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Abstract

Measurements of the hardening process course of the selected self-hardening moulding sands with the reclaimed material additions to the matrix, are presented in the hereby paper. Moulding sands were produced on the „Szczakowa” sand (of the Sibelco Company) as the matrix of the main fraction FG 0,40/0,32/0,20, while the reclaim was added to it in amounts of 20, 50 and 70%. Regeneration was performed with a horizontal mechanical regenerator capacity of 10 t/h. In addition, two moulding sands, one on the fresh sand matrix another on the reclaimed matrix, were prepared for comparison. Highly-fluid urea-furfuryl resin was used as a binder, while paratoluensulphonic acid as a hardener. During investigations the hardening process course was determined, it means the wave velocity change in time: cL = f(t). The hardening process kinetics was also assessed (dClx/dt = f(t)). Investigations were carried out on the research stand for ultrasound tests. In addition strength tests were performed.

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Authors and Affiliations

Ł. Jamrozowicz
J. Kolczyk
P. Wojtuń
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Abstract

This paper presents a new perspective on the issue of reclamation of moulding and core sands. Taking as a premise that the reclamation process must remain on the surface of grains some not separated binding materials rests, it should be chosen the proper moulding sand’s composition that will be least harmful for the reclaim quality. There are two different moulding and core sands taken into examinations. The researches prove that a small correction of their compositions (hardener type) improves the quality of the received reclaims. Carried out in this article studies have shown that such an approach to the problem of reclamation of the moulding and core sands is needed and reasonable.

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Authors and Affiliations

S.M. Dobosz
K. Major-Gabryś
M. Hosadyna
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Abstract

The method of the ongoing assessment of the reclaim quality originating from the mechanical reclamation is described in this paper. In the process, the triboelectric system of measuring amounts of dust in the dedusting part of a reclamation device was applied. Based on the online measurements of the amounts of dust generated in the spent sand-reclamation process and the post-process determinations of the ignition losses and granular structures of the removed dust, the proper work parameters of the experimental reclaimer were selected. The allowable value of the ignition losses as well as the main fraction of the reclaimed matrix being similar to fresh sand was assumed as the main criteria of the positive assessment of the process. Within the presented investigations, a periodically operating device for rotor-mechanical reclamation was developed. The possibility of changing the intensity and time of the reclamation treatment as well as the triboelectric system of the dust-amount measuring were applied in this device. Tests were performed for the spent moulding sand with phenol-resol resin Carbophen 5692 hardened by CO2. This sand represents the moulding sand group with a less harmful influence on the surroundings for which the recovery of the quartz matrix utilising the reclamation requires stricter control of the parameters of the reclamation process and reclaim quality.
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Bibliography

[1] Boenisch, D. (1991, March). Reclamation of spent sands containing bentonite. Guidelines for an economical leading to minimized waste. Giesserei 77, nr 19, 1990. In and AFS International Sand Reclamation Conference, Conference Proceedings, Novi/MI (p. 211).
[2] Dańko, J., Dańko, R., Łucarz, M. (2007). Processes and devices for the matrix regeneration of spent molding sands. Akapit. 291. (in Polish).
[3] Dańko, R. (2007). Development of energetic model for dry mechanical reclamation process of used foundry sands. International Journal of Cast Metals Research. 20(4), 228-232.
[4] Dańko, R. (2012). Strength model of self-setting moulding sands with synthetic resins in an aspect of the of the integrated matrix recycling process. Gliwice: Archives of Foundry Engineering.
[5] Łucarz, M. & Dereń, M. (2017). Conditions of thermal reclamation process realization on a sample of spent moulding sand from an aluminum alloy foundry plant. Archives of Foundry Engineering. 17(2), 197-201.
[6] Leidel, D. S. (1993). Low temperature sand reclamation for dramatically improved quality and reduced cost. Transactions-Japan Foundrymen’s Society. 12, 1-1.
[7] Lewandowski, L. (1997). Materials for foundry molds. Akapit. (in Polish).
[8] Siddique, R., Kaur, G. & Rajor, A. (2010). Waste foundry sand and its leachate characteristics. Resources, Conservation and Recycling. 54(12), 1027-1036.
[9] Svidro, J.T. (2010). The effect of sulphur content in chemical bonded sand moulds on the mechanism of penetration. International Foundry Research. 62(4), 32-41.
[10] Polzin, H., Nitsch, U., Tilch, W. & Flemming, E. (1997). Regenerierung anorganisch gebundener Altsande mit einer mechanisch arbeitender Pilotanlage. Giesserei-Praxis. 23, 500-507.
[11] Vijayakumar, S., Srinivasan, M.V. & Govindaraju, M. (2021). Reduction of waste in furan molding process from cast iron foundry. Materials Today: Proceedings. 46, 5032-5035.
[12] Wang, J.N. & Fan, Z.T. (2010). 'Freezing–mechanical'reclamation of used sodium silicate sands. International Journal of Cast Metals Research. 23(5), 257-263.
[13] Wang, L.C., Jiang, W.M., Gong, X.L., Liu, F.C. & Fan, Z.T. (2019). Recycling water glass from wet reclamation sewage of waste sodium silicate-bonded sand. China Foundry. 16(3), 198-203.
[14] Cruz, N., Briens, C. & Berruti, F. (2009). Green sand reclamation using a fluidized bed with an attrition nozzle. Resources, Conservation and Recycling. 54(1), 45-52.
[15] Dungan, R.S., Huwe, J. & Chaney, R.L. (2009). Concentrations of PCDD/PCDFs and PCBs in spent foundry sands. Chemosphere. 75(9), 1232-1235.
[16] Zitian, F., Fuchu, L., Wei, L. & Guona, L. (2014). A new low-cost method of reclaiming mixed foundry waste sand based on wet-thermal composite reclamation. China Foundry. 11(5).
[17] Ghormley, S., Williams, R. & Dvorak, B. (2020). Foundry Sand Source Reduction Options: Life Cycle Assessment Evaluation. Environments. 7(9), 66.
[18] Holtzer, M. & Kmita, A. (2020). Mold and Core Sands in Metalcasting: Chemistry and Ecology. Sustainable Development. Springer, Cham.

