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Effect of Atmosphere in a Foundry Mould on Casting Surface Quality

A. Chojecki J. Mocek
Archives of Foundry Engineering | 2012 | No 1 | DOI: 10.2478/v10266-012-0003-3
Keywords Sand mould Defects on casting surface Hydrogen concentration Ductile iron
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Abstract

Changes of gas pressure in the moulding sand in the zone adjacent to mould cavity were analysed during pouring of cast iron. No significant effect of pressure on the surface quality of castings was observed. In the second series of tests, the concentration of hydrogen in the gas atmosphere was measured. It has been found that the value of this concentration depends on metal composition and is particularly high in cast iron containing magnesium. This is due to the reduction of water vapour with the element that has high affinity to oxygen. The presence of hydrogen causes the formation of gas-induced defects on the casting surface.

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Authors and Affiliations

A. Chojecki
J. Mocek

High Temperature Thermal Properties of Bentonite Foundry Sand

P.K. Krajewski W.K. Krajewski J.S. Suchy G. Piwowarski
Archives of Foundry Engineering | 2015 | No 2 | DOI: 10.1515/afe-2015-0036
Keywords Castings solidification Bentonite sand mould Thermo-physical properties
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Abstract

The paper presents results of measuring thermal conductivity and heat capacity of bentonite foundry sand in temperature range ambient –

900 OC. During the experiments a technical purity Cu plate was cast into the green-sand moulds. Basing on measurements of the mould

temperature field during the solidification of the casting, the temperature relationships of the measured properties were evaluated. It was

confirmed that water vaporization strongly influences thermal conductivity of the moulding sand in the first period of the mould heating by

the poured casting.

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Authors and Affiliations

P.K. Krajewski
W.K. Krajewski
J.S. Suchy
G. Piwowarski

Simulation of the Moulding Process of Bentonite-Bonded Green Sand

Dheya Abdulamer A. Kadauw
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 67-73 | DOI: 10.24425/afe.2021.136080
Keywords Green sand mould Moulding process COMSOL Multiphysics Time-dependent study
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Abstract

Finite Element Method FEM via commercially available software has been used for numerical simulation of the compaction process of bentonite-bonded sand mould. The mathematical model of soil plasticity which involved Drucker-Prager model match with Mohr-Coulomb model was selected. The individual parameters which required for the simulation process were determined through direct shear test based on the variation of sand compactability. The novelty of this research work is that the individual micro-mechanical parameters were adopted depend on its directly proportional to the change of sand density during the compaction process. Boundary conditions of the applied load, roller and fixed constraint were specified. An extremely coarse mesh was used and the solution by time-dependent study was done for investigation of material-dependent behaviour of green sand during the compaction process. The research implemented also simulation of the desired points in sand mould to predict behaviour of moulding process, and prevent failure of the sand mould. Distance-dependent displacement and distance-dependent pressure have been determined to investigate the effective moulding parameters without spent further energy and cost for obtaining green sand mould. The obtained numerical results of the sand displacement show good agreement with the practical results.
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Bibliography

