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Abstract

Sodium silicate is one of the most successful inorganic binder. Along with the broad application of sodium silicate for domestic and industrial purposes, the composition analysis, include modulus (m), ratio of SiO2:Na2O, Na2O%, SiO2%, and solid-containing content, is important for the products strength and service life. However, it is perplexing to operate, inefficient and low precision for traditional standard testing method of these parameters. In this study, an automatic measurement system of sodium silicate composition analysis, with the potential electrode for potentiometer titration, micro-controller, PCB, heater, stirrer, printer and micro peristaltic pump, was developed according to the determine method principle. The end-points of pH value in the two titrating steps, first was 4.3 and second was 6.0, were set in the micro-controller to control the reaction in the processing of the sodium silicate composition analysis. And all the potential signals of the pH electrode were transited in the special PCB for the micro-controller.
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Bibliography

[1] Rabbii, A. (2001). Sodium silicate glass as an inorganic binder in foundry industry. Iranian Polymer Journal. 10(4), 229-235.
[2] Stachowicz, M., Pałyga, Ł.& Kȩpowicz, D. (2020). Influence of automatic core shooting parameters in hot-box technology on the strength of sodium silicate olivine moulding sands. Archives of Foundry Engineering. 20(1), 67-72.
[3] Huafang, W., Wenbang, G. & Jijun, L. (2014). Improve the humidity resistance of sodium silicate sands by estermicrowave composite hardening. Metalurgija. 53(4), 455-458.
[4] Nowak, D. (2017). The impact of microwave penetration depth on the process of heating the moulding sand with sodium silicate. Archives of Foundry Engineering. 17(4), 115-118.
[5] M. Stachowicz, K. Granat, & D. Nowak. (2011). Application of microwaves for innovative hardening of environment-friendly water-glass moulding sands used in manufacture of cast-steel castings. Archives of Civil and Mechanical Engineering. XI(1), 209-219.
[6] Zhu, CX. (2007). Recent advances in waterglass sand technologies. China Foundry. 4(1), 13-17.
[7] Masuda Yuki, Tsubota Keiji, Ishii Kenichi, Imakoma Hironobu, Ohmura Naoto. (2009) Drying rate and surface temperature in solidification of glass particle layer with inorganic binder by microwave drying. Kagaku Kogaku Ronbunshu. 35(2). 229-231.
[8] Standardization Administration of the P.R.C. (2008). GB/T4209-2008, Sodium silicate for industry use[S]. Beijing, China Standard Press.
[9] Bourikas K., Kordulis C. & Lycourghiotis A. (2005). Differential potentiometric titration: Development of a methodology for determining the point of zero charge of metal (Hydr)oxides by one titration curve. Environmental Science & Technology. 39(11), 4100-4108.
[10] Fan ZT, Liu M, Wang HF, Long W, Hu XT. (2010). Chinese Patent No. 201010558029.3. Beijing, China National Intellectual Property Administration.
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Authors and Affiliations

Huafang Wang
1
ORCID: ORCID
Quanrun Wang
1
Wu Zhang
1
Xiang Gao
1
Jijun Lu
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, Wuhan 430073, China
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Abstract

The sodium silicate sands hardened by microwave have the advantages of high strength, fast hardening speed and low residual strength with the lower addition of sodium silicate. However, the sodium ion in the sands will absorb moisture from the atmosphere, which would lead to lower storing strength, so the protection of a bonding bridge of sodium silicate between the sands is crucial. Methyl silicone oil is a cheap hydrophobic industrial raw material. The influence of the addition amount of methyl silicone oil modifier on compressive strength and moisture absorption of sodium silicate sands was studied in this work. The microscopic analysis of modified before and after sodium silicate sands has been carried on employing scanning electron microscopy(SEM) and energy spectrum analysis(EDS). The results showed that the strength of modified sodium silicate sands was significantly higher than that of unmodified sodium silicate sands, and the best addition of methyl silicone oil in the quantity of sodium silicate was 15%. It was also found that the bonding bridge of modified sodium silicate sands was the density and the adhesive film was smooth, and the methyl silicone oil was completely covered on the surface of the sodium silicate bonding bridge to protect it.
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Bibliography