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Authors and Affiliations

R. Dańko
1
A. Pietrzak
1
D. Gruszka
1

  1. AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Poland
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Abstract

The problem of recycled materials application in road construction is one of the key issues in contemporary road engineering. This article describes attempts to produce a hot mix asphalt (HMA) mixture entirely from processed reclaimed asphalt pavement (RAP) material. Due to the binder ageing process, rejuvenating agent was a necessary additive to the mixture. The mixture was tested to determine its parameters, including the content of voids, fatigue life, rutting resistance, stiffness and water sensitivity. The test results demonstrated that the rejuvenated RAP mixture is not inferior to fresh produced mixtures in terms of physical and strength parameters. Such results are, however, conditional on appropriate handling of the RAP material.

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Authors and Affiliations

W. Sorociak
B. Grzesik
J. Bzówka
P. Mieczkowski
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Abstract

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.
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Bibliography

[1] Lewandowski, J.L. (1997). Materials for foundry moulds. Kraków: WN Akapit. ISBN: 83-7108-21-2 (in Polish).
[2] Kamińska, J., Puzio, S., Angrecki, M., Stachowicz, M. & Łoś, A. (2019). Preliminary tests of innovative eco-friendly furfuryl resins and foundry sand mixtures based on these resins. Journal of Ecological Engineering. 20(9), 285-292, DOI: 10.12911/22998993/112510.
[3] Acharya, S.G., Vadher, J.A. & Kanjariya, P.V. (2016). Identification and quantification of gases releasing from furan no bake binder. Archives of Foundry Engineering. 16(3), 5-10. DOI: 10.1515/afe-2016-0039.
[4] Chate, G.R., Patel, GC M., Deshpande, A.S. & Parappagoudar, M.B. (2018). Modeling and optimization of furan moulding sand system using design of experiments and particle swarm optimization. Journal of Process Mechanical Engineering. 232(5), 1-20. DOI: 10.1177/0954408917728636.
[5] Sappinen, T., Orkas, J. & Konqvist, T. (2018). Thermal Reclamation of Foundry Sands Using Repurposed Sand Dryer Equipment. Archives of Foundry Engineering. 18(4), 99-102. DOI: 10.24425/afe.2018.125176.
[6] Kamińska, J., Puzio, S., Angrecki, M. & Łoś, A. (2020). Effect of reclaim addition on the mechanical and technological properties of moulding sands based on pro-ecological furfuryl resin. Archives of Metallurgy and Materials. 65(4), 1425-1429. DOI: 10.24425/amm.2020.133709.
[7] Yan-lei, L., Guo-hua, W., Wen-cai, L., An-tao, C., Liang, Z. & Ying-xin Wang, W. (2017). Effect of reclaimed sand additions on mechanical properties and fracture behavior of furan no-bake resin sand. China Foundry. 14(2), 128-137. DOI: 10.1007/s41230-017-6024-3.
[8] Holtzer, M., Dańko, R., Kmita, A., Drożyński, D., Kubecki, M., Skrzyński, M. & Roczniak, A. (2020). Environmental impact of the reclaimed sand addition to moulding sand with furan and phenol-formaldehyde resin—A comparison, Materials. 13(19), 4395; DOI: https://doi.org/10.3390/ma13194395.
[9] Holtzer, M., Dańko, R. & Kmita, A. (2016). Influence of a reclaimed sand addition to moulding sand with furan resin on its impact on the environment. Water Air and Soil Pollution. 227(16), 1-12. DOI: 10.1007/s11270-015-2707-9.
[10] Hosadyna, M. (2012). The effect of sulphur contained in self-hardening moulding sands on the structure of surface layer in ductile iron castings. Doctoral dissertation, Kraków. (in Polish).