[1] Naeimi, K., Baradaran, H., Ahmadi, R. & Shekari, M. (2015). Study and simulation of the effective factors on soil compaction by tractors wheels using the finite element method. Journal of Computational Applied Mechanics. 46(2), 107-115. DOI: 10.22059/jcamech.2015.55093.
[2] Soane, B. (1990). The role of organic matter in soil compatibility: A review of some practical aspects. Soil & Tillage Research. 16(1-2), 179-201. DOI: https://doi.org/ 10.1016/0167-1987(90)90029-D.
[3] Minaei, S. (1984). Multi pass effects of wheel and track- type vehicles on soil compaction. MS Thesis, Virginia Polytechnic Institute and State University.
[4] Chen, Y. Tessier, Y. & Rauffignat, S. (1998). Soil bulk density estimation for tillage systems and soil texture. Transactions of the American Society of Agricultural and Biological Engineers. 41(4), 1601-1610.
[5] Wenzhen, L. & Junjiao, W. (2007). Numerical Simulation of Compacting Process of Green Sand Molding Based on Sand Filling. Materials Science Forum. 561-565, 879-1882. DOI: https://doi.org/10.4028/www.scientific.net/MSF.561-565.1879.
[6] Hovad, E., Larsen, P., Walther, J., Thorborg, J. & Hattel,. J.H. (2015). Flow Dynamics of green sand in the DISAMATIC moulding process using Discrete element method (DEM). IOP Conference Series Materials Science and Engineering. 84(1) 1-8. DOI: 10.1088/1757-899X/84/1/012023.
[7] Hua, L., Junjiao, W., Tianyou, H. & Hiroyasu, M. (2011). A new numerical simulation model for high pressure squeezing moulding. China foundry. 8(1) 25-29. ID: 1672-6421(2011)01-025-05.
[8] Schijndel, van, A.W.M.(2007). Integrated heat air and moisture modeling and simulation. Doctoral dissertation, Eindhoven University of Technology. https://doi.org/ 10.6100/IR622370.
[9] Terzaghi, K. (1976). Earthwork mechanics based on soil physics (in German). G. Gistel & Cie. GmbH, Wien.
[10] Tomas, J. (1991). Modeling of the flow behavior of bulk solids on the basis of the interaction forces between the particles and applications in the design of bunkers (in German). Habilitation thesis, TU Bergakademie Freiberg.
[11] Inoue, Y., Motoyama, Y., Takahashi, H., Shinji, K. & Yoshida, M. (2013). Effect of sand mold models on the simulated mold restraint force and the contraction of the casting during cooling in green sand molds. Journal of Materials Processing Technology. 213(7), 1157-1165. https://doi.org/10.1016/j.jmatprotec.2013.01.011.
[12] Kadauw, A. (2006). Mathematical modeling of the moulding material processes (in German). Doctoral dissertation, TU- Bergakademie Freiberg.
[13] Lang, H.-J., Huder, J., Amann, P., Puzrin, A.M. (1996). Soil mechanics and foundation (in German). Springer, Berlin Heidelberg.
[14] Suroso, P., Samang, L., Tjaronge, W. & Muhammad Ramli. (2016). Estimates of Elasticity and Compressive Strenght in Soil Cement Mixed With Ijuk-Aren, International Journal of Innovative Research in Advanced Engineering (IJIRAE), 3(4), 21-26.
[15] Nujid, M.M. & Taha, M.R. (2016). Soil Plasticity Model for Analysis of Collapse Load on Layers Soil. EDP Sciences, MATEC Web of Conferences. 47(03020) 1-6. DOI: 10.1051/matecconf/ 20164703020.
[16] Chen, W.F. Mizuno, E. (1990). Nonlinear Analysis in Soil Mechanics: Theory and Implementation, Elsevier Science Publishers B. V., ISBN 978-0444430434, 5-36.
[17] Bast, J., Kadauw, A. (2004). 3D-Numerical Simulation of Squeeze Moulding with the Finite element Method. Proceeding of 66th World Foundry Congress Istanbul, 247 - 258.
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Authors and Affiliations

Dheya Abdulamer
ORCID: ORCID
A. Kadauw
1 2
  1. IMKF. TU - Bergakademie Freiberg, Germany
  2. Salahddin University-Erbil, Iraq

Humidity Migration in Surface Layers of Sand Moulds During Processes of Penetration and Drying of Protective Coatings

Ł. Jamrozowicz J. Zych
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 72-78 | DOI: 10.24425/afe.2022.143952
Keywords Core Sand mould Porous medium Humidity migration Protective coatings Resistance measurement
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Abstract