[1] Stachowicz, M., Pałyga, Ł. & Kȩpowicz, D. (2020). Influence of automatic core shooting parameters in hot-box technology on the strength of sodium silicate olivine moulding sands. Archives of Foundry Engineering. 20(1), 67-72.
[2] Nowak, D.(2017).The impact of microwave penetration depth on the process of hardening the moulding sand with sodium silicate. Archives of Foundry Engineering. 17(4), 115-118.
[3] Gal, B., Granat, K. & Nowak, D. (2017). Effect of compaction degree on permittivity of water-glass containing moulding sand. Metalurgija. 56(1), 17-20.
[4] Kaźnica, N. & Zych, J. (2019). Indicator wso: a new parameter for characterization of protective coating efficiency against humidity. Journal of Materials Engineering and Performance. 28(7), 3960-3965.
[5] Bae, M.A., Lee, M.S. & Baek, J.H. (2020). The effect of the surface energy of water glass on the fluidity of sand. Journal of Korean Institute of Metals and Materials. 58(5), 319-325.
[6] Peng, Q.S., Wang, P.C., Huang, W., & Chen, H.B. (2020). The irradiation-induced grafting of nano-silica with methyl silicone oil. Polymer. 192(4), 122315.
[7] Stachowicz, M., Granat, K., & Payga. (2017). Influence of sand base preparation on properties of chromite moulding sands with sodium silicate hardened with selected methods. Archives of Metallurgy and Materials. 62(1), 379-383.
[8] Zhu, C. (2007). Recent advances in waterglass sand technologies. China Foundry. 4(1), 13-17.
[9] Huafang, W., Wenbang, G. & Jijun, L. (2014). Improve the humidity resistance of sodium silicate sands by ester-microwave composite hardening. Metalurgija. 53(4), 455-458.
[10] Masuda, Y., Tsubota, K., Ishii, K., Imakoma, H. & Ohmura, N. (2009). Drying rate and surface temperature in solidification of glass particle layer with inorganic binder by microwave drying. KAGAKU KOGAKU RONBUNSHU. 35(2), 229-231.
[11] Kosuge, K., Sunaga, M., Goda, R., Onodera, H. & Okane, T. (2018). Cure and collapse mechanism of inorganic mold using spherical artificial sand and water glass binder. Materials transactions. 59(11), 1784-1790.
[12] Zhang, Y.H., Liu, Z.Y., Liu, Z.C. & Yao, L.P. (2020). Mechanical properties of high-ductility cementitious composites with methyl silicone oil. Magazine of Concrete Research. 72(14), 747-756.
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Authors and Affiliations

Huafang Wang
1
ORCID: ORCID
Xiang Gao
1
Lei Yang
1
ORCID: ORCID
Wei He
1
Jijun Lu
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
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Abstract

The exothermic insulating riser played an important role in the solidification process of metal liquid for the improvement of casting quality. This paper focused on the use of organosilicon slag to replace part of the aluminum powder as an exothermic agent for the riser, to reduce production costs and turn waste into treasure. The experiments firstly studied the effect of organosilicon slag content on the combustion temperature and holding time and determined the components of the riser exothermic agent and organosilicon slag. On this basis, the effects of the content of Na3AlF6 flux and alkali phenolic resin binder on the combustion heating time and strength properties of the riser were studied. And the ratio of mixed oxidants was determined by single-factor orthogonal experiments to optimize the addition of three oxidants, Fe3O4, MnO2, and KNO3. Finally, the performance of the riser prepared after optimization was compared with that of the riser prepared with general aluminum powder. The results showed that with the mixture of 21% organosilicon slag and 14% aluminum powder as the exothermic agent, the highest combustion temperature of the prepared exothermic insulating riser was 1451℃ and the holding time was 193 s; the optimal content of Na3AlF6 flux was 4%, and the best addition alkali phenolic resin binder was 12%; the optimized mixing ratio of three oxidants was 12% for Fe3O4, 6% for MnO2, and 6% for KNO3. Under the optimized ratio, the maximum combustion temperature of the homemade riser was 52℃ and the heat preservation time was 14% longer compared with the conventional exothermic insulating riser with 25-35% aluminum powder.
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Authors and Affiliations

Jijun Lu
1
ORCID: ORCID
Jiangbing Qian
1
ORCID: ORCID
Lei Yang
1
ORCID: ORCID
Huafang Wang
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
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Abstract

