
with bentonite and Portland cement is demonstrated in Fig. 15, where 
one can see two types of binding materials used in the research, i.e. ben-
tonite and Portland cement. Compressive, shear, and tensile tests were 
performed on the moulding sand specimens. The results of the tests are 
shown in Table 4. These researches found that the addition of a mixture 
of bentonite and Portland cement in moulding sand mixture had an ef-
fect on compressive strength, shear strength and tensile strength [28].
As presented in Table 4, the moulding sand composed of 6% of ben-
tonite and 4% of Portland cement had the highest compressive strength, 
Fig. 15. The study 
scheme for mould-
ing sand composi-
tions with bento ni-
te Portland cement 
bin der [28]
Table 4. Comparison of tensile, shear, and compressive strengths 
of moulding sand with bentonite (B)–Portland cement (PC) binder [28]
Type of testing
B (5%) + 
+ PC (5%)
B (4%) + 
+ PC (6%)
B (6%) + 
+ PC (4%)
B (7%) + 
+ PC (3%)
Compressive strength, N/cm2 7.20 7.03 8.13 7.93
Shear strength, N/cm2 2.60 2.70 2.63 2.86
Tensile strength, N/cm2 0.51 0.51 0.51 0.46
408 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
while that mixed with 4% of bentonite and 6% of Portland cement had 
the lowest. The shear test results showed that the highest shear strength 
belonged to the moulding sand added with 7%of bentonite and 3% of 
Portland cement, whereas the lowest was found in the mixture with 5% 
of bentonite and 5% of Portland cement. Regarding tensile strength, 
the moulding sand containing three different concentrations of bin -
ding materials (5% bentonite and 5% Portland cement, 4% bentonite 
and 6% Portland cement, and 6% bentonite and 4% Portland cement) 
had the same highest tensile strength, leaving the mixture composed 
of 7% bentonite and 3% Portland cement with the lowest tensile 
strength [28].
8. New Optimal Binder Compositions for Sand Moulding
Based on reports of previous studies, bentonite is an ideal binding agent 
for sand moulding despite its higher price compared to other types of 
binders [21]. The findings of past research on binder compositions are 
summarised as follows.
Based on Table 5, the highest compressive strength can be seen in 
the binder with composition of silica sand (81%), volcanic ash (15%) 
and water (4%) with a value of 22.8 N/cm2, while the lowest compres-
sive strength is in accordance with silica sand (86%), bentonite (6%), 
fly ash (3%) and water (5%) with a value of 0.93 N/cm2. The highest 
shear strength was in the binder with composition of silica sand (81%), 
volcanic ash (15%) and water (4%) at 17.3 N/cm2, while the lowest 
P. Puspitasari and J.W. Dika
Table 5. Mechanical properties sand moulding based on binder variation
Year Composition
Compressive 
strength, 
N/cm2
Shear 
strength, 
N/cm2
Tensile 
strength, 
N/cm2
Permea-
bility, 
cm3/min
Ref.
2009 Silica sand (86%)
Bentonite (9%)
Fly ash (0%)
Water (5%)
1.05 – – – [21]
Silica sand (86%)
Bentonite (8%)
Fly ash (1%)
Water (5%)
1.09 – – –
Silica sand (86%)
Bentonite (7%)
Fly ash (2%)
Water (5%)
1.17 – – –
Silica sand (86%)
Bentonite (6%)
Fly ash (3%)
Water (5%)
0.93 – – –
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 409
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
The End of Table 5 
Year Composition
Compressive 
strength, 
N/cm2
Shear 
strength, 
N/cm2
Tensile 
strength, 
N/cm2
Permea-
bility, 
cm3/min
Ref.
