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Assessment Method of Overheating Degree of a Spent Moulding Sand with Organic Binder, After the Casting Process

R. Dańko
Archives of Foundry Engineering | 2013 | No 2 | DOI: 10.2478/afe-2013-0028
Keywords moulding sand Thermal degradation Organic binder Simulation calculations
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Abstract

A proper management of sand grains of moulding sands requires knowing basic properties of the spent matrix after casting knocking out. This information is essential from the point of view of the proper performing the matrix recycling process and preparing moulding sands with reclaimed materials. The most important parameter informing on the matrix quality – in case of moulding sands with organic binders after casting knocking out – is their ignition loss. The methodology of estimating ignition loss of spent moulding sands with organic binder– after casting knocking out - developed in AGH, is presented in the paper. This method applies the simulation MAGMA software, allowing to determine this moulding sand parameter already at the stage of the production preparation.
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Authors and Affiliations

R. Dańko

Quality Assessment of Castings Manufactured in the Technology of Moulding Sand with Furfuryl-Resole Resin Modified with PCL Additive

M. Hosadyna-Kondracka K. Major-Gabryś M. Warmuzek M. Brůna
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 2 | 753-758 | DOI: 10.24425/amm.2022.137814
Keywords Moulding sand Organic binder Biodegradable PCL additive Ductile cast iron
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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

The Influence of Biomaterial in a Binder Composition on Biodegradation of Waste from Furan Moulding Sands

K. Major-Gabryś I. Stachurek M. Hosadyna-Kondracka
Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 17-24 | DOI: 10.24425/afe.2022.140222
Keywords Moulding sand Organic binder Biodegradable PCL additive Biodegradation process
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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

[1] Bastian, K.C., Alleman, J.E. (1996). Environmental bioassay evaluation of foundry waste residuals. Joint Transportation Research Program Technical Report Series, Purdue University, Purdue e-Pubs.
[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

Technological Properties of Thermo-insulating Moulding Sands with Organic Binder

K. Stec Marian Cholewa Ł. Kozakiewicz
Archives of Foundry Engineering | 2020 | vol. 20 | No 2 | 105-110 | DOI: 10.24425/afe.2020.131311
Keywords Skeleton castings Moulding sand Organic binder Technological properties CRS
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Abstract

A thermo-insulating moulding sand with a binder made of aluminosilicate microspheres with organic binder was subjected to testing. The aim of the analysis was to determine selected technological properties of the developed compounds. Compressive strength, friability and gas permeability were determined. The binder content was changed within a range of 5÷20 wt% with a 5% step. The applied matrix is characterized by good thermo-insulating properties and a small size of grains, while synthetic organic binder has favourable functional properties, among which the most noteworthy are the extended life and setting time, good rheological properties as well as high resistance to chemical agents. The intended use of the compound is the casting of 3D CRS (Composite Reinforced Skeletons), which are characterized by a well-developed heat transfer surface area, good absorption of impact energy, low mass and a target thickness of connectors within a range of 1.5÷3 mm. The construction of 3D CRS castings is an original concept developed by the employees of the Department of Foundry Engineering at the Silesian University of Technology.

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Authors and Affiliations

K. Stec
Marian Cholewa
Ł. Kozakiewicz

Research on Assessment of the Applicability of Malted Barley Binder in Moulding Sand Technology

B. Samociuk B. Gal D. Nowak
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 74-80 | DOI: 10.24425/afe.2021.136081
Keywords Innovative foundry technologies and materials Mechanical properties Moulding and core sand Organic binder Malted barley
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Abstract

The foundry industry is looking for solutions that improve the quality of the finished product and solutions that reduce the negative impact of the industry on the natural environment [26]. This process leads to work on the use of new or previously unused materials for binders. Organic and inorganic foundry binders are replaced by renewable materials of plant origin to meet the requirements of both the foundry customers and the environmental and health and safety regulations. The aim of this work was to identify the applicability of renewable and organic malted barley binder in moulding sand technology. The influence of the malt binder content on dry tensile strength, dry bending strength, dry permeability, dry wear resistance and flowability were evaluated. The results show that the malted barley binder can be self-contained material binding the high-silica sand grains. Selected mechanical properties of moulding sands were found to increase with an increase in binder content. It was observed that malted barley binder creates smooth bonding bridges between high-silica sand grains.
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Bibliography