The results of investigations of humidity migration in near surface layers of sand mould during processes of penetration and drying of protective coatings are presented in the hereby paper. The process of the humidity exchanging between surroundings and moulding sands as porous materials, is widely described in the introduction. In addition, the humidity flow through porous materials, with dividing this process into stages in dependence of the humidity movement mechanism, is presented. Next the desorption process, it means the humidity removal from porous materials, was described. Elements of the drying process intensity as well as the water transport mechanisms at natural and artificial drying were explained. The innovative research stands for measuring resistance changes of porous media due to humidity migrations was applied in investigations. Aqueous zirconium coatings of two apparent viscosities 10s and 30s were used. Viscosity was determined by means of the Ford cup of a mesh clearance of 4mm. Coatings were deposited on cores made of the moulding sand containing sand matrix, of a mean grain size dL = 0.25 mm, and phenol-formaldehyde resin. Pairs of electrodes were placed in the core at depths: 2, 3, 4, 5, 8, 12 and 16 mm. Resistance measurements were performed in a continuous way. The course of the humidity migration process in the core surface layer after covering it by protective coating was determined during investigations. Investigations were performed in the room where the air temperature was: T = 22˚C but the air humidity was not controlled, as well as in the climatic chamber where the air temperature was: T = 35˚C and humidity: H = 45%. During the research, it was shown that the process of penetration (sorption) of moisture into the moulding sand is a gradual process and that the moisture penetrates at least 16 mm into the sand. In the case of the drying (desorption) process, moisture from the near-surface layers of the moulding sand dries out much faster than moisture that has penetrated deeper into the sand. Keywords: Core, Sand mould, Porous medium, Humidity migration, Protective coatings, Resistance measurement
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Bibliography

