Casting process takes a major percentage of manufacturing products into consideration. No-bake casting is swiftly developing technology for foundry industries. In the no-bake family, furan no-bake casting process employs resins and acid catalyst to form a furan binder system. However, this process configures castings with augmented strength and quality surface finish. Compressive strength, transverse strength and tensile strength of moulds are also high in this furan binder system. Hence this method is apt for producing accurately dimensioned castings. Our well thought-out deliberations in the subsequent write up entail the numerous effects of variation of resin and acid catalyst on the surface defect i.e. sulfur diffusion on the surface of FNB casting. Furan resin; used in the production of casting is furfuryl alcohol and acid catalyst is sulphonic acid. Sulfur diffusion is tested by Energy-dispersive X-ray spectroscopy (EDX) analysis and also by the spectrometer with jet stream technology. This paper also comprises economic advantages of optimizing resin because furan resin is expensive and catalyst with reduction of sulfur diffusion defect as it saves machining, labor cost, and energy.

APNB (alkaline phenolic no bake), widely known as Alphaset is one of the major sand binder systems used in foundries to make molds and cores without application of heat or gas. This is a two part system comprising of a phenol-formaldehyde resin in alkaline medium as binder and range of esters of dibasic acids and/or polyhydric alcohols as hardeners.

Resin performance varies depending upon formulations. Major variables in formulations are mole ratio of phenol: formaldehyde, total alkali content, ratio of two alkalis (NaOH & KOH) and molecular weight of polymers i.e. chain length.

In present work, one mole ratio of phenol & formaldehyde has been chosen to prepare 8 resins with following details.

Table 1.

Physical and chemical properties of eight (fresh) resins, A to H

Properties of these 8 formulations have been studied for strength and viscosity over a period of 12 weeks in 4 week interval.

Attempt has been made to develop a simple test for simulating hot & retained strength of molds in laboratory. Process followed for chasing hot and retained strength is described under clause 2.

With more and more understanding of the chemistry of alphaset system in last three & half decades it has been possible to identify role of variables contributing towards specific properties vis a vis developing tailor made formulations to fulfill requirements of individual foundries right from mold making to de coring.

The goal of this article is to application of non-silica sands based on alumininosilicates as an alternative of traditionally used chromite sand for alloyed steel and iron castings. Basic parameters as bulk density, pH value of water suspension, refractoriness, grain shape of the testing sands were evaluated. Also mechanical properties of furan no-bake moulding mixtures with testing sand were determined. Finally, the influence of non-silica sand on casting quality was evaluated via semi-scale under normal casting production for sand characterization Optimization of production process and production costs were described.

Sand samples with furan binder were prepared using Sand, Furfuryl Alcohol and Toluene Sulfonic Acid with ratio 100:0.85:0.30. To

identify and quantify gases releasing from furan binder various studies like FTIR, TGA and GC-MS were carried out. After analyzing our

materials using above mentioned characterizations the chemical formula of the Resin and Binder and amount of gases releasing from

composition were confirmed. After studying various reports on pyrolysis process of furan binder calculation of the % of various gases

emitting during pyrolysis process of furan was carried out. Sample of gas collected from mold was analyzed using GC-MS. Based on GCMS

measurement various gases emitting from furan sand mold were identified and their amount were calculate and compared with the

international standers of permissible gas emission limits in a foundry. The purpose of this paper is to assist foundries in pollution

prevention by devising clean technologies which maintain or improve the quality of ambient surrounding. This paper aimed at

minimization of pollution of air by using various techniques.