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Abstract

This paper deals with the issue of using moulding sands with a new two-component binder: furfuryl-resole resin – PCL polycaprolactone for the production of ductile iron heavy castings. The previous laboratory studies showed the possibility of using biodegradable materials as binders or parts of binders’ compositions for foundry moulding and core sands. The research proved that addition of new biodegradable PCL in the amount of 5% to the furfuryl-resole resin does not cause significant changes in moulding sand’s properties. The article presents research related to the production of ductile iron castings with the use of moulds with a modified composition, i.e. sands with furfuryl resole resin with and without PCL. Mechanical properties and microstructure of the casting surface layer at the metal/ mould interface are presented. The obtained test results indicate that the use of a biodegradable additive for making foundry moulds from moulding sand with a two-component binder does not deteriorate the properties of ductile iron castings.
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Authors and Affiliations

M. Hosadyna-Kondracka
1
ORCID: ORCID
K. Major-Gabryś
2
ORCID: ORCID
M. Warmuzek
1
ORCID: ORCID
M. Brůna
3
ORCID: ORCID

  1. Lukasiewicz Research Network – Krakow Institute of Technology, 73 Zakopiańska Str., 30-418 Krakow, Poland
  2. AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-ferrous Metals, Al. Mickiewicza 30, 30-059 Krakow, Poland
  3. University of Žilina, Department of Technological Engineering, Faculty of Mechanical Engineering, Univerzitná 1, 010 26, Slovak Republic
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Abstract

Due to the observed increase in the amount of waste in landfills, there has been an increase in the demand for products made of biomaterials and the composition of biomaterials with petroleum-derived materials. The problem of waste disposal/management also applies to waste from the casting production process with the use of disposable casting moulds made with the use of organic binders (resins), as well as residues from the process of regeneration of moulding sands. A perspective solution is to add a biodegradable component to the moulding/core sand. The authors proposed the use of polycaprolactone (PCL), a polymer from the group of aliphatic polyesters, as an additive to a casting resin commonly used in practice. As part of this study, the effect of PCL addition on the (bio) degradation of dust obtained after the process of mechanical regeneration of moulding sands with organic binders was determined. The (bio) degradation process was studied in the environment reflecting the actual environmental conditions. As part of the article, dust samples before and after the duration of the (bio) degradation process were tested for weight loss by thermogravimetry (TG) and for losses on ignition (LOI).
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Bibliography

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[2] Brenner, V. (2003). Biodegradace persistentních xenobiotik. Biodegradace. VI, 2003, 45-47.
[3] Sobków, D., Barton, J., Czaja, K., Sudoł, M. & Mazoń, B. (2014). Research on the resistance of materials to environmental factors. CHEMIK. 68(4), 347–354. (in Polish).
[4] Stachurek I. (2010). Biomedical systems of polyethylene oxide biodegradable in the aquatic environment. PhD thesis, Politechnika Krakowska. (in Polish).
[5] Eastman, J. (2000). Protein-based binder update: performance put to the test. Modern Casting. 90, 32-34.
[6] Kramářová, D., Brandštetr, J., Rusín, K. & Henzlová, P. (2003). Biogenic polymeric materials as binders for foundry molds and cores. Slévárenství. 60(2-3), 71-73. (in Czech).
[7] Grabowska, B., Holtzer, M., Dańko, R., Górny, M., Bobrowski, A. & Olejnik, E. (2013). New bioco binders containing biopolymers for foundry industry. Metalurgija. 52(1), 47-50.
[8] Grabowska, B., Szucki, M., Suchy, J.Sz., Eichholz, S., Hodor, K. (2013). Thermal degradation behavior of cellulose-based material for gating systems in iron casting production. Polimery. 58(1), 39-44.
[9] Major-Gabryś, K. (2016). Environmentally Friendly Foundry Moulding and Core Sands. Katowice-Gliwice, Archives of Foundry Engineering, ISBN 978-83-63605-24-7 (in Polish)
[10] Major-Gabryś, K. (2019). Environmentally Friendly Foundry Molding and Core Sands. Journal of Materials Engineering and Performance. 28(7), 3905-3911.
[11] Holtzer, M. (2001). Management of waste and by-products in foundries. Kraków: University Scientific and Didactic Publishers, AGH, Poland. (in Polish).
[12] Skrzyński, M., Dańko, R. & Czapla, P. (2014). Regeneration of used moulding sand with furfuryl resin on a laboratory stand. Archives of Foundry Engineering. 14(spec.4), 111-114. (in Polish).
[13] Dańko, R., Łucarz, M. & Dańko, J. (2014). Mechanical and mechanical-thermal regeneration of the used core sand from the cold-box process. Archives of Foundry Engineering. 14(spec.4), 21-24. (in Polish).
[14] Rui, T., Liu, J. (2010). Study of modified furan resin binder system for large steel castings. In Proceedings of 69th World Foundry Congress, 16 - 20 October 2010. Hangzhou, China, World Foundry Organization (pp. 996 – 999).
[15] Dańko, R., Holtzer, M., Dańko, J. (2015). Characteristics of dust from mechanical reclamation of moulding sand with furan cold-setting resins – impact on environment. In Proceedings of the 2015 WFO International Forum on Moulding Materials and Casting Technologies, 25 – 28 September 2015. Changsha, China. WFO Moulding Materials Commission, Foundry Institution of Chinese Mechanical Engineering Society, Productivity Center of Foundry Industry of China (38-46).
[16] Iwamoto, A. & Tokiwa, Y. (1994). Enzymatic degradation of plastics containing polycaprolactone. Polymer Degradation and Stability. 45(2), 205-213.
[17] Eastmond, G.C. (2000). Poly(ε-caprolactone) blends. Advances in Polymer Science. 149, 59-222.
[18] Gutowska, A., Michniewicz, M., Ciechańska, D. & Szalczyńska, M. (2013). Methods of testing the biodegradability of biomass materials. CHEMIK. 67(10), 945-954. (in Polish).
[19] Major-Gabryś, K., Hosadyna-Kondracka, M., Skrzyński, M., Pastirčák, R. (2020). The quality of reclaim from moulding sand with furfuryl resin and PCL additive. The abstract paper at XXVI international conference of Polish, Czech and Slovak founders: 7-9.09.2020 r. Baranów Sandomierski, Poland.
[20] Major-Gabryś, K., Hosadyna-Kondracka, M. & Stachurek, I. (2020). Determination of mass loss in samples of post-regeneration dust from moulding sands with and without PCL subjected to biodegradation processes in a water environment. Journal of Applied Materials Engineering. 60(4), 121-129.
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Authors and Affiliations

K. Major-Gabryś
1
ORCID: ORCID
I. Stachurek
2
ORCID: ORCID
M. Hosadyna-Kondracka
2
ORCID: ORCID

  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Mickiewicza 30, 30-059 Cracow, Poland
  2. ŁUKASIEWICZ Research Network - Foundry Research Institute, Zakopianska 73, 30-418 Cracow, Poland

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