Iron black commonly employs in thermal insulation riser sleeves due to its ability to react with aluminum powder, generating heat. However, the complex production process and unstable composition of iron black lead to high production costs. The potential of using arc furnace flue ash (AFFA) as a complete substitute for iron black and MnO2 and KNO3 oxidizing agents in conventional riser sleeves was investigated in this study. Waste material can be transformed into a valuable resource, while production costs can be reduced by utilizing arc furnace flue ash. The research examined the impact of varying types and amounts of arc furnace flue ash on riser sleeve temperature and holding time by conducting single-factor and orthogonal optimization experiments. The orthogonal optimization experiment determined that the optimum ratio of each oxidant was 6 % arc flue ash, 3 % MnO2 and 6 % KNO3. At this time, the highest temperature was 1512 ℃ and the holding time was 244 s. Results indicated that different types of arc furnace flue ash used as an oxidizing agent demonstrated superior holding capacity and heat generation performance compared to iron black. Additionally, a comparative analysis of factory casting experiments using ductile iron 600-3 (IS) revealed that both arc furnace flue ash and iron black risers effectively countered shrinkage. However, arc furnace flue ash risers exhibited improved mechanical properties, as evidenced by the hardness of the castings.
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Bibliography

[1] Lu, J.J., Qian, J.B., Yang, L. & Wang, H.F. (2023). Preparation and performance optimization of organosilicon slag exothermic insulating riser. Archives of Foundry Engineering. 23(1), 75-82. DOI: 10.24425/afe.2023.144283.
[2] Vasková, I., Conev, M. & Hrubovčáková, M. (2017). The influence of using different types of risers or chills on shrinkage production for different wall thickness for material EN-GJS-400-18LT. Archives of Foundry Engineering. 17(2), 131-136. DOI: 10.1515/afe-2017-0064.
[3] Sowa, L., Skrzypczak, T. & Kwiatoń, P. (2019). The influence of riser shape on feeding effectiveness of solidifying casting. Archives of Foundry Engineering. 19(4), 91-94. DOI: 10.24425/afe.2019.129636.
[4] Krajewski, P.K., Gradowski, A. & Krajewski, W.K. (2013). Heat exchange in the system mould - riser - ambient. part ii: surface heat emission from open riser to ambient. Archives of Metallurgy and Materials. 58(4), 1149-1153. DOI: 10.2478/amm-2013-0140.
[5] Xu, X. Hui,G,D. Ma, B, H . et al. (2017). Research on high efficiency heat insulation risers for casting. Casting technology. 38(03), 726-728. (in Chinese).
[6] Zhang, S.L., Wu, B., Qin, Z.G.,et al .(2010). Ignition temperature of 2Al/Fe2O3 aluminum thermite. Energy Containing Materials. 18(02), 162-166. (in Chinese).
[7] Duan, W. H., Li, G., Zu. C.S., et al (2017). Control of critical characteristics of heat-insulating riser sleeves and countermeasures for application problems. China Casting Equipment and Technology, 2017(06), 20-24. (in Chinese).
[8] Sambo, A. & Szymanek, A. (2014). Analysis of the distribution of chemical compounds from fly ash exposed to weather. Chemical and Process Engineering. 35(3), 265-275. DOI: 10.2478/cpe-2014-0020.
[9] Chen, J. (2022). Application of steelmaking electric arc furnace ash in sintered bricks[J]. Brick and Tile, 2020 (7): 25-27. DOI:10.16001/j.cnki.1001-6945.2020.07.011.
[10] Wang, J., Zhang, Y.Y., Cui, K.K., Fu. T., Gao, J.J. Shahid Hussain, Tahani Saad AlGarni. (2021). Pyrometallurgical recovery of zinc and valuable metals from electric arc furnace dust – A review. Journal of Cleaner Production. 298, 126788. DOI:10.1016/j.jclepro.2021.126788.
[11] Donald, J.R. & Pickles, C.A. (1996). Reduction of electric arc furnace dust with solid iron powder. Canadian Metallurgical Quarterly. 35(3), 255-267. DOI:10.1016/0008-4433(96)00009-2.
[12] Lin, X.L. Peng. Z.W., Yan. J.X., Li. Z., Z. Hwang, J.Y. Zhang, Y.B., Li, G.H., Jiang, T. (2017). Pyrometallurgical recycling of electric arc furnace dust. Journal of Cleaner Production. 149, 1079-1100. DOI:10.1016/j.jclepro.2017.02.128.
[13] Abhilash T. Nair, Aneesh Mathew, Archana A R, M Abdul Akbar.(2022). Use of hazardous electric arc furnace dust in the construction industry: A cleaner production approach. Journal of Cleaner Production. 377, 134282, 0959-6526. DOI:10.1016/j.jclepro.2022.134282
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Authors and Affiliations

Junjie Zhu
1
ORCID: ORCID
Jian Feng
2
ORCID: ORCID
Ling Liu
1
ORCID: ORCID
Huafang Wang
1
ORCID: ORCID
Jijun Lu
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
  2. CRRC Corporation Limited, China

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