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Development of Water-Soluble Composite Salt Sand Cores Made by a Hot-Pressed Sintering Process

Xiaona Yang Long Zhang Xing Jin Jun Hong Songlin Ran Fei Zhou
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 51-58 | DOI: 10.24425/afe.2023.146662
Keywords Water-soluble cores Hollow composite castings Salt cores Collapsibility
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Abstract

A wide variety of water-soluble cores are widely used in hollow composite castings with internal cavities, curved channels, and undercuts. Among them, the cores made by adding binders of inorganic salts in the form of aqueous solutions have excellent solubility in water. However, excellent collapsibility is often accompanied by poor moisture absorption resistance. In this study, a water-soluble core with moderate strength and moisture absorption resistance was prepared by hot pressing and sintering the core sand mixture of sand, bentonite, and composite salts, and a tee tube specimen was cast. The experimental results showed that the cores with KCl-K2CO3 as binder could obtain strength of more than 0.9 MPa and still maintain 0.3 MPa at 80±5% relative humidity for 6 hours; the subsequent sintering process can significantly improve the resistance to moisture absorption of the hot pressed cores (0.6 MPa after 24 hours of storage at 85±5% relative humidity); the water-soluble core prepared by the post-treatment can be used to cast tee pipe castings with a smooth inner surface and no porosity defects, and it is easy to remove the core.
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Authors and Affiliations

Xiaona Yang
1
Long Zhang
1
Xing Jin
2
Jun Hong
3
Songlin Ran
2
Fei Zhou
3
  1. School of Metallurgical Engineering, Anhui University of Technology, China
  2. Anhui Province Key Laboratory of Metallurgical Engineering & Resources Recycling, Anhui University of Technology, China
  3. Technical Department, Anhui Highly Precision Casting Co., Ltd, China

Simulation and Heat Treatment Process of Carbon Nanotube Modified Aluminum Alloy (ZL105)

Ziqi Zhang Zhilin Pan Rong Li Qi Zeng Yong Liu Quan Wu
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 38-50 | DOI: 10.24425/afe.2023.146661
Keywords cast aluminum alloy heat treatment CNTs First principle Mechanical performance
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Abstract

To further improve the mechanical properties of carbon nanotubes (CNTs) modified aluminum alloy (ZL105), the first principle was used to build the atomic structure of the alloy system and the alloy system was simulated by the VASP. After that, the heat treatment process of the cast aluminium alloy material with CNTs to enhance the alloy performance by the orthogonal experiment. The results of the research show that: (1) The energy status of the alloy system could be changed by adding the C atoms, but it did not affect the formation and structural stability of the alloy system, and the strong bond compounds formed by C atoms with other elements inside the solid solution structure can significantly affect the material properties. (2) The time of solid solution has the greatest influence on the performance of material that was modified by CNTs. The solution temperature and aging temperature were lower strength affection, and the aging time is the lowest affection. This paper provides a new research method of combining the atomic simulation with the casting experiment, which can provide the theoretical calculations to reduce the experiment times for the casting materials’ performance improvement.
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Authors and Affiliations

Ziqi Zhang
1
Zhilin Pan
1
ORCID: ORCID
Rong Li
1
ORCID: ORCID
Qi Zeng
2
ORCID: ORCID
Yong Liu
3
ORCID: ORCID
Quan Wu
1
  1. School of Mechanical & Electrical Engineering, Guizhou Normal University, China
  2. Guiyang Huaheng Mechanical Manufacture CO., LTD, China
  3. Guizhou University, China

Assessment of Foundry Chromite Sand Crushability under Thermal-Mechanical Loading

J.K. Kabasele K.D. Nyembwe H. Polzin
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 16-21 | DOI: 10.24425/afe.2023.144310
Keywords Innovative foundry technologies and materials Environment protection Crushability Chromite sand Moulding aggregates
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Abstract

When used for sand casting, foundry sand is stressed in several ways. These stresses, thermal and mechanical, compromise the grain integrity, resulting in size reduction and the production of small particles to the point where the sand is no longer viable for sand casting. This study evaluates the crushability of chromite sand, a crucial characteristic for determining how resistant sand is to size reduction by crushing. To replicate the heat and mechanical strain that sand is subjected to during the industrial sand-casting process, a sinter furnace and rod mill were employed. After nine minutes of heat and mechanical stress application, the crushing ratio, which was used to gauge the crushability of chromite sand, ranged from 1.72 to 1.92 for all samples. There were differences in the rate at which fine particles were produced among the samples, with sample E producing the highest proportion of fine particles in the same length of time. Understanding the properties that control the crushability performance of chromite sand will enable foundries to buy chromite sand with higher recycling yield, reducing the environmental impact of waste foundry sand and eliminating the risk to the workforce's pulmonary health in line with the current industry standards. Foundries will also be able to optimize the current industrial process while continually pushing for innovative foundry technologies and materials.
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Bibliography