[11] Holtzer, M., Zych, J. & Retel, K. (1996). The effect of mould-liquid cast iron interaction on the surface quality of castings. Przegląd Odlewnictwa. 6(1996), 129-134. (in Polish).
[12] Riposan, I., Chisamera, M., Stan, S., Skaland, T. (2008). Surface graphite degeneration in ductile iron castings for resin molds. Tsinghua Science and Technology. 13(2), 157-163.
[13] Linke, T., Sluis, J.R. (1993). The influence of coatings on the graphite structure in the rim-zone of ductile iron castings. 60th World Foundry Congress, The Netherlands
[14] Hosadyna, M., Dobosz, St.M. & Jelinek, P. (2009). The diffusion of sulphur from moulding sand to cast and methods of its elimination. Archives of Foundry Engineering. 9(4), 73-76.
[15] Sheladiya, M.V., Acharya, S.G., Mehta, K., Acharya, G.D. (2019). Evaluate sulphur diffusion at mould-metal interface in no-bake mould system. Archives of Foundry Engineering. 19(1), 63-70. DOI: 10.24425/afe.2018.125193.
[16] Anca, D., Stan, I., Chisamera, M., Riposan, I. & Stan, S. (2021). Experimental study regarding the possibility of blocking the diffusion of sulfur at casting-mold interface in ductile iron castings. Coatings. 11(673), 1-10. DOI: https://doi.org/10.3390/coatings11060673.
[17] Dańko, J., Dańko, R. & Łucarz, M. (2007). Processes and devices for the matrix regeneration of spent molding sands. Kraków: WN Akapit. ISBN: 978-83-89541-88-8 (in Polish).
[18] Holtzer, M., Bobrowski, A., Drożyński, D., Isendorf, B., Mazur, (2012). Influence of the reclaim on the properties of moulding sands with furfuryl resin applied for moulds for manganese steel castings. Archives of Foundry Engineering. 12(1), 57-62.
[19] Dańko, R., Górny, M., Holtzer, M., Żymankowska-Kumon, S. (2014). Effect of the quality of furan moulding sand on the skin layer of ductile iron castings. ISIJ International. 54(6), 1288-1293. DOI: https://doi.org/10.2355/isijinternational.54.1288.
[20] Pałyga, Ł., Stachowicz, M., Granat, K. (2015). Evaluation of 2D and 3D surface roughness of die castings from alloy AlSi9Cu3. Archives of Foundry Engineering. 15(1), 75-80.

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Authors and Affiliations

J. Kamińska
1
ORCID: ORCID
M. Angrecki
1
ORCID: ORCID
S. Puzio
1
ORCID: ORCID
M. Stachowicz
2
ORCID: ORCID

  1. Łukasiewicz Research Network – Krakow Institute of Technology, Poland
  2. Wroclaw University of Technology, Faculty of Mechanical Engineering, Poland
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Abstract

The results of testing the strength properties of experimental ceramic materials containing spending moulding sand after initial mechanical reclamation as a material for subsequent layers of the stucco composition were presented. Tests were carried out on spent moulding sands from various foundry technologies, i.e. sand with furfuryl resin and sand with hydrated sodium silicate. The spent, agglomerated moulding sand has undergone a crushing process. Next, the required granular fractions used for individual layers of the stucco material were separated. Ceramic samples, in which the spent moulding sand was a substitute for fresh silica sand in successive layers of the stucco composition, were prepared. As a reference material, identical ceramic samples were used but with all layers made from the fresh silica sand. Samples prepared in this way were used to determine the bending strength of ceramic materials in the temperature range from 20 to 900ºC. The obtained values of the bending strength have demonstrated that spent moulding sand can be used in investment casting with no adverse effect on the strength of ceramic materials.