[1] Lewandowski, J.L., (1997). Moulding materials. Kraków: Akapit Publisher. (in Polish).
[2] Czerwinski, F., Mir, M. & Kasprzak, W. (2015). Application of cores and binders in metalcasting. International Journal of Cast Metals Research. 28(3), 129-139. DOI: 10.1179/1743133614Y.0000000140.
[3] Ferreira, S. H. G. da, J. C. E., Kumar, V. & Garza-Reyes, J. A. (2020). Benchmarking of cleaner production in sand mould casting companies. Management of Environmental Quality: An International Journal. 31(5), 1407-1435. DOI: 10.1108/MEQ-12-2019-0272.
[4] Fayomi, O.S.I. (2016). Hybrid effect of selected local binders on the moulding properties of river niger silica sand for industrial application. Journal of Nanoscience with Advanced Technology. 1(4), 19-23. DOI: 10.24218/jnat.2016.19.
[5] Yaro, S.A. & Suleiman, M.U. (2006), Cassava/guinea corn starches and soybean oil as core binders in sand casting of aluminium silicon (Al-Si)lloy. Journal of Engineering and Technology. 1(1), 47-55.
[6] Grabowska, B. & others. (2018). Influence of carbon fibers addition on selected properties of microwave-cured moulding sand bonded with BioCo2 binder. Archives of Foundry Engineering. 18(3), 152-160. DOI: 10.24425/123618.
[7] Chowdhury, S.I. Rashid, H. & Mumtaz, G.R. (2016) Comparison and CFD verification of binder effects in sand mould casting of aluminum alloy. ANNALS of Faculty Engineering Hunedoara - International Journal of Engineering. 14(1), 143-146.
[8] Manley, D. (2000). 9 - Meals, grits, flours and starches (other than wheat). Technology of Biscuits, Crackers and Cookies (Third Edition). (104–111). Red. Woodhead Publishing.
[9] Yu, W., Quek, W., Li, C., Gilbert, R. & Fox, G. (2018) Effects of the starch molecular structures in barley malts and rice adjuncts on brewing performance. Fermentation. 4(4), 103-124. DOI: 10.3390/fermentation4040103.
[10] Fox, G.P. (2009). Chemical composition in barley grains and malt quality. Genetics and Improvement of Barley Malt Quality. (63-98). Zhang G. & C. Li, Red. Berlin, Heidelberg: Springer Berlin Heidelberg. [11] Pezarski, F., Izdebska-Szanda I., Smoluchowska, E., Świder, R. & Pysz, A. (2011). Application of moulding sands with geopolymer binder in the manufacture of castings from aluminium alloys. Prace Instytutu Odlewnictwa. 51(2), 23-34. (in Polish).
[12] Stachowicz, M. Granat, K. & Nowak, D. (2012). Bending strength measurement as a method of binder quality assessment on the example of water-glass containing moulding sands. Archives of Foundry Engineering. 12(1), 175-178. (in Polish).
[13] Stachowicz, M., Granat, K. & Nowak, D. (2010). Studies on the possibility of more effective use of water glass thanks to application of selected methods of hardening. Archives of Foundry Engineering. 10 (spec.2), 135-140.
[14] Szymański, A., (2007). Soil mechanics. Warszawa: Wydawnictwo SGGW. (in Polish).
[15] Ochulorl, E.F., Ugboaja, J.O. & Olowomeye, O.A. (2019). Performance of kaolin and cassava starch as replacements for bentonite in moulding sand used in thin wall ductile iron castings. Nigerian Journal of Technology. 38(4), 947-956. DOI: 10.4314/njt.v38i4.18.
[16] Popoola, A.P.I., Abdulwahab, M. & Fayomi, O.S.I. (2012). Synergetic performance of palm oil (Elaeis guineensis) and pine oil (Pinus sylvestris) as binders on foundry core strength. International Journal of the Physical Sciences. 7(24), 3062-3066. DOI: 10.5897/IJPS12.347.
[17] Atanda, P.O., Akinlosotu, O.C. & Oluwole, O.O. (2014). Effect of some polysaccharide starch extracts on binding characteristics of foundry moulding sand. International Journal of Scientific & Engineering Research. 5(3), 362-367.
[18] Pezarski, F., Maniowski, Z., Izdebska-Szanda, I. & Smoluchowska, E. (2006). Investigations of moulding and core sands made with a new geopolymer binder assigned for production of steel castings. Archives of Foundry. 6(20), 65-70. (in Polish).
[19] Pezarski, F., Smoluchowska, E. & Izdebska-Szanda, I. (2008). Application of geopolymer binder in manufacturing of casting from ferrous alloys. Prace Instytutu Odlewnictwa. 48(2), 19-34. (in Polish).
[20] Jaworski, J. (2006). Research of stability of preparation system of circulating moulding sands. Archives of Foundry Engineering. 6(18), 495-500. (in Polish).
[21] Michta-Stawiarska, T. (2000). The selected iron castings defects as the effect of the sandmix quality. Solidification of Metais and Alloys. 2(43), 345-347. (in Polish).
[22] Lewandowski, J.L. (1971). Moulding materials. Warszawa Kraków: Wydawnictwo Naukowe PWN. (in Polish).
[23] Bobrowski, A. (2018). The phenomenon of dehydroxylation of selected mineral materials from the aluminosilicates group as the determinant factor of the knock-out improvement of moulding and core sands with inorganic binder. Wydawnictwo Archives of Foundry Engineering, Komisja Odlewnictwa PAN Katowice. (in Polish).
[24] Paduchowicz, P., Stachowicz, M. & Granat, K. (2017). Effect of Microwave Heating on Moulding Sand Properties with Gypsum Binder. Archives of Foundry Engineering. 17(3), 97-102.
[25] Sakwa, W., Wachelko, T. (1981). Foundry materials for molds and foundry cores. Katowice: Śląsk Publisher. (in Polish).
[26] Zhoua, X. , Yang J. & Quc. G. (2007). Study on synthesis and properties of modified starch binder for foundry. Journal of Materials Processing Technology. 183. 407-411.
[27] Aramide, F. O., Aribo, S. & Folorunso, D.O. (2011). Optimizing the moulding properties of recycled ilaro silica sand. Leonardo Journal of Sciences. 19, 93-102.
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Authors and Affiliations