[1] Campbell, J. (2015). Complete Casting Handbook. UK: Second ed.. Butterworth-Heinemann.
[2] Güngen, A.C., Aydemir, Y., Çoban, H., Düzenli, H. & Tasdemir, C. (2016). Lung cancer in Patients Diagnosed with Silicosis Should be Investigated. Respiratory Medicine Case Reports. 18(1), 93-95. DOI: 10.1016/j.rmcr.2016.04.011.
[3] Dai, Y., Ma, Q.Y., X.H. Li, X.H., Zhang, X., Hu, F.P., Zhang, Y. & Xie, W.D. (2017). The research on characterization of crushability for foundry sand particles. Archives of Foundry Engineering. 17(4), 231-235. DOI: 10.1515/afe-2017-0161.
[4] Khan, M.M., Mahajani, S.M., Jadhav, G.N., Vishwakarma, R., Malgaonkar, V. & Mandre, S. (2021). Mechanical and thermal methods for reclamation of waste foundry sand. Journal of Environmental Management. 279(1), 111628. https://doi.org/10.1016/j.jenvman.2020.111628.
[5] Dańko, J.S., Dańko, R. & Holtzer, M. (2003). Reclamation of used sand in foundry production. Metalurgija. 42(3), 173-177. ISSN 0543-5846.
[6] Ghormley, S., Williams, R. & Dvorak, B. (2020). Foundry sand source reduction options: Life cycle assessment evaluation. Environments. 7(9), 66, 1-15. https://doi.org/10.3390/environments7090066.
[7] Das, S.K.. & Das, A. (2022). A critical state based viscoplastic model for crushable granular materials. Soils and Foundations. 62(1), 1-16. https://doi.org/10.1016/j.sandf.2021.101093.
[8] Kabasele, J.K. (2022). Investigation of South African Foundry Chromite sand Crushability, Masters thesis. Johannesburg: University of Johannesburg
[9] Kabasele, J.K. & Nyembwe, K.D. (2021). Assessment of local chromite sand as ‘green’ refractory raw materials for sand casting applications. South African Journal of Industrial Engineering. 32(2), 65-74. http://dx.doi.org/10.7166/32-3-2615.

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Authors and Affiliations

J.K. Kabasele
1
ORCID: ORCID
K.D. Nyembwe
1
ORCID: ORCID
H. Polzin
2
  1. Department of Metallurgy, University of Johannesburg, 55 Beit Street, Doornfontein, Johannesburg, South Africa
  2. Peak Deutschland GmbH, Dresdner Straße 58, 01683 Nossen, Germany

Effectiveness of Absorbing Microwaves by the Multimaterial Sodium Silicate Base Sand - PLA (Polylactide) Mould Wall Systems

M. Stachowicz
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 30-37 | DOI: 10.24425/afe.2023.144312
Keywords foundry Microwaves Sodium silicate base sand PLA Lossiness measurements
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Abstract

In the paper presented are results of a research on effectiveness of absorbing electromagnetic waves at frequency 2.45 GHz by unhardened sodium silicate base sands (SSBS) prepared of high-silica base sand and a PLA (Polylactide) 3D-prited (3DP) mould walls. Measurements of power loss of microwave radiation (P in) expressed by a total of absorbed power (P abs), output power (P out) and reflected power (P ref) were carried-out on a stand of semiautomatic microwave slot line for determining balance of microwave power emitted into selected multimaterial systems. Values of microwave power loss in the rectangular waveguide filled with unhardened moulding sands and prepared by fused deposition modelling (FDM) 5 mm polylactide (PLA) walls with grid infill density from 25% to c.a. 100% served for determining effectiveness of microwave heating. Balance of microwave power loss is of technological importance for microwave manufacture of high-quality casting sand moulds and cores in possibility of use 3D-printed mould tools and core boxes. It was found that apparent density of SSBS placed in a waveguide with PLA walls influences parameters of power output (P out) and power reflected (P ref). The PLA wall position and grid infill density were identified to have a limited effect on effectiveness of absorbing microwaves (P abs).
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Authors and Affiliations

M. Stachowicz
1
ORCID: ORCID
  1. Wroclaw University of Technology, Poland

Correlation Between K-value, Density Index and Bifilm Index in Determination of Liquid Al Cleanliness

A. Tigli M. Tokatli E. Uslu M. Colak D. Dispinar
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 22-29 | DOI: 10.24425/afe.2023.144311
Keywords A206 aluminum casting K mold Liquid metal cleaning RPT Secondary aluminum
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Abstract

Aluminum alloys are widely used in the industry thanks to its many advantages such as light weight and high strength. The use of this material in the market is increasing day by day with the developing technology. Due to the high energy inputs in the primary production, the use of secondary ingots by recycling from scrap material are more advantageous. However, the liquid metal quality is quite important in the use of secondary aluminum. It is believed that the quality of recycled aluminum is low, for this purpose, many liquid metal cleaning methods and test methods are used in the industry to assess the melt cleanliness level. In this study, it is aimed to examine the liquid metal quality in castings with varying temperature using K mold. A206 alloy was used, and the test parameters were selected as: (i) at 725 °C, 750 °C and 775 °C casting temperatures, (ii) different hydrogen levels. The hydrogen level was adjusted as low, medium and high with degassing, as-cast, and upgassing of the melt, respectively. The liquid metal quality of the cast samples was examined by the K mold technique. When the results were examined, it was determined that metal K values and the number of inclusions were high at the as-cast and up-gas liquid with increasing casting temperatures. It has been understood that the K mold technique is a practical method for the determination of liquid metal quality, if there is no reduced pressure test machine available at the foundry floor.
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Authors and Affiliations

A. Tigli
1 2
ORCID: ORCID
M. Tokatli
3
E. Uslu
3
ORCID: ORCID
M. Colak
3
D. Dispinar
1 4
ORCID: ORCID
  1. Istanbul Technical University, Turkey
  2. Sinop University, Turkey
  3. Bayburt University, Turkey
  4. Foseco, Netherlands

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