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1
Content available The Influence of Biomaterial in a Binder Composition on Biodegradation of Waste from Furan Moulding Sands
Major-Gabryś Katarzyna, Stachurek I., Hosadyna-Kondracka M.
Archives of Foundry Engineering
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2022
|
Vol. 22, iss. 2
17--24
EN
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).
2
Content available Research on Assessment of the Applicability of Malted Barley Binder in Moulding Sand Technology
Samociuk Bartłomiej, Gal B., Nowak D.
Archives of Foundry Engineering
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2021
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Vol. 21, iss. 1
74--80
EN
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.
3
Content available Organic Moulding Sands for Production of Large-Size Castings
Major-Gabryś K., Hosadyna-Kondracka M.
Archives of Foundry Engineering
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2019
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iss. 3
99--105
EN
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.
4
Content available Method of Selecting the Reclamation Temperature of Spent Moulding Sands with Organic Binders
Łucarz M.
Archives of Foundry Engineering
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2018
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Vol. 18, iss. 1
65--70
EN
The thermal reclamation process as a utilisation method of spent moulding and core sands is more costly than other reclamation methods, but in the majority of cases it simultaneously provides the best cleaning of mineral matrices from organic binders. Thus, the application of the thermal analysis methods (TG-DSC), by determining the temperature range within which a degradation followed by a destruction of bounded organic binders in moulding sands, can contribute to the optimisation of the thermal reclamation process and to the limiting its realisation costs. The thermal analysis results of furan resin, one of the most often applied binder in foundry practice, are presented in the hereby paper. The influence of the heating rate of the sample - placed in the thermal analyser - on its degradation and destruction process under oxygen-free (argon) and oxygen (air) conditions, were compared. The recorded TG and DSC curves were used for analysing these processes as the temperature as well as the time function. The obtained results were analysed with regard to determining the required temperature of the thermal reclamation of the investigated organic binder. The usefulness of the developed methodology was found out, however under conditions of meeting several essential requirements concerning the repeatability of performed analyses.
5
Dekorowanie powierzchni w erze cyfrowej – poszerzenie możliwości zdobienia szkła
Raz N.
Świat Szkła
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2017
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R. 22, nr 12
42--43
6
Content available State of Spent Molding Sands in the Mold Large-Size Cast
Łucarz M.
Archives of Foundry Engineering
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2016
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Vol. 16, iss. 4
69--74
EN
The results of investigations of spent moulding sands taken from the mould at various distances from the surface of the produced casting, are presented in the paper. The casting mould was made with an application of the cooling system of the metal core in order to increase the cooling rate of the ladle casting. As temperature measurements in the mould indicated the heat flow from the metal did not create conditions for the complete burning of a moulding sand. The analysis was performed to find out changes of spent moulding sands caused by degradation and destruction processes of organic binders. Conditions occurring in the casting mould were discussed on the bases of testing: ignition losses, dusts contents, pH reactions and the surface morphology of the moulding sand samples. Factors limiting the effective mould degassing were pointed out. Operations, possible for realisation, which can limit the reasons of a periodical occurrence of increased amounts of casting defects due to changing gas evolution rates being the result of the technological process, were also indicated.
7
Content available Analysis of Spent Moulding Sands with Binders of Various Thermal Degradations, in an Aspect of a Possibility of a Directional Mould Degassing
Łucarz M.
Archives of Foundry Engineering
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2016
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Vol. 16, iss. 2
21--26
EN
The results of investigations of spent moulding sands taken from the mould in which the metal core cooling system - to increase the cooling rate of the ladle casting - was applied, are presented in the hereby paper. The changes of the spent moulding sand at the casting external side being the result of degradation and destruction processes of organic binder, were analysed in this publication. Since the reclaimed