B. Samociuk
1
B. Gal
1
D. Nowak
1
  1. Department of Foundry Engineering, Plastics and Automation, Wroclaw University of Technology, ul. Smoluchowskiego 25, 50-372 Wrocław, Poland

Organic Moulding Sands for Production of Large-Size Castings

K. Major-Gabryś M. Hosadyna-Kondracka
Archives of Foundry Engineering | 2019 | vol. 19 | No 3 | 99-105 | DOI: 10.24425/afe.2019.129618
Keywords Innovative foundry technologies and materials Moulding sand Organic binder Furfuryl resin Reduced sulphur hardener Alkyd resin Alphaset process
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Abstract

Recently, some major changes have occurred in the structure of the European foundry industry, such as a rapid development in the production of castings from compacted graphite iron and light alloys at the expense of limiting the production of steel castings. This created a significant gap in the production of heavy steel castings (exceeding the weight of 30 Mg) for the metallurgical, cement and energy industries. The problem is proper moulding technology for such heavy castings, whose solidification and cooling time may take even several days, exposing the moulding material to a long-term thermal and mechanical load. Owing to their technological properties, sands with organic binders (synthetic resins) are the compositions used most often in industrial practice. Their main advantages include high strength, good collapsibility and knocking out properties, as well as easy mechanical reclamation. The main disadvantage of these sands is their harmful effect on the environment, manifesting itself at various stages of the casting process, especially during mould pouring. This is why new solutions are sought for sands based on organic binders to ensure their high technological properties but at the same time less harmfulness for the environment. This paper discusses the possibility of reducing the harmful effect of sands with furfuryl binders owing to the use of resins with reduced content of free furfuryl alcohol and hardeners with reduced sulphur content. The use of alkyd binder as an alternative to furfuryl binder has also been proposed and possible application of phenol-formaldehyde resins was considered.

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Authors and Affiliations

K. Major-Gabryś
ORCID: ORCID
M. Hosadyna-Kondracka
ORCID: ORCID

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