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Authors and Affiliations

M. Angrecki
ORCID: ORCID
J. Kamińska
ORCID: ORCID
J. Jakubski
ORCID: ORCID
P. Wieliczko
ORCID: ORCID
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Abstract

As a wafer cleaning process, RCA (Radio Corporation of America) cleaning is mainly used. However, RCA cleaning has problems such as instability of bath life, re-adsorption of impurities and high-temperature cleaning. Herein, we tried to improve the purity of silicon wafers by using a chelating agent (oxalic acid) to solve these problems. Compounds produced by the reaction between the cleaning solution and each metal powder were identified by referring to the pourbaix diagram. All metals exhibited a particle size distribution of 10 μm or more before reaction, but a particle size distribution of 500 nm or less after reaction. In addition, it was confirmed that the metals before and after the reaction showed different absorbances. As a result of elemental analysis on the surface of the reclaimed silicon wafer cleaned through such a cleaning solution, it was confirmed that no secondary phase was detected other than Si.
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Bibliography

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[17] C.H. Bamford, R.G. Compton, C.F.H. Tipper, Reactions of metallic salts and complexes, and organometallic compounds, Elsevier 1972.
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Authors and Affiliations

Keunhyuk Ryu
1
Myungsuk Kim
1
Jaeseok Roh
1
ORCID: ORCID
Kun-Jae Lee
1
ORCID: ORCID

  1. Dankook University, Department of Energy Engineering, Cheonan 31116, Republic of Korea
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Abstract

The paper presents the comparison of dynamic modulus and phase lag in different loading conditions for asphalt concrete mixture with or without reclaimed asphalt shingles (RAS) addition. For each mixture, 6 samples were tested using the four point bending beam method, at four temperatures and at six frequencies. The results of the study were subjected to the analysis of the statistical significance of differences between mixtures. The graphic form of results presentation includes Black curves and Cole-Cole plots. Then, matching the sigmoidal functions enabled the creation of master curves of the complex stiffness module and the phase shift angle, being a function of the load frequency. It has been observed that the mixture with the addition of RAS has higher stiffness and elasticity in the range of higher temperatures (20°C and 30°C) and lower load frequencies, which results in higher values of the complex stiffness module and lower values of the phase lag. At 0°C, the behavior of both mixtures is very similar, while at 10°C significant differences between the tested mixtures were found only for low frequency loads (up to 5 Hz). Test results have shown that mixtures with the addition of RAS have a lower thermal sensitivity in terms of the complex stiffness modulus and phase lag than the reference mixture. The above results confirmed an improvement in rutting resistance for RAS mixes observed in previous work.
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Bibliography


[1] Pouranian M. R., Shishehbor M., “Sustainability Assessment of Green Asphalt Mixtures: A Review”, Environments 2019, 6, 73, p. 55. https://doi.org/10.3390/environments6060073
[2] Williams R.C., Cascione A., Yu J., Haugen D., Marasteanu M., McGraw J., “Performance of recycled asphalt shingles in hot mix asphalt”, Institute for Transportation and Iowa State University, August 2013.
[3] J.J. Foxlow, J.S. Daniel, A.K. Swamy, ”RAP or RAS? The differences in performance of HMA containing reclaimed asphalt pavement and reclaimed asphalt shingles”, Journal of the Association of Asphalt Paving Technologists, Volume 80, pp 347–376, 2011.
[4] Barry K., Daniel J. S., Foxlow J., Gray K., “An evaluation of reclaimed asphalt shingles in hot mix asphalt by varying sources and quantity of reclaimed asphalt shingles”, Road Materials and Pavement Design, Vol. 15, No. 2, 2014, pp. 259–271. https://doi.org/10.1080/14680629.2013.861765
[5] H. Baaj, M. Ech, N. Tapsoba, C. Sauzeat, H. Di Benedetto, “Thermomechanical characterization of asphalt Mixtures modified with high contents of asphalt shingle modifier (ASM®) and reclaimed asphalt pavement (RAP)”, Materials and Structures, 2013, https://doi.org/10.1617/s11527-013-0015-7
[6] Zhou F., Li H., Hu S., Button J.W., Epps J.A., ”Characterization and best use of recycled asphalt shingles in hot-mix asphalt”, Report No. FHWA/TX-13/0-6614-2, TEXAS A&M TRANSPORTATION INSTITUTE, USA, 2013, p. 107.
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[9] P. Zieliński, “Study of the possibility of increasing manufacture waste asphalt shingles additive to hot mix asphalt”, 18 International Multidisciplinary Scientific GeoConference SGEM 2018, Volume 18, 2018, pp. 191–198. https://doi.org/10.5593/sgem2018/4.2/S18.025
[10] PN-EN 12697-33 „Mieszanki mineralno-asfaltowe. Metody badań mieszanek mineralno-asfaltowych na gorąco”. Część 33: Przygotowanie próbek zagęszczanych urządzeniem wałującym.
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Authors and Affiliations

Piotr Zieliński
1
ORCID: ORCID

  1. Cracow University of Technology, Faculty of Civil Engineering, ul. Warszawska 24, 31-155 Kraków, Poland

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