2014 Kelud mountain eruption sand (80%)
Bentonite (15%)
Water (5%) WET
8.7 5.03 0.7 — [22]
Kelud mountain eruption sand (80%)
Sidoarjo mud (15%)
Water (5%) WET
4.4 3.7 0.4 —
Kelud mountain eruption sand (80%)
Portland cement (15%)
Water (5%) WET
4.2 2.3 0.7 —
Kelud mountain eruption sand (80%)
Bentonite (15%)
Water (5%) DRY
14.55 6.5 0.8 —
Kelud mountain eruption sand (80%)
Sidoarjo Mud (15%)
Water (5%) DRY
13.3 5.7 1.3 —
Kelud mountain eruption sand (80%)
Portland cement (15%)
Water (5%) DRY
10.9 3.5 0.7 —
2015 Silica sand (91%)
Volcanic ash (5%)
Water (4%)
13 10.3 — — [25]
Silica sand (86%)
Volcanic ash (10%)
Water (4%)
15.5 12.3 — —
Silica sand (81%)
Volcanic ash (15%)
Water (4%)
Silica sand (81%)
Volcanic ash (15%)
Water (4%)
22.8 17.3 — —
2016 Green sand (86%)
Bentonite (7%)
Fly ash (2%)
Water (5%)
7.58 — — 231.67
Green sand (86%)
Bentonite (5%)
Fly ash (4%)
Water (5%)
6.35 — — 166.67
Green sand (86%)
Bentonite (3%)
Fly ash (6%)
Water (5%)
4.27 — — 238.33
410 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
shear strength was in mountain eruption sand (80%), Portland cement 
(15%), water (5%) in wet conditions with a value of 2.3 N/cm2. The 
highest tensile strength in binder with composition of Kelud mountain 
eruption sand (80%), Sidoarjo mud (15%), water (5%) in dry conditions 
with a value of 1.3 N/cm2, while the lowest tensile strength in sand 
from Kelud eruption (80%), Sidoarjo (15%) and water (5%) in wet con-
ditions with a value of 0.4 N/cm2. The highest permeability is the bind-
er with composition of green sand (86%), bentonite (3%), fly ash (6%) 
and water (5%) with a value of 238.33 cm3/minute, while permeability 
is lower in green sand (86%), bentonite (5%), fly ash (4%) and water 
(5%) with a value of 166.67 cm3/minute.
The types of sand used in producing sand moulds can vary and are 
dependent on the location of the source. The quality of the sand greatly 
affects the quality of casting. High-quality castings can be realized if 
the sand has the following five characteristics. (i) Strength, i.e. the abil-
ity of the sand to sustain its shape once formed. (ii) Permeability, i.e. 
the ability of gas to escape through the sand; higher permeability is 
capable of reducing porosity in castings. (iii) Thermal stability, i.e. the 
ability of the sand to withstand heat damage such as cracking and dis-
tortion. (iv) Collapsibility, i.e. the ability of the sand to compress or 
collapse during solidification. Finally (v) reusability, i.e. the ability of 
the sand to be recycled for subsequent use for environmental and eco-
nomic significance.
The results of the above studies suggest that previous tests on sand 
moulds with various types of binders aimed to investigate the strength 
of each composition, revealing the compressive strength, hardness, 
shear strength, and tensile strength. The past studies were carried out 
with the aim of improving one aspect of casting quality optimisation, 
i.e. strength. Reviewing the research literature on sand moulding, we 
found that the moulding sand containing tapioca flour as a binder and 
used in dry condition had the highest overall strength, namely, com-
pressive strength of 25.16 (N/cm2), shear strength of 18.16 (N/cm2), 
and shear strength of 1.73 (N/cm2).
Metal casting involves two separate activities. The first one is the 
production of patterns and moulds, whereas the second is the casting 
process including melting metal, controlling its composition and impu-
rities, and pouring the molten metal into a mould, cleaning the casting, 
giving heat treatment, and inspecting the casting for defects [29]. Met-
al moulds are permanent and reusable, unlike those made out of sand. 
In sand casting, the mould making is a critical stage, which must be 
performed for each casting. A sand mould is formed by compacting the 
moulding sand. The types of sand commonly used for moulding are 
natural sand and artificial sand–clay mixtures [11]. Metals are among 
the most important and most extensively used materials in different 
P. Puspitasari and J.W. Dika
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
engineering fields, particularly in the casting industry. Of all non-fer-
rous metals, aluminium has become of great importance in engineering 
[1], which is widely used for casting [30]. Aluminium alloys have also 
been used in the manufacture of components for automotive applica-
tions, such as piston, engine block, cylinder head, valve, and others [31, 
32]. Since its pure form is not as good as other metals, aluminium is 
often alloyed with other elements such as copper, magnesium, silicon, 
manganese and zinc to improve its castability, corrosion-resistance, 
machinability, and weldability properties [33]. Combining aluminium 
as the predominant metal with other elements results in aluminium 
alloys [31, 34–36]. The use of aluminium in the automotive industry 
has escalated in the past few decades and served as a frequent substitute 
for iron and steel because aluminium contributes in the reduction of 
structural mass and exhaust emissions [37, 38]. Aluminium alloys have 
excellent properties including lightweight, good castability, and high 
thermal conductivity, hence wide applications in field of computer, 
communications, electronics and automotive [39–43]. ADC12, a type 
of Al–Si alloys, even exhibits additional properties, i.e. high produc-
tivity, low shrinkage rate, corrosion resistance [44, 45], and high 
durability [46].
