Facing sand composition and method of incorporation in a mold

A method of preparing a facing sand composition for retaining surface detail comprising:

• preparing a fine green sand comprising the steps of mixing a fine silica sand with between about 5-7% of a binder mixture of sodium montmorillonite and quaternary amine;
• and
• mulling the fine green sand with about 4-10% refined oil, a catalyst compatible with the binder mixture, about 6-10% of coarse green sand, and between 14-18% burned sand for forming the facing sand composition;
• wherein all percentages are based on the amount of fine green sand.

A method of preparing a mold for retaining surface detail in a pattern comprising the steps of:

• preparing a facing sand composition comprising the steps of mixing a fine silica sand with about 5-7% of a binder mixture of sodium montmorillonite and quaternary amine, mulling the fine sand with about 4-10% refined oil, and a catalyst compatible with the binder mixture, about 6-10% of coarse green sand, and about 14-18% burned sand for form a facing sand composition;
• optionally resting and mulling the facing sand composition, and wherein all percentages are based on the amount of fine sand;
• arranging a pattern in a flask having at least a portion of the pattern containing surface detail;
• riddling a thin layer of the facing sand composition over the pattern and surface detail and compacting the facing sand about the pattern;
• riddling a thin layer of a dry system sand over the compacted facing sand;
• riddling a layer of the dry system sand across the flask including over the pattern and compacting the dry system sand outside a periphery of the surface detail;
• and
• riddling a layer of dry system sand in across the pattern and compacting the dry system sand across the flask including over the pattern.