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2025, Vol: 3, Issue: 1
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Review Article 


A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application

Suleiman Iliyasu Tanimu, Katsina Christopher Bala, Sunday Albert Lawal, Aliyu Alhaji Abdullahi, Muhammad Isah.


Abstract
This paper presents a review that briefly examines the functional characteristics of the constituents of moulding sand namely silica, binders (bentonite), and additives used in green sand casting. It captures the role these constituents play in optimizing the sand-casting process especially for Aluminium and Aluminium alloy. The review features how each component contributes to the quality of casts produced- silica sand being the primary or base material and usually comprising 85-91% of the mould mixture provides the required structural support and thermal resistance, binders (organic or inorganic) provides the required cohesion and plasticity and the additives enhances some specific attributes such as strength, collapsibility and quality of the surface. The paper further reviews the use of design of experiment techniques such as Taguchi methodology, response surface methodology (RSM) as well as fractional factorial design in optimizing the process parameters for a quality and defect free Al-6063 pot cast. The review further highlights the abundance and suitability of these constituents in Nigeria aligning the study with sustainable development goals specifically goal 12 which is about sustainable consumption and production. The review will provide directional insights for future research on understanding the functional characteristics of green moulding sand constituents

Key words: AL-6063, Taguchi, Scheffes Model, Response surface methodology, Green Mould


 
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How to Cite this Article
Pubmed Style

Tanimu SI, Bala KC, Lawal SA, Abdullahi AA, Isah M. A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. NJEAS. 2025; 3(1): 234-247. doi:10.5455/NJEAS.282428

Web Style

Tanimu SI, Bala KC, Lawal SA, Abdullahi AA, Isah M. A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. https://www.nilejeas.com/?mno=282428 [Access: June 23, 2026]. doi:10.5455/NJEAS.282428

AMA (American Medical Association) Style

Tanimu SI, Bala KC, Lawal SA, Abdullahi AA, Isah M. A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. NJEAS. 2025; 3(1): 234-247. doi:10.5455/NJEAS.282428


Vancouver/ICMJE Style

Tanimu SI, Bala KC, Lawal SA, Abdullahi AA, Isah M. A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. NJEAS. (2025), [cited June 23, 2026]; 3(1): 234-247. doi:10.5455/NJEAS.282428


Harvard Style

Tanimu, S. I., Bala, . K. C., Lawal, . S. A., Abdullahi, . A. A. & Isah, . M. (2025) A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. NJEAS, 3 (1), 234-247. doi:10.5455/NJEAS.282428


Turabian Style

Tanimu, Suleiman Iliyasu, Katsina Christopher Bala, Sunday Albert Lawal, Aliyu Alhaji Abdullahi, and Muhammad Isah. 2025. A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. Nile Journal of Engineering and Applied Science, 3 (1), 234-247. doi:10.5455/NJEAS.282428


Chicago Style

Tanimu, Suleiman Iliyasu, Katsina Christopher Bala, Sunday Albert Lawal, Aliyu Alhaji Abdullahi, and Muhammad Isah. "A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application." Nile Journal of Engineering and Applied Science 3 (2025), 234-247. doi:10.5455/NJEAS.282428


MLA (The Modern Language Association) Style

Tanimu, Suleiman Iliyasu, Katsina Christopher Bala, Sunday Albert Lawal, Aliyu Alhaji Abdullahi, and Muhammad Isah. "A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application." Nile Journal of Engineering and Applied Science 3.1 (2025), 234-247. Print. doi:10.5455/NJEAS.282428


APA (American Psychological Association) Style

Tanimu, S. I., Bala, . K. C., Lawal, . S. A., Abdullahi, . A. A. & Isah, . M. (2025) A Review on Green Sand Moulding and Design of Experiments for Aluminium and Aluminium Alloys Casting: Materials, Properties and Application. Nile Journal of Engineering and Applied Science, 3 (1), 234-247. doi:10.5455/NJEAS.282428


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1. Prof. Abdulhameed Danjuma Mambo
   Editor-in-Chief
abdulhameed.mambo@nileuniversity.edu.ng
2. Dr. Adekunle Adeleke
    Associate Editor-in-Chief
    adekunle.adeleke@nileuniversity.edu.ng
3. Dr. Ifeyinwa Obianyo
Managing Editor
ifeyinwa.obianyo@nileuniversity.edu.ng