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This paper seeks to review the industrial applications of state‐of‐the‐art additive manufacturing (AM) techniques in metal casting technology. An extensive survey of concepts, techniques, approaches and suitability of various commercialised rapid casting (RC) solutions with traditional casting methods is presented.

The tooling required for producing metal casting such as fabrication of patterns, cores and moulds with RC directly by using different approaches are presented and evaluated. Relevant case studies and examples explaining the suitability and problems of using RC solutions by various manufacturers and researchers are also presented.

Latest research to optimize the current RC solutions, and new inventions in processing techniques and materials in RC performed by researchers worldwide are also discussed. The discussion regarding the benefits of RC solutions to foundrymen, and challenges to produce accurate and cost‐effective RC amongst AM manufacturers concludes this paper.

The research related to this survey is limited to the applicability of RC solutions to sand casting and investment casting processes. There is practically no implication in industrial application of RC technology.

This review presents the information regarding potential AM application – RC, which facilitates the fabrication of patterns, cores and moulds directly using the computer‐aided design data. The information available in this paper serves the purpose of researchers and academicians to explore the new options in the field of RC and especially users, manufacturers and service industries to produce casting in relatively much shorter time and at low cost and even to cast complex design components which otherwise was impossible by using traditional casting processes and CNC technology.

The purpose of the paper is to illustrate application of the cleaner production concept so as to incorporate environmental protection into business performance. The study analyses areas pertaining to the foundry industry that impact negatively on the environment leading to unsustainable resource utilisation and suggests options for promoting sustainable development within the industry, with specific focus on a foundry in a lower income country (LIC).

Data were collected using the cleaner production (CP) Methodology. Pre‐assessment and assessment was carried out and options generated. The options included both low cost and capital intensive approaches.

The paper finds that the CP approach adopted provides clear guidance for generating options and can be used as a practical basis for managerial decision making and policy formulation. Of major concern is resource depletion and pollution associated with the foundry processes. Used resin sand contains toxic chemicals cause leaching and as such, reclamation of resin sand is suggested. There is need for low income countries (LIC's) to identify the best available technologies (BAT's) that are available within the foundry industry and take these aboard or better still improve on them.

This research developed environmental options that can be applied in the foundry industry. However, it can be said that the findings may have limited global application since the analysis was carried out at one Foundry Company.

The paper focuses on a single foundry factory, since the case study approach was used. As such, environmental indicators and options may vary, since the processes from one foundry to another are bound to differ.

This paper is an attempt at combining theoretical and practical ideas to cover the scope of sustainable manufacturing in the setting of a developing country with a view to identify the lessons that can be learnt and to identify the points of departure when compared with studies done elsewhere. The work informs cleaner production assessment at any level, with a focus of production experiences in the foundry industry in a lower technology, developing economy that is less industrialized. The paper establishes a framework of options that can be applied in the foundry industry and other pollution‐intensive industries.

In the construction sector, river sand has turned into a costly material due to various reasons. In the current study, used foundry sand (UFS) and spent garnet sand (SGS) are used as a partial and full replacement to sand in concrete production.

The objective of the work is to develop non-conventional concrete by replacing river sand with a combination of UFS (constant 20Wt.% replacement) and SGS at various percentages (20, 40, 60 and 80 Wt.%).

Compared to conventional concrete, the 28 days compressive strength of non-conventional concrete (with UFS at 20% and spent garnet sand at 20%, 40% and 60% were 8.12%, 6.77% and 0.83% higher, respectively. The 28 days split tensile strength of non-conventional concrete (UFS at 20% and SGS at 20 and 40%) were 32.2% and 51.6% higher, respectively.

It can be concluded that 60 Wt.% of river sand can be combined replaced with 20 Wt.% UFS and 40 Wt.% SGS to produce good quality concrete whose properties are on par with conventional concrete.

The results showed that combined SGS and UFS can be used as a partial replacement of river sand in the manufacturing of concrete that is used in all the applications of construction sector such as buildings, bridges, dams, etc. and non-structural applications such as drainpipes, kerbs, etc.

Disposal of industrial by-product wastes such as SGS and UFS affects the environment. A sincere attempt is made to use the same as partial replacement of river sand.

Based on the literature study, no work is carried out in replacing the river sand combined with SGS and UFS in concrete.

