CARBO ENGINEERED CERAMIC CASTING MEDIA IS A COMPLETE SOLUTION:

Eliminate OSHA PEL concerns Red dot Improve casting quality Red dot Reduce costs

CARBO ceramic casting media is engineered to outperform specialty and silica sands. It is manufactured with a unique combination of thermal, physical and chemical properties that provide important economic, performance and safety advantages.

CARBO ceramic casting media has proven effective in a wide range of metal casting applications:

  • Vacuum process
  • Phenolic urethane cold box (PUCB)
  • Phenolic urethane no-bake (PUNB)
  • Alkyd oil no–bake (AONB)
  • Shell hot–box
  • Sodium silicate

Watch our webcast recently hosted by Modern Casting:

CERAMICS: A SYNTHETIC NON-SILICA ALTERNATIVE FOR METALCASTING

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ELIMINATE RESPIRABLE SILICA DUST

Unlike silica sand, CARBO ceramic casting media does not generate airborne dust particles and produces no respirable silica dust, so it easily complies with OSHA (1926.1153) silica dust permissible exposure limits (PEL). In fact, in rigorous testing under foundry conditions, CARBO ceramic media was proven silica dust-free at a detection threshold of 0.0056 mg/m3 – roughly 10 times less than the new permissible exposure limit of 0.05 mg/m3.

Reduce the costs of OSHA compliance

Replacing silica sand with CARBO ceramic casting media is the most cost-effective way for a foundry to meet OSHA requirements for silica dust exposure. Simply upgrading to CARBO ceramic media avoids the considerable costs and complications of installing expensive equipment that would be necessary to meet the PEL requirements.

OSHA silca compliance in other industries

CARBO ceramic media is the optimum solution for OSHA silica PEL compliance in a wide variety of applications. Learn more >

improve casting quality

The technology that creates CARBO casting media produces significantly greater particle strength, durability, smoothness, consistency and thermal stability than sand. This results in superior casting quality, increased dimensional accuracy and enhanced casting capabilities.

  • Low thermal expansion results in high quality, precision castings that reduce defects such as veining, penetration and burn-on to minimize finishing, cleaning and scrap costs.
  • Uniform particle size and shape maximizes mold porosity and enhances permeability. These characteristics improve pellet strength to resist gas defects and breakdown.
  • Chemically inert and proven compatible with various metals, resins and additives used in metal casting processes.

DOWNLOAD CASE HISTORY:
Casting defects eliminated, saving a billion-dollar casting project

Improve casting quality

REDUCE TOTAL CASTING COSTS

The engineered characteristics of CARBO ceramic media reduce casting costs in a number of ways (see chart), especially by minimizing casting defects and reducing media consumption.

Increasing quality, reducing the costs of defects

The increased thermal stability and dimensional precision of CARBO ceramic media produce castings of superior quality, thus minimizing the costs of finishing, cleaning and scrap.

Improved media reclamation and reduced consumption

CARBO ceramic casting media greatly enhances reclamation and recycling. The structural strength, consistent shape and smooth surfaces of ceramic pellets allow them to be reclaimed and reused multiple times—reducing media consumption as well as disposal and replacement costs.

DOWNLOAD CASE HISTORY:
Cast media costs reduced by 55% per cubic foot and cleaning time lowered by 75%

How CARBO ceramic media reduces casting costs

Performance characteristics     Impact on casting costs
Does not generate silica dust   Avoids the cost and hassle of retrofitting or installing environmental control equipment associated with OSHA silica PEL compliance
Pulverization strength   High hardness and durability resists particle breakdown and reduces media consumption—improving recycling and reuse
Decreases transportation, disposal and product replacement costs
Improved media flow   Increases production cycle rates, reduces production and energy costs
Smooth surface   Reduces resin usage and associated binder costs
Low thermal expansion   Avoids expansion-related defects such as veining, penetration and burn-on and the associated costs to clean, correct or scrap

Potentially eliminates some additives, coatings or washes
Uniform particle size   Maximizes mold porosity and enhances permeability to resist gas defects and breakdown—reducing scrap and cleaning costs

VIEW CLIENT SUCCESS STORIES

CASE HISTORY

CASE HISTORY

Production rate increase avoids capital investment for a new line addition

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CASE HISTORY

CASE HISTORY

Cleaning cost reduced while achieving high casting precision

Download case history

CASE HISTORY

CASE HISTORY

Casting defects eliminated, saving a billion-dollar casting project

Download case history

CASE HISTORY

CASE HISTORY

Reduction in media use and metal penetration significantly lowers operational cost

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DOWNLOAD PRODUCT INFORMATION

CARBO engineered ceramic casting media products are available in formulations and densities that provide distinct advantages in any application.

Low– and intermediate-density high performance ceramic casting media

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Ultra high-performance, low-density ceramic casting media

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OSHA SILICA COMPLIANCE FOR OTHER INDUSTRIES

Upgrading from sand to CARBO ceramic media products is an effective way to meet OSHA silica PEL requirements in a wide range of industries and applications. CARBO ceramic products are chemically inert and require no special handling during transportation, storage, handling, use and reclamation.

Other applications for CARBO ceramic media

Other industrial applications Learn more >

  • Abrasives
  • Catalyst supports
  • Heat transfer
  • Turf infill
  • Mine and tunnel roof support
  • Water filtration and absorption
  • Wear resistance

LEARN HOW TO ELIMINATE SLICA DUST FROM YOUR FOUNDRY

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