Revealing the remarkable properties of aluminium alloys leads to an 
increase in its demand, reaching 29 million tons per year consisting of 
22 million tons of new aluminium and 7 tons of recycled one [47]. There 
is no substantial difference in quality between pure and recycled alu-
minium alloys, and thus they have become the most frequently used 
Fig. 16. Thin wall heat dissipation shells (a, b, and c — front, back, and perspective 
view, respectively), which are produced by air cooled stirring rod (ACSR) process 
combined with high-pressure die casting machine [51]. Here, A, B, C, and D — re-
gions from which the samples were prepared [51] to study their microstructure and 
mechanical properties
412 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
materials after steel [48, 49]. The aluminium consumption in Indonesia 
reaches between 200.000–300.000 tonnes per year with a price of US$ 
1.951,50 per ton [50].
The growing demand for high quality casts made with stricter toler-
ances, as in Fig. 16, is more difficult to meet if using sand casting [51]. 
As a result, some companies are beginning to develop and use sophisti-
cated casting machines equipped with automatic control systems. As 
discussed in depth in the American Metalcasting Consortium (AMC), 
the high-pressure die casting (HPDC) technique involves smart ma-
chines, manufacturing, testing, and control [52]. The HPDC is continu-
ously being developed to make the best use of it.
HPDC technique is one of the metal casting techniques utilising 
permanent moulds into which molten metal is poured under very high 
pressure. This technique is employed commonly in the manufacture of 
alloy parts [53–55]. The HPDC technique offers several advantages 
such as cast products with thin walls, near-net shapes, and stable and 
precise dimensions, fast cooling rates, high productivity levels [56, 57], 
and efficient production which leads to low manufacturing costs [55, 
58, 59].
Notwithstanding the above beneficial aspects, high-pressure die-
casting has its drawbacks. Its final products often suffer from internal 
defects [60, 61], one of which is gas porosity due to air or gas entrapped 
during the mould filling done under high speeds which adversely affects 
the mechanical properties of the material [55, 62].
9. Overview of Rheo-Die Casting
Adding a touch of new technology is one of the ways to remedy the 
shortcomings of high-pressure die casting technique. Since this cas -
ting technique applies the smart machine, manufacturing, testing, and 
control, the addition of a new device to the system is considered a 
favourable solution. As a result, rheo-HPDC has been pioneered as a 
developed version of high-pressure die casting technique, integrating 
HPDC with semi-solid processing [63–65]. Over the past few years, this 
technology has produced high-quality components with a good micro-
structure [53, 66–68]. Rheo-HPDC has attracted increasing attention 
and been continuously developed [69, 70] due to the effectiveness of 
this smart manufacturing process to offer improved mechanical pro-
perties [63] and produce a more refined microstructure, hence better 
aluminium alloy properties and reduction of shrinkage [71]. Also, the 
products of rheo-HPDC exhibit lower porosity than the conventional 
HPDC techniques [72, 70]. Based on their mechanical properties, the 
results of rheo-HPDC have superior properties than those manufactured 
by HPDC [66].
P. Puspitasari and J.W. Dika
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
As one can see in Fig. 17, the microstructure AZ91D alloy compo-
nent at different locations is homogeneous after the rheo-die casting 
(RDC) procedure. Based on the microstructure, it can also be seen that 
RDC can increase strength and ductility compared to products from 
HPDC [74].
10. Mechanism of Rheo-Die Casting
Rheo-die casting is a version of semi-solid metal (SSM) technology [75] 
that has become the focus of research work in recent years [69, 73, 74] 
due to its high production volume [74] and been developed continuously 
to meet scientific and industrial demands [70]. Rheo (or rheology) is 
closely related to viscosity and includes slurry mixing to be poured into 
a container or mould under high pressures. In other words, rheo-process-
ing requires a liquid metal alloy, which is then cooled to obtain a liquid–
Fig. 17. Microstructure for the rheo-die cast AZ91D magnesium 
alloy component at various positions [74]
Fig. 18. Development of casting process optimization through high-pressure rheo-
die casting from 2005–2017
414 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
solid alloy (slurry) and cast in a permanent mould through HPDC [61, 
78]. With the above procedure, this highly innovative technique is able 
to cast precise components with a high complexity, improved mechani-
cal properties [73–75, 79], and fine grain size [80].
In fact, slurry serves a very significant role in producing high-
quality castings, and thus proper preparation is necessary before rheo-
HPDC [81–83]. The core of rheo-die casting process consists of, first, 
the preparation of slurry which is then processed in the HPDC machine 
and, second, the forming process through rheo-HPDC [64]. In other 
words, the molten metal will undergo both primary and secondary so-
lidification [84]. SSM casting is, indeed, a novel metal casting techni-
que that involves rheological properties to process components [63, 85].