This paper presents the effects of replacing fine aggregate (FA) with waste foundry sand (WFS) in natural aggregate and construction waste aggregate concrete specimens without and with superplasticizer (SP), silica fume (SF) and fiber (F) to solve the disposal problems of various wastes along with saving the environment. This study aims to investigate the effect of construction waste, WFS along with additives on the stress-strain behavior and development of compressive strength with age.

The various concrete specimen were prepared in mix proportion of 1: 2: 4 (cement (C): sand: coarse aggregate). The water-cement ratio of 0.5 (decreased by 10% for samples containing SP) to grading 1: 2: 4 under air-dry condition was adopted in the preparation of concrete specimens. The compressive strength of various concrete specimen were noticed for 3, 7 and 28 days by applying load through universal testing machine.

Upon adding construction and demolition waste aggregates, the compressive strength of concrete after 28 days was comparable to that of the control concrete specimen. An enhancement in the value of compressive strength is perceived when FA is replaced with WFS to the extent of 10%, 20% and 30%. If both construction and demolition waste aggregate and WFS replacing FA are used, the compressive strength increases. When FA is interchanged with WFS in natural aggregate or construction demolition waste aggregate concrete including usage of SF or F, the compressive strength improves significantly. Further, when construction and demolition waste aggregate and WFS replacing FA including SP are used, the compressive strength improves marginally compared to that of control specimen. The rate of strength development with age is observed to follow similar trend as in control concrete specimen. Therefore, construction and demolition waste and or WFS can be used effectively in concrete confirming an improvement in strength.

The utilization of these wastes in concrete will resolve the problem of their disposal and save the environment.

The purpose of this research is to evaluate construction and industrial waste materials in concrete using different additives.

The experimental study investigated the effect of waste foundry sand (WFS), waste glass (GW) as partial substituent to natural sand and addition of waste glass fibers (GFs) and silica fume (SF) in natural/construction waste aggregate concrete on mechanical properties, durability and microstructure using.

The results reveal significant strength enhancement on using two admixtures, the maximum increase in compressive strength was obtained on using 20% WFS and 0.75% GF for both natural (75% increment) and construction waste (72% increment) coarse aggregates. Using three admixtures simultaneously, the maximum enhancement in compressive strength was found for (WFS(20%) + GW(10%) + GF(0.75%)) for both natural aggregates (122% increment) and construction waste (114% increment) coarse aggregates as compared to control mix. The 28 days split tensile and flexural strength of natural/construction waste aggregate concrete improve with age appreciably for optimal contents of single, two or three admixtures and the maximum tensile and flexural strength increment was 135 and 97% for mix (WFS(20%) + GW(10%) + GF(0.75%)) with natural aggregates as compared to control mix. The microstructural analysis results indicate improved microstructure upon partial substitution of sand with WFS, GW and SF along with addition of waste GFs.

The use of construction and industrial waste as a substituent to natural aggregate/sand will provide far reaching benefits for the green construction and the environment at large.

Waste foundry sand (WFS) is a by-product of the metal casting industries and is used for land filling purposes. Disposing of waste creates problems to environment and increases disposal values. To reduce environmental pollutions and solving disposal problems, several authors in worldwide are carried out research work by partial and complete replacing of natural sand with WFS in concrete mixtures. It is found that WFS can be used for production of structural grade concrete. The mechanical characteristics and flexural properties of RC beams has been reviewed in this paper. From this literature review, it has been noticed that there are improvements in concrete strength properties with WFS.

The results of various properties of concrete have been discussed in this review articles such as compressive strength, split tensile strength, flexural strength, modulus of elasticity, SEM micro-structures and flexural strength properties of RC beams.

From the literature review, it is found that there is gap of research on flexural behavior of reinforced concrete beam with WFS.

By using WFS effectively, the environmental pollutions and dumping of waste can be reduced. WFS can be successfully used in structural concrete members.

The structural behavior of reinforced concrete (RC) beams made with waste foundry sand (WFS) was examined in this study by using investigational data. Five RC beams were tested in this present work, four beams with varying WFS content and one beam with natural aggregates. The factors considered for studying the flexural performance of RC beams were WFS content (10%, 20%, 30% and 40%), 15% Ground Granulated Blast Furnace Slag (GGBS) is used as supplementary cementitious (SCM) content for all beams and tension reinforcement ratio (0.95%). The crack pattern of the RC beams with WFS (RCB1, RCB2, RCB3 and RCB4) was similar to that of referral beam–RCB0. The RC beams made with WFS (RCB1, RCB2, RCB3 and RCB4) show lesser number of cracks than referral beam–RCB0. It is observed that RCB1 beam shows higher ultimate moment carrying capacity than other RC beams. A detailed assessment of the investigational results and calculations based on IS: 456-2000 code for flexural strength exhibited that the present provisions conservatively predicts the flexural strength and crack width of RC beams with WFS and 15% GGBS. It is suggested that 10% WFS can be used to make RC beam.

