Bauxite Sand for Foundries FAQ: Specifications, Ordering and Support Questions

Bauxite sand is gaining wide adoption as a foundry molding sand across iron, steel, aluminum and copper casting operations. The questions below address the specifications, applications and ordering details buyers and procurement teams most commonly ask about this material. For technical details and sample enquiries, see Shenghuo New Material Technology Co., Ltd.'s Premium Bauxite Sand product page.

What is bauxite sand and what are its key chemical properties?

Bauxite sand is an artificial, engineered foundry sand whose mineralogical composition is Mullite + Corundum. Its confirmed chemical specification is:

The mullite and corundum phases give this material a refractoriness of ≥ 1 800 °C and a thermal expansion of 4.5 – 6.5 × 10⁻⁶/K (RT to 1 200 °C).

What particle sizes and grain shapes are available?

The material is produced with a spherical grain shape and an angular coefficient of ≤ 1.1. The full particle size range spans 45 µm to 2 000 µm. Standard mesh codes and typical AFS numbers are shown below:

Custom particle size distributions can be specified to meet particular mold requirements.

Which foundry processes is this material compatible with?

It can be used as a single sand in the following processes:

• Resin-coated sand
• No-bake sand
• Cold core box
• Green sand
• Precision casting
• Lost foam casting
• 3D printing casting

Its controlled particle size distribution and spherical shape make it well suited for 3D printing foundry applications, where uniform flow and consistent packing are required.

How does it compare with zircon, chromite and cerabeads?

It is a direct substitute for fused ceramic sand, cerabeads, chromite sand, zircon sand and silica sand.

Similar high refractoriness and durability to zircon sand are achieved at substantially lower cost, resulting in a higher return on investment without compromising casting quality.

Why does it require less resin than other foundry sands?

The spherical grain shape and specific surface structure reduce the surface area that binder must coat. Published specifications state that 30 to 50 % less resin is required compared with standard foundry sands, directly lowering raw material chemical costs per batch.

What bulk density and thermal expansion values should I use for mold design?

Use the following published physical parameters:

• Bulk density: 1.45 – 1.6 g/cm³
• Thermal expansion (RT – 1 200 °C): 4.5 – 6.5 × 10⁻⁶/K

The low thermal expansion contributes to more accurate casting dimensions and better mold performance compared with higher-expansion alternatives such as silica sand.

Can I order a custom particle size distribution, and how do I contact the supplier?

Yes. Particle size distribution can be fully customized across the 45 µm to 2 000 µm range. Contact Shenghuo New Material Technology Co., Ltd. to discuss your target AFS number or mesh range before placing an order. Standard grades and enquiry details are available on the product page linked above.

What quality parameters are monitored in production?

Published product information identifies the following quality-control focus areas:

• Al₂O₃ and Fe₂O₃ levels, to ensure consistent chemical purity in every batch
• L.O.I. maintained below 0.1 % for maximum reliability
• Grain shape and angular coefficient (spherical, ≤ 1.1)
• Particle size distribution verified against agreed mesh codes

For specific lot certifications or quality documentation, contact Shenghuo New Material Technology Co., Ltd. directly.