11. Development of Rheo-Die Casting
Judging from its viscosity level, slurry has a higher viscosity than 
molten or liquid metal. This leads to the less entrapped gas contained 
in the mate rials and hence a final product with no porosity defects 
[86–88]. Rheo-die casting is, in fact, smart manufacture that fulfils 
the needs the industry since it frequently utilises aluminium alloys 
in the process [69]. The development of slurry processing through 
this smart machine, manu facturing, testing and control from 2005 
to 2017 is illustrated in Fig. 18.
11.1. Rheo-Die Casting with a Twin-Screw Slurry Maker
Making slurry using a twin-screw system is one of the alternatives to 
produce high-quality cast products; this method had been studied 
until 2008. Figure 19 exhibits the use of the twin-screw slurry mak-
er in rheo-die casting.
As shown in Fig. 19, the RDC process with twin screw consists of 
two main components, the twin-screw slurry maker and the HPDC ma-
P. Puspitasari and J.W. Dika
Fig. 19. The rheo-die cast-
ing process with twin screw 
to make slurry [74]
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
chine. The screw slurry has a pair 
of screws that rotate inside the 
cylin der. The function of this 
component is to convert molten 
metal into high-quality semi-solid 
slurry. The next component is the 
standard HPDC machine. The func-
tion of this HPDC machine is to 
achieve the formation of final pro-
duct. The products produced from 
the RDC process with twin screw are having low porosity (0.1–0.3%), 
smooth and uniform mic ro structures on all surfaces, and better ductil-
ity than HPDC [74].
11.2. Rheo-Die Casting with an Ultrasonic Slurry Maker
The preparation of slurry using the twin-screw system, judged from its 
cast products, was considered to have significant shortcomings. Owing 
to this, in 2011, many researchers started to switch their focus to the 
slurry-making process using the indirect ultrasonic vibration system. 
Figure 20 illustrates the equipment of ultrasonic vibration.
Based on Fig. 20, it can be seen that the component of indirect ul-
trasonic vibration consists of an ultrasonic generator, ultrasonic horn, 
metal cup, ejector rod, pneumatic cylinder and heating furnace. The 
horn that is on the outside of the metal cup has the duty to vibrate the 
molten metal. The vibration is produced from an ultrasonic generator 
that has a power of 2.6 kW with a vibration frequency of 20 kHz. The 
products produced have a smooth microstructure and better tensile 
strength as compared to conventional die casting [69].
11.3. Rheo-Die Casting with an MRB Slurry Maker
In an effort to improve the quality of casts through rheo-HPDC, re-
searchers have developed many innovations, one of which is a mechani-
cal rotational barrel (MRB), which has been introduced in 2016.
Based on Fig. 21, it can be understand that the preparation of semi-
solid slurry through a MRB system is to use a stainless steel barrel with 
a length of 500 mm, a diameter of 150 mm and a tilt angle of 45°. Liq-
uid becomes high-quality semi-solid slurry. This is due to the presence 
of high shear and turbulence through solidification [75].
Fig. 20. Components of indirect ultrason-
ic vibration [69]: schematic illustration
416 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
P. Puspitasari and J.W. Dika
11.4. Rheo-Die Casting with an ACSR Slurry Maker
Researchers also introduced a new invention called an air-cooled stir-
ring rod (ACSR) in 2016. Figure 22 shows the preparation of slurry for 
rheo-HPDC using the ACSR.
Based on Fig. 22, one can see that the ACSR consists of an air com-
pressor, airway, stirring rod, crucible and thermocouple. Preparation of 
semi-solid slurry is by continuously flowing air into the stirring rod. An 
air release valve controls the airflow. Thus, the liquid metal can turn 
into semi-solid slurry. Products produced from this method can increase 
tensile strength, yield strength, hardness and thermal conductivity [51].
11.5. Rheo-Die Casting with SIM
The latest innovation among all slurry-making processes above is the 
self-inoculation method (SIM) (see Fig. 23).
Fig. 21. Rheo-casting (RC) and 
rheo-die-casting (RDC) with me-
chanical rotational barrel (MRB) 
system to make semisolid slurry 
[78]
Fig. 22. Components of the air 
cooled stirring rod (ACSR), where 
1 — air compressor, 2 — airway, 
3 — stirring rod, 4 — melt, 5 — 
crucible, 6 — thermocouple, 7 — 
primary α-Al particle) [51]
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Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
Fig. 23. The RDC process 
combined with self-inocula-
tion method (SIM) [84]
We can see in Fig. 
