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Investigations of the Mechanism of the Sand Shooting into the Core Box

R. Dańko
Archives of Foundry Engineering | 2018 | vol.18 | No 3 | 113-119
Keywords core shooting blowing process core sand
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Abstract

The results of investigations of sand shooting into the core box are presented in the hereby paper. The investigations concern the formation of the diphase sand-air flux, its motion, flowing and compaction in the cavity during the core forming. Conditions deciding on the course of individual phases of the process are discussed with taking into consideration the influence of such factors as: the shot pressure, shooting hole diameter, number and distribution of deaerating vents in experimental core boxes (of a single cavity and of multi cavities) on the core sand compaction state. Investigations were performed by means of the modernised experimental shooting machine SR-3D, of the shooting chamber volume of 3.3 dm3, connected with the system of pneumatic supply ensuring the stable pressure supply of values: 0.4 MPa, 0.5 MPa and 0.6 MPa. Two diameters of the shooting hole, equal 10 mm and 20 mm, were applied for filling three experimental core boxes differing in dimensions of cavities and in number and distribution of deaerating vents. The filling process of core boxes was recorded by means of the digital camera PHANTOM V210 with the filming rate of 3000 pictures in second. Simultaneously, during the shot, other values allowing to determine the intensity of the core sand outflow from the shooting chamber to the core box, were tested. The presented in this publication results constitute the important element of the experimental verification of the blowing process simulation calculations which will be performed.
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Authors and Affiliations

R. Dańko

Evaluation of the Possibilities of Sodium Silicate Sands Application in Automated Hot-Box Process of Cores Shooting

M. Stachowicz K. Granat P. Obuchowski
Archives of Foundry Engineering | 2017 | vol. 17 | No 4 | DOI: 10.1515/afe-2017-0149
Keywords Foundry Sodium silicate Core-box core shooting Bending strength
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Abstract

The paper presents the results of preliminary research on the use of silica sands with hydrated sodium silicate 1.5% wt. of binder for the performance of eco-friendly casting cores in hot-box technology. To evaluate the feasibility of high quality casting cores performed by the use of this method, the tests were made with the use of a semiautomatic core shooter using the following operating parameters: initial shooting pressure of 6 bar, shot time 4 s and 2 s, core-box temperature 200, 250 and 300 °C and core heating time 30, 60, 90 and 150 s. Matrixes of the moulding sands were two types of high-silica sand: fine and medium. Moulding sand binder was a commercial, unmodified hydrated sodium silicate having a molar module SiO2/Na2O of 2.5. In one shot of a core-shooter were made three longitudinal samples (cores) with a total volume of about 2.8 dm3. The samples thus obtained were subjected to an assessment of the effect of shooting parameters, i.e. shooting time, temperature and heating time, using the criteria: core-box fill rate, bending strength (RgU), apparent density and surface quality after hardening. The results of the trials on the use of sodium silicate moluding sands made it possible to further refine the conditions of next research into the improvement of inorganic warm-box/hot-box technology aimed at: reduction of heating temperature and shot time. It was found that the performance of the cores depends on the efficiency of the venting system, shooting time, filling level of a shooting chamber and grains of the silica matrix used.

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Authors and Affiliations

M. Stachowicz
K. Granat
P. Obuchowski

Compaction of Cores Made by Blowing Methods – Model Investigations

R. Dańko
Archives of Foundry Engineering | 2018 | vol.18 | No 2
Keywords core shooting blowing process core sand core box
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Abstract

The results of model investigations of the influence of the blowing process selected parameters on the distribution of the compaction of the core made by the blowing method, are presented in the hereby paper. These parameters were: shooting pressure, shooting hole diameter, amount and distribution of deaerating holes. Investigations were performed using the horizontal core box of the cuboidal cavity and the same core box into which inner inserts were introduced. These inserts were dividing the primary volume into three sectors differing in their direction, introduction conditions and the character of the core sand flow. As the compaction measure the apparent sand density was assumed. The density was determined in five measuring points in case of uniform cores, and in three measuring points in case of cores obtained in the core box with three separated sectors. The apparent density of the compacted core sand in the core box cavity was determined on the basis of the measurements of masses and volumes of samples cut-out from the determined core places by means of the measuring probe. Investigations were performed at three values of the working pressure equal 0.4, 0.5 and 0.6MPa for two diameters of the shooting hole: 10 and 20 mm. During tests the core box deaeration, controlled by an activisation of the determined number of deaerating vents placed in the core box, was also subjected to changes.
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Authors and Affiliations

