A wear analysis study of selected alternative foundry tooling materials using impact abrasion testing

The purpose of this study was to simulate the wear characteristics of foundry tooling using an impact abrasion test apparatus. The wear characteristic was exhibited by non-metallic materials and was measured as a function of percentage weight loss and was benchmarked against Class 30 gray iron. The research question focused on whether or not a non-metallic material exists that exhibits comparable or superior wear characteristics to Class 30 gray iron for possible consideration as tooling materials for foundry applications. The information obtained adds to knowledge and is useful to foundry professionals in making tooling decisions.;The 34 test materials were procured from leading non-metallic tooling manufacturers as well as from non-traditional sources. The test procedure used 2 samples of each material tested independently for 3 four hour cycles. The samples were cleaned and weighed and the abradant changed after each 4 hour cycle. The test apparatus was used in three previous studies to experiment on potential tooling materials.;Upon analysis of the data, a wear factor equation was developed to better interpret the tool life as compared to Class 30 gray iron. The development of this wear factor can indicate to a foundry professional how long he/she can expect a tool to last as compared to cast iron.;Of the non-metallic materials tested there was a wide range in percentage weight loss numbers exhibited. The best performer in terms of percentage weight loss was the Conathane TU-900 exhibiting a 0.3440% weight loss and a wear factor of 2.97. The worst performer was the Ultralloy 40 demonstrating a 9.5043 percentage weight loss with a corresponding wear factor of 81.93.;It appears from the data generated in this study that there is no alternative non-metallic material that exhibits the wear resistance of Class 30 gray iron. However, comparing the results of other tests done previously, it is concluded that with new formulations it is only a matter of time before a non-metallic material will demonstrate the wear resistance of iron.