23, that the RDC proc-
ess with SIM uses a flu-
id director to prepare 
semi-solid slurry. There 
is a specification of flu-
id director having a 
length of 500 mm and a 
tilt angle of 45°. The 
addition of self-inocu-
lants (5% of alloy mass) 
is carried out when the 
molten metal is then stirred quickly. The last step of this method is to 
provide treatment in the form of isothermal holding. The results ob-
tained from this method are the eutectic growth rate in RDC is 4 times 
faster than HPDC [84].
12. Discussion
This section examines the advantages of rheo-HPDC viewed from sev-
eral aspects of its cast products including mechanical properties, poros-
ity, and microstructure.
12.1. Mechanical Properties
The mechanical properties to be discussed are the tensile strength, hard-
ness, and some others; the properties of casts produced by rheo-HPDC are 
compared with those of the products of the conventional HPDC technique.
Table 6. Comparison of mechanical properties, density and thermal 
conductivity of samples produced by HPDC and ACSR rheo-HPDC [51]. 
Here, UTS — ultimate tensile strength, YS — yield strength
Process
Air 
flow, 
Ls−1
Mechanical Properties
Density, 
g⋅cm−3
Thermal 
conductivity, 
W  ⋅  m−1  ⋅  K−1UTS, MPa
YS, 
MPa
Elongation, 
%
Hardness, 
HV
HPDC 217 108 2.6 88 2.618 139
ACSR rheo-HPDC 0 231 112 3.2 92 2.635 143
1 239 113 3.7 94 2.645 145
3 255 119 4.6 97 2.660 151
5 261 124 4.9 99 2.664 153
418 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
According to Table 6, the rheo-HPDC could improve the mechanical 
properties of a material. The ultimate tensile strength of specimen cast 
using the conventional HPDC was 217 MPa, while that of products cast 
by rheo-HPDC was up to 261 MPa. Moreover, the rheo-HPDC produced 
casts with a higher yield strength (124 MPa at highest), compared to 
the product of the conventional HPDC which only reached 108 MPa. 
Based on its elongation, the cast of the conventional HPDC only reached 
2.6%, whereas those produced by rheo-HPDC had higher elongation 
value, i.e. up to 4.9%. The cast density of the conventional HPDC and 
rheo-HPDC was 2.618 g/cm3 and 2.664 g/cm3, respectively. The hard-
ness achieved by the conventional HPDC was 88 HV and by rheo-HPDC 
was 99 HV. Lastly, the thermal conductivity of the result of the conven-
tional was 139 W  ·  m–1  ·  K–1, while that of the products of rheo-HPDC 
was up to 153 W  ·  m–1  ·  K–1.
P. Puspitasari and J.W. Dika
Fig. 24. Comparison of porosity levels for Mg–Al (AM50) alloy produced by rheo-
casting (RC) and high pressure die casting (HPDC) [75]
Fig. 25. Typical microstructure of the as-cast Al–Si–Mg (A357) alloy, which is pre-
pared through the RDC (a) and HPDC (b) methods [70]. In the figure left (a), α1–α3 
denote primary α-Al globules (α1), dendritic fragments (α2), and equiaxed particles 
(α3) [70]
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 419
12.2. Porosity
Porosity is a form of defect that may reduce the mechanical properties 
or performance of a material, and thus, it should be prevented. Figure 
24 illustrates the comparison of porosity levels in casts produced by the 
conventional HPDC and rheo-HPDC [75].
Figure 24 suggests that the rheo-HPDC leads to a reduced porosity. 
The thing that needs to be highlighted here is the size of porosity, 
smaller pores (0–150) appeared more in the products of rheo-HPDC, 
while pores bigger than 150 appeared more in the casts of HPDC [75].
12.3. Microstructure
In addition to mechanical properties, microstructure is another aspect 
should be analysed to investigate the advantages of a material. Based on 
the mechanical properties, the products of rheo-HPDC have better prop-
erties than the conventional HPDC. Figure 25 shows the microstructure 
of rheo-HPDC and conventional HPDC.
The image of microstructure in Fig. 25, a is much better and clear-
er than the image in Fig. 25, b. The clearly visible grain boundaries and 
the homogeneity of the spherical microstructure support the superior 
mechanical properties of casts produced by rheo-HPDC [70].
13. Conclusions
The use of bentonite as a binding agent in moulding sand can be re-
placed by tapioca flour if viewed from the resulting strength. Tapioca 
starch, as a binder, is potentially preferable, since it can produce higher 
strength in sand moulds when in dry condition than bentonite.
As a recommendation for further research, this study suggests the 
more comprehensive studies on the use of tapioca flour as a new type of 
binder in the metal casting industry. Future researchers should take a 
closer look at other sand characteristics for optimising casting quality. 