R. Dańko

Research on Selected Types of Lustrous Carbon Carriers After the High-Temperature Pyrolysis

J. Kamińska M. Stachowicz M. Kubecki
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 56-62 | DOI: 10.24425/afe.2021.136078
Keywords foundry Green moulding sand Lustrous carbon Pyrolysis Core shooting
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Abstract

For research purposes and to demonstrate the differences between materials obtained from the carbonaceous additives to classic green moulding sands, five lustrous carbon carriers available on the market were selected. The following carbonaceous additives were tested: two coal dusts (CD1 and CD2), two hydrocarbon resins (HR1 and HR2) and amorphous graphite (AG1). The studies of products and material effects resulting from the high-temperature pyrolysis of lustrous carbon carriers were focused on determining the tendency to gas evolution, including harmful compounds from the BTEX group (benzene, toluene, ethylbenzene and xylene). Moreover, the content of lustrous carbon (LC), the content of volatile matter and loss on ignition (LOI) of the carbonaceous additives were tested. The solid products formed during high-temperature pyrolysis were used for the quantitative and qualitative evaluation of elemental composition after the exposure to temperatures of 875oC in a protective atmosphere and 950oC in an oxidizing atmosphere. The conducted studies have indicated the necessity to examine the additives to classic green moulding sands, which is of particular importance for the processing, rebonding and storage of waste sand. The studies have also revealed some differences in the quantitative and qualitative composition of elements introduced to classic moulding sands together with the carbonaceous additives that are lustrous carbon carriers. It was also considered necessary to conduct a research on lustrous carbon carriers for their proper and environmentally friendly use in the widely propagated technology of classic green sand system.
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Bibliography

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Authors and Affiliations

J. Kamińska
1
ORCID: ORCID
M. Stachowicz
2
ORCID: ORCID
M. Kubecki
3
  1. Łukasiewicz Research Network – Krakow Institute of Technology, Poland
  2. Wroclaw University of Technology, Faculty of Mechanical Engineering, Poland
  3. Łukasiewicz Research Network – Institute for Ferrous Metallurgy, Gliwice, Poland

Influence of Automatic Core Shooting Parameters in Hot-Box Technology on the Strength of Sodium Silicate Olivine Moulding Sands

M. Stachowicz Ł. Pałyga D. Kępowicz
Archives of Foundry Engineering | 2020 | vol. 20 | No 1 | 67-72 | DOI: 10.24425/afe.2020.131285
Keywords Foundry Sodium silicate Olivine sand Hot-box process Core shooting
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Abstract

The paper presents the results of preliminary research on the application of olivine moulding sands with hydrated sodium silicate containing 1.5 % wt. of binder to perform ecological casting cores in hot-box technology using a semi-automatic core shooter. The following parameters were used in the process of core shooting: initial shot pressure of 6 bar, shot time 3 s, the temperature of the corebox: 200, 250 and 300 °C and the core curing time: 30, 60, 90, 120 and 150 s. The matrix of the moulding mixture was olivine sand, and the binder of the sandmix was commercial, unmodified hydrated sodium silicate with molar module SiO2/Na2O of 2.5. In one shot of the automatic core-shooter were formed three longitudinal specimens (cores) with a dimensions 22.2×22.2×180 mm. The samples obtained in this way were subjected to the assessment of the influence of the shooting parameters, i.e. shooting time, temperature and curing time in core-box, using the following criteria: core box fill rate, mechanical strength to bending Rg U, apparent density, compaction degree and susceptibility to friability of sand grains after hardening. The results of trials on the use of olivine moulding sands with hydrated sodium silicate (olivine SSBS) in the process of core shooting made it possible to determine the conditions for further research on the improvement of inorganic hot-box process technology aimed at: reduction of the heating temperature and the curing time. It was found that correlation between the parameters of the shooting process and the bending strength of olivine moulding sands with sodium silicate is observed.

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Authors and Affiliations

M. Stachowicz
ORCID: ORCID
Ł. Pałyga
D. Kępowicz

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