[1] Pigoń, K., Ruziewicz, Z. (2005). Physical chemistry. Phenomenological foundations. Warszawa: PWN, (in Polish) [2] Zarzycki, R. (2005). Heat transfer and mass movement in environmental engineering. Warszawa: Wydawnictwo Naukowo-Techniczne. (in Polish) [3] Płoński, W., Pogorzelski, J. (1979). Building physics. Warszawa: Arkady. (in Polish) [4] Świrska-Perkowska, J. (2012). Adsorption and movement of moisture in porous building materials under isothermal conditions. Warszawa: Komitet Inżynierii Lądowej i Wodnej PAN. (in Polish) [5] Kubik, J. (2000). Moisture flows in building materials. Opole: Oficyna Wydawnicza Politechniki Opolskiej. (in Polish) [6] Gawin, D. (2000). Modeling of coupled hygrothermal phenomena in building materials and elements. Łódź: Politechnika Łódzka. (in Polish) [7] Rose, D. (1963). Water movement in porous materials. Part 1: isothermal vapour transfer. British Journal of Applied Physics. (14), 256-262. DOI:10.1088/0508-3443/14/5/308. [8] Rose, D. (1963): Water movement in porous materials. part 2: the separation of the components of water movement. British Journal of Applied Physics. (14), 491-496. DOI: 10.1088/0508-3443/14/8/310. [9] Marynowicz, A., Wyrwał, J. (2005). Testing the moisture properties of selected building materials under isothermal conditions. Warszawa: INB ZTUREK. (in Polish) [10] Kiessl, K. (1983) Kapillarer und dampffoermiger Fauchtetransport in mahrschichtigen Bauteilen. Essen: Dissertation. University Essen. [11] Politechnika Gdańska. The process of drying food substances - laboratory exercises. Retrieved January, 2022, from https://mech.pg.edu.pl/documents/4555684/4565480/suszenie.pdf (in Polish). [12] Baranowski, J., Melech, S., Adamski, P. (2002). Temperature and humidity control systems in the processes of drying food products. Zielona Góra: VI Sympozjum Pomiary i Sterowanie w Procesach Przemysłowych. (in Polish) [13] Ważny, J., Karyś, J. (2001). Protection of buildings against biological corrosion. Warszawa: Arkady. (in Polish) [14] Brooker, D., Bakker-Arkema, F., Hall, C. (1992). Drying and Storage of Grains and Oilseeds. New York: Van Nostrand Reinhold. [15] Reeds, J. (1991). Drying. ASM International Handbook Committee. 131-134. [16] Pel, L., Sawdy, A. & Voronina, V. (2010). Physical principles and efficiency of salt extraction by poulticing. Journal of Cultural Heritage. 11(1), 59-67. DOI:10.1016/j.culher. 2009.03.007. [17] Hii, C., Law, C. & Cloke, M. (2008). Modelling of thin layer drying kinetics of cocoa beans during artificial and natural drying. Journal of Engineering Science and Technology. 3(1), 1-10. [18] Zych, J. & Kolczyk, J. (2013). Kinetics of hardening and drying of ceramic moulds with the new generation binder – colloidal silica. Archives of Foundry Engineering. 13(4), 112-116. DOI: 10.2478/afe-2013-0093. [19] Kolczyk J. & Zych J. (2014). The kinetics of hardening and drying of ceramic molds with a new generation binder - colloidal silica. Przegląd Odlewnictwa. 64(3-4), 84-92. (in Polish) [20] Zych, J., Kolczyk, J. & Jamrozowicz, Ł. (2015). The influence of the shape of wax pattern on the kinetics of drying of ceramic moulds. Metalurgija. 54(1), 15-18. ISSN 0543-5846. [21] Jamrozowicz, Ł., Zych, J. & Kolczyk, J. (2015). The drying kinetics of protective coatings used on sand molds. Metalurgija. 54(1), 23-26. ISSN 0543-5846. [22] Jamrozowicz, Ł. & Siatko, A. (2020). The assessment of the permeability of selected protective coatings used for sand moulds and cores. Archives of Foundry Engineering. 20(1), 17-22. DOI: 10.24425/afe.2020.131276. [23] Jamrozowicz, Ł., Kolczyk-Tylka, J. & Siatko, A. (2018) Investigations of the thickness of protective coatings deposited on moulds and cores. Archives of Foundry Engineering. 18(4), 131-136. DOI: 10.24425/afe.2018. 125182. [24] Zych, J. & Snopkiewicz, T. (2010). Drying and hardening of ceramic moulds used in a modern investemnt casting technique – investigations of the process kinetics. Foundry Journal of the Polish Foundrymen's Association. 9-10, 506-512. [25] Zych, J., Snopkiewicz, T. (2018). Method for study the drying process self-hardening molding sand or core compound. Patent PL 228373 B1.
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Authors and Affiliations

Ł. Jamrozowicz
1
ORCID: ORCID
J. Zych
1
ORCID: ORCID
  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Cast Non-Ferrous Metals, Al. Mickiewicza 30, 30-059 Kraków, Poland

Optimizing Sand Moulding Process through Regression Models and Destructive Testing

Dheya Abdulamer
Archives of Foundry Engineering | 2023 | vol. 23 | No 4 | 163-168 | DOI: 10.24425/afe.2023.148959
Keywords Green sand mould Moulding parameters design of experiments Destructive tests regression methods
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Abstract

The main objective of the present study is enhanced of the sand moulding process through addressing the sand mould defects and failures, ultimately lead to improve production of the sand castings with well-defined of pattern profiles. The research aimed to reduce the cost and energy expenditure associated with the compaction time of the sand moulding process. Practical destructive tests were conducted to assess properties of the green sand moulds. Linear regression and multi-regression methods were employed to identify the key factors influencing the sand moulding process. The proposed experimental destructive tests and predicted regression methods facilitated measurement of the green sand properties and enabled evaluation of the effective moulding parameters, thereby enhancing the sand moulding process. Factorial design of experiments approach was employed to evaluate effect of parameters of water content and mixing time of the green sand compaction process on the mechanical properties of green sand mould namely the tensile strength, and compressive strength.
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Bibliography