We can offer research recommendations that appear below.
1. To test the permeability level of moulding sand with tapioca flour 
as the binder.
2. To test the thermal stability level of moulding sand with tapioca 
flour as the binder.
3. To test the collapsibility level of moulding sand with tapioca 
flour as the binder.
4. To test the reusability level of moulding sand with tapioca flour 
as the binder.
Rheo-HPDC is a smart manufacture technique in metal casting. One 
of the crucial aspects of the casting process is the proper preparation of 
slurry. Based on the development of its equipment, rheo-HPDC involv-
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
420 ISSN 1608-1021. Prog. Phys. Met., 2019, Vol. 20, No. 3
P. Puspitasari and J.W. Dika
ing the self-inoculation method is the latest system and able to improve 
the quality of the cast products. Compared to the conventional HPDC, 
the rheo-HPDC resulted in improved mechanical properties such as ulti-
mate tensile strength, yield strength, elongation, hardness, density, and 
thermal conductivity.
In addition, rheo-HPDC could lead to a homogeneous and uniform mic-
rostructure, and reduce porosity. In conclusion, this technique has high 
pro ductivity and is reliable to produce excellent casts with great precision.
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Received April 25, 2019; 
in final version, June 20, 2019
Ï. Ïóñï³òàñàð³, Äæ.Â. ijêà
Êàôåäðà êîíñòðóþâàííÿ ìàøèí, 
Äåðæàâíèé óí³âåðñèòåò Ìàëàí´ó, 
âóë. Ñåìàðàí´ó, 5, 65145 Ìàëàí´, Ñõ³äíà ßâà, ²íäîíåç³ÿ
ÏÎ˲ÏØÅÍÍß ßÊÎÑÒÈ ËÈÒÒß Ç ÂÈÊÎÐÈÑÒÀÍÍßÌ 
ÍÎÂÈÕ ÇÂ’ßÇÓÂÀËÜÍÈÕ ÏÐÈ ËÈÒÒ² Ó Ï²ÙÀÍÓ ÔÎÐÌÓ
ÒÀ ÊÎʲËÜÍÎÌÓ ËÈÒÒ² ÇÀ ÂÈÑÎÊÎÃÎ ÒÈÑÊÓ
ßê³ñòü ëèòâà º ÷èííèêîì äîñêîíàëîñòè äëÿ ì³ðÿííÿ óñï³øíîñòè ëèòòÿ ìåòàëó. 
Îäí³ºþ ç³ ñïðîá îäåðæàòè âèñîêîÿê³ñíèé ëèâàðíèé ïðîäóêò º âèçíà÷åííÿ ÿêîñ òè 
âèêîðèñòîâóâàíî¿ ôîðìîâêè ó ï³ñêóâàòî-ãëèíèñòî¿ ñóì³ø³. ²äåíòèô³êàö³ÿ ÿêîñ òè 
ôîðìóâàííÿ ï³ñêóâàòî-ãëèíèñòî¿ ñóì³ø³ âèçíà÷àºòüñÿ òàêèìè õàðàêòåðèñòèêàìè 
ÿê òâåðä³ñòü, ì³öí³ñòü íà çñóâ, ðîçòÿã òà ïðîíèêí³ñòü. Ó ö³é ñòàòò³ ðîçãëÿäàþòüñÿ 