In this present work, four RC beams made WFS and one RC beam made with natural aggregates. 15% GGBS is used as SCM for all RC beams. After casting of RC beams, the specimens were cured with wetted gunny bags for 28 days. After curing, RC beams like RCB0, RCB1, RCB2, RCB3 and RCB4 were tested under a four-point loading simply supported condition. An assessment of investigational results and calculations as per IS: 456-2000 code provisions has been made for flexural strength and crack width of RC beams with WFS and 15% GGBS. The crack pattern is also studied.

From this experimental results, it is found that 10% WFS can be used for making RC beam. The RCB1 with 10% WFS shows better flexural performance than other RC beams. RC beams made with WFS show lesser number of cracks than referral beam–RCB0. IS: 456-2000 code provisions can be safely used to predict the moment capacity and crack width of RC beams with WFS and 15% GGBS.

By utilization of WFS, the dumping of waste and environmental pollution can be reduced. By experimental investigation, it is suggested that 10% WFS can be used to make RC structural members for low cost housing projects.

The purpose of this paper is to investigate experimentally the effect of volume of casting, pouring temperature of different materials and shell mould wall thickness on the surface roughness of the castings obtained by using ZCast direct metal casting process.

Taguchi's design of experiment approach was used for this investigation. An L9 orthogonal array (OA) of Taguchi design which involves nine experiments for three factors with three levels was used. Analysis of variance (ANOVA) was then performed on S/N (signal‐to‐noise) ratios to determine the statistical significance and contribution of each factor on the surface roughness of the castings. The castings were obtained using the shell moulds fabricated with the ZCast process and the surface roughness of castings was measured by using the surface roughness tester.

Taguchi's analysis results showed that pouring temperature of materials was the most significant factor in deciding the surface roughness of the castings and the shell mould wall thickness was the next most significant factor, whereas volume of casting was found insignificant. Confirmation test was also carried out using the optimal values of factor levels to confirm the effectiveness of this approach. The predicted optimal value of surface roughness of castings produced by ZCast process was 6.47 microns.

The paper presents experimentally investigated data regarding the influence of various control factors on the surface roughness of castings produced by using ZCast process. The data may help to enhance the application of ZCast process in traditional foundry practice.

The purpose of this paper is to attempt to use two industrial wastes; waste foundry sands (WFS) and molasses (M) along with lime (L) to improve the strength characteristics of clayey soil.

In the first part of the study, the optimum percentages of materials (WFS, molasses, lime) have been found out by conducting differential free swell (DFS) and consistency limit tests on clayey soil by adding various admixtures. The second and third part of the study investigates the compaction behaviour and unconfined compressive strength (UCS) of clayey soil on addition of optimum amount of various materials alone and in combination with each other. Finally, the micro-structural behaviour of addition of optimum percentages of lime, WFS and molasses using Scanning electron microscopic technique has been discussed.

The laboratory results revealed that the addition of optimum content of lime along with WFS and molasses reduced DFS and plasticity index and increased maximum dry density and UCS values. The microstructural behaviour showed that the presence of lime and molasses filled the voids present in the soil and the addition of WFS helped in providing compact structure, thus improving the strength characteristics.

The study will be helpful in designing low-cost pavement designs for rural roads.

The adverse effect of waste materials on environment may be solved by using them in improving the strength characteristics of clayey soils, thereby providing healthy environment to living beings.

The study will help to provide low-cost methods to improve strength characteristics of clayey soil along with the use of waste materials; the disposal of whose is a challenging task.

SAND is very harmful to engines. During recent tests conducted by me in the North African Deserts, as much as half a pound of sand has been collected in ten minutes in each air intake of a Mosquito aircraft taxying, alone, downwind on a desert airfield. Had the Mosquito been following another aircraft, or had its air intake been situated lower, the quantity of sand would have been much larger. Under such conditions the importance of having efficient air cleaning intakes fitted to every aircraft engine is obvious. Sandy conditions are not confined to desert airfields, some airfields in this country and on the Continent are as bad.