[1] Abdulamer, D. & Kadauw, A. (2019). Development of mathematical relationships for calculating material-dependent flowability of green molding sand. Journal of Materials Engineering and Performance. 28(7), 3994-4001. DOI: https://doi.org/10.1007/s11665-019-04089-w.
[2] Shahria, S., Tariquzzaman, M., Rahman, H., Al Amin, M., & Rahman, A. (2017). Optimization of molding sand composition for casting Al alloy. International Journal of Mechanical Engineering and Applications. 5(3), 155-161. DOI:10.11648/j.ijmea.20170503.13.
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[7] Said, R. Kamal, M. Miswan, N. & Ng, S. (2018). Optimization of moulding composition for quality improvement of sand casting. Journal of Advanced Manufacturing Technology. 12(1(1), 301-310.
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[9] Abdulamer, D. (2023). Impact of the different moulding parameters on engineering properties of the green sand mould. Archives of Foundry. 23(2), 5-9. DOI: 10.24425/afe.2023.144288.
[10] Kumar, S. Satsangi, P. & Prajapati, D. (2011). Optimization of green sand casting process parameters of a foundry by using taguchi’s method. International Journal of Advanced Manufacturing Technology. 55(1-4), 23-34. DOI: 10.1007/s00170-010-3029-0.
[11] Murguía, P. Ángel, R. Villa González del Pino, E. Villa, Y. & Hernández del Sol, J. (2016). Quality improvement of a casting process using design of experiments. Prospectiva. 14(1), 47-53. DOI: 10.15665/rp.v14i1.648.
[12] Abdullah, A. Sulaiman, S. Baharudin, B. Arifin, M. & Vijayaram, T. (2012). Testing for green compression strength and permeability properties on the tailing sand samples gathered from ex tin mines in perak state, Malaysia. Advanced Materials Research. 445, 859-864. DOI: 10.4028/www.scientific.net/AMR.445.859.
[13] Abdulamer, D. (2021). Investigation of flowability of the green sand mould by remote control of portable flowability sensor. Archives of Materials Science and Engineering, 112(2), 70-76. DOI: 10.5604/01.3001.0015.6289.
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Authors and Affiliations

Dheya Abdulamer
1
ORCID: ORCID
  1. University of Technology- Iraq

Gases Emission From Surface Layers of Sand Moulds and Cores Stored Under the Humid Air Conditions

N. Kaźnica J. Zych J. Mocek
Archives of Foundry Engineering | 2017 | vol. 17 | No 4 | DOI: 10.1515/afe-2017-0134
Keywords Surface layer Sand mould Emission of gasesHigh air humidity High air humidity Moulding sands with chemical binders
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Abstract

A large number of defects of castings made in sand moulds is caused by gases. There are several sources of gases: gases emitted from moulds, cores or protective coatings during pouring and casting solidification; water in moulding sands; moisture adsorbed from surroundings due to atmospheric conditions changes. In investigations of gas volumetric emissions of moulding sands amounts of gases emitted from moulding sand were determined - up to now - in dependence of the applied binders, sand grains, protective coatings or alloys used for moulds pouring. The results of investigating gas volumetric emissions of thin-walled sand cores poured with liquid metal are presented in the hereby paper. They correspond to the surface layer in the mould work part, which is decisive for the surface quality of the obtained castings. In addition, cores were stored under conditions of a high air humidity, where due to large differences in humidity, the moisture - from surroundings - was adsorbed into the surface layer of the sand mould. Due to that, it was possible to asses the influence of the adsorbed moisture on the gas volumetric emission from moulds and cores surface layers by means of the new method of investigating the gas emission kinetics from thin moulding sand layers heated by liquid metal. The results of investigations of kinetics of the gas emission from moulding sands with furan and alkyd resins as well as with hydrated sodium silicate (water glass) are presented. Kinetics of gases emissions from these kinds of moulding sands poured with Al-Si alloy were compared.

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Authors and Affiliations

N. Kaźnica
J. Zych
J. Mocek

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