ïîÿñíåííÿ ì³öíîñòè ôîðìîâêè ç ï³ñêó ç êîìïîçèö³éíîþ çì³íîþ òèïó çâ’ÿçó âàëü-
íîãî: (1) ôîðìóâàííÿ ç ï³ñêó, áåíòîí³òó, çîëè âèíîñó òà âîäè; (2) ï³ñîê âèâåðæåí-
íÿ ãîðè Êåëóä, áåíòîí³ò ³ âîäà; (3) ï³ñîê âèâåðæåííÿ ãîðè Êåëóä, áðóä ѳäîàðäæî 
òà âîäà; (4) ï³ñîê âèâåðæåííÿ ãîðè Êåëóä, ïîðòëàíäöåìåíò ³ âîäà; (5) ï³ñîê, 
âóëêàí³÷íèé ïîï³ë ³ âîäà; (6) çåëåíèé ï³ñîê, áåíòîí³ò, ëåòþ÷à çîëà òà âîäà; (7) 
ï³ ñîê ³ç Ìàëàí´ó, áåíòîí³ò, ïóäðè ç òàï³îêè òà ñà´î; (8) ï³ñîê äëÿ ôîðìîâêè, 
áåíòîí³ò, ïîðòëàíäöåìåíò ³ âîäà. Êîê³ëüíå ëèòòÿ çà âèñîêîãî òèñêó (çàçâè÷àé â³-
äîìå â àíãë³éñüê³é ë³òåðàòóð³ ÿê rheo-HPDC) º íîâèì ìåòîäîì ëèòòÿ ó âèðîáíèöòâ³ 
ÿê³ñíèõ ëèâàðíèõ âèðîá³â. Çðîñòàþ÷èé ïîïèò íà ðèíêó ñòèìóëþº ðîçðîáêó íîâî¿ 
òåõíîëî㳿, çà äîïîìîãîþ ÿêî¿ ìîæíà âèðîáëÿòè âèëèâêè ç ÷óäîâèìè ìåõàí³÷íèìè 
âëàñòèâîñòÿìè, õîðîøîþ ì³êðîñòðóêòóðîþ òà íåçíà÷íèìè äåôåêòàìè ëèòâà. Ìå-
òîä êîê³ëüíîãî ëèòòÿ ï³ä âèñîêèì òèñêîì, ùî º âäîñêîíàëåíèì ñïîñîáîì âèëè-
âàííÿ â êîê³ëü, ìîæíà ðîçãëÿäàòè ÿê ðîçóìíó òåõíîëîã³þ âèãîòîâëÿííÿ, îñê³ëüêè 
âîíà óçàãàëüíþº òåõíîëîã³þ íàï³âòâåðäîãî ìåòàëó, ÿêà âðàõîâóº ïðàâèëüíå ïðè-
ãîòóâàííÿ ñóñïåí糿. Ïðîöåñ ïðèãîòóâàííÿ ãíî¿âêè ïîñò³éíî âäîñêîíàëþºòüñÿ, ³ 
íîâ³òí³ì ìåòîäîì ãîòóâàííÿ º ìåòîä ñàìîçàáðóäíåííÿ. Ó äàí³é îãëÿäîâ³é ñòàòò³ 
îáãîâîðþþòüñÿ ïðîöåäóðà, ìåõàí³çì, ðîçðîáëåííÿ òà ÿê³ñòü ïðîäóêö³¿ ëèòòÿ â 
ï³ñêîâó ôîðìó ç âèêîðèñòàííÿì íîâèõ çâ’ÿçóâàëüíèõ, à òàêîæ ìåòîäè ëèòòÿ ó 
êîê³ëü çà âèñîêîãî òèñêó.
Êëþ÷îâ³ ñëîâà: ÿê³ñòü â³äëèâàííÿ, ôîðìóâàëüíèé ï³ñîê, çâ’ÿçóâàëüí³, 
êîê³ëü íå ëèòòÿ çà âèñîêîãî òèñêó (rheo-HPDC), ³íòåëåêòíèé ìåõàí³çì, 
àëþì³í³é.
ISSN 1608-1021. Usp. Fiz. Met., 2019, Vol. 20, No. 3 425
Casting Quality Enhancement Using Binders on Sand Casting and Rheo-HPDC
Ï. Ïóñïèòàñàðè, Äæ.Â. Äèêà
Êàôåäðà êîíñòðóèðîâàíèÿ ìàøèí, 
Ãîñóäàðñòâåííûé óíèâåðñèòåò Ìàëàíãà,
óë. Ñåìàðàíãà, 5, 65145 Ìàëàíã, Âîñòî÷íàÿ ßâà, Èíäîíåçèÿ
ÏÎÂÛØÅÍÈÅ ÊÀ×ÅÑÒÂÀ ËÈÒÜß Ñ ÈÑÏÎËÜÇÎÂÀÍÈÅÌ 
ÍÎÂÛÕ ÑÂßÇÓÞÙÈÕ ÏÐÈ ËÈÒÜÅ Â ÏÅÑ×ÀÍÓÞ ÔÎÐÌÓ 
È ÊÎÊÈËÜÍÎÌ ËÈÒÜÅ ÏÎÄ ÂÛÑÎÊÈÌ ÄÀÂËÅÍÈÅÌ
Êà÷åñòâî ëèòüÿ ÿâëÿåòñÿ ôàêòîðîì ñîâåðøåíñòâà äëÿ èçìåðåíèÿ óñïåøíîñòè ëè-
òüÿ ìåòàëëà. Îäíîé èç ïîïûòîê ïîëó÷èòü âûñîêîêà÷åñòâåííûé ëèòåéíûé ïðî-
äóêò ÿâëÿåòñÿ îïðåäåëåíèå êà÷åñòâà èñïîëüçóåìîé ôîðìîâêè â ïåñ÷àíî-ãëèíèñòîé 
ñìåñè. Èäåíòèôèêàöèÿ êà÷åñòâà ôîðìîâêè ïåñ÷àíî-ãëèíèñòîé ñìåñè îïðåäåëÿåò-
ñÿ òàêèìè õàðàêòåðèñòèêàìè êàê òâ¸ðäîñòü, ïðî÷íîñòü íà ñäâèã, ðàñòÿæåíèå è 
ïðîíèöàåìîñòü.  ýòîé ñòàòüå ðàññìàòðèâàþòñÿ îáúÿñíåíèÿ ïðî÷íîñòè ôîðìîâêè 
èç ïåñêà ñ êîìïîçèöèîííûì èçìåíåíèåì òèïà ñâÿçóþùåãî: (1) ôîðìîâàíèå èç 
ïåñêà, áåíòîíèò, çîëà óíîñà è âîäà; (2) ïåñîê èçâåðæåíèÿ ãîðû Êåëóä, áåíòîíèò 
è âîäà; (3) ïåñîê èçâåðæåíèÿ ãîðû Êåëóä, ãðÿçü Ñèäîàðäæî è âîäà; (4) ïåñîê èç-
âåðæåíèÿ ãîðû Êåëóä, ïîðòëàíäöåìåíò è âîäà; (5) ïåñîê, âóëêàíè÷åñêèé ïåïåë è 
âîäà; (6) çåë¸íûé ïåñîê, áåíòîíèò, ëåòó÷àÿ çîëà è âîäà; (7) ïåñîê èç Ìàëàíãà, 
áåíòîíèò, ïóäðû èç òàïèîêè è ñàãî; (8) ïåñîê äëÿ ôîðìîâàíèÿ, áåíòîíèò, ïîðò-
ëàíäöåìåíò è âîäà. Êîêèëüíîå ëèòü¸ ïîä âûñîêèì äàâëåíèåì (÷àñòî èçâåñòíîå â 
àíãëèéñêîé ëèòåðàòóðå êàê rheo-HPDC) ÿâëÿåòñÿ íîâûì ìåòîäîì ëèòüÿ â ïðîèç-
âîäñòâå êà÷åñòâåííûõ ëèòåéíûõ èçäåëèé. Ðàñòóùèé ñïðîñ íà ðûíêå ñòèìóëèðó-
åò ðàçðàáîòêó íîâîé òåõíîëîãèè, ñ ïîìîùüþ êîòîðîé ìîæíî ïðîèçâîäèòü îòëèâ-
êè ñ ïðåâîñõîäíûìè ìåõàíè÷åñêèìè ñâîéñòâàìè, õîðîøåé ìèêðîñòðóêòóðîé è 
íåçíà÷èòåëüíûìè äåôåêòàìè ëèòüÿ. ßâëÿþùèéñÿ óñîâåðøåíñòâîâàííûì ñïîñî-
áîì ëèòüñÿ â êîêèëü ìåòîä êîêèëüíîãî ëèòüÿ ïîä âûñîêèì äàâëåíèåì ìîæíî 
ðàññìàòðèâàòü êàê ðàçóìíóþ òåõíîëîãèþ èçãîòîâëåíèÿ, ïîñêîëüêó îíà îáîáùàåò 
òåõíîëîãèþ ïîëóòâ¸ðäîãî ìåòàëëà, êîòîðàÿ ó÷èòûâàåò ïðàâèëüíîå ïðèãîòîâëå-
íèå ñóñïåíçèè. Ïðîöåññ ïðèãîòîâëåíèÿ íàâîçíîé æèæè ïîñòîÿííî ñîâåðøåíñòâó-
åòñÿ, è íîâåéøèì ìåòîäîì ïîäãîòîâêè ÿâëÿåòñÿ ìåòîä ñàìîçàãðÿçíåíèÿ. Â äàí-
íîé îáçîðíîé ñòàòüå îáñóæäàþòñÿ ïðîöåäóðà, ìåõàíèçì, ðàçðàáîòêà è êà÷åñòâî 
ïðîäóêöèè ëèòüÿ â ïåñ÷àíóþ ôîðìó ñ èñïîëüçîâàíèåì íîâûõ ñâÿçóþùèõ, à òàê-
æå ìåòîäà ëèòüÿ â êîêèëü ïîä âûñîêèì äàâëåíèåì.
Êëþ÷åâûå ñëîâà: êà÷åñòâî îòëèâêè, ôîðìîâî÷íûé ïåñîê, ñâÿçóþùèå, êî-
êèëüíîå ëèòü¸ ïîä âûñîêèì äàâëåíèåì (rheo-HPDC), èíòåëëåêòíûé ìåõàíèçì, 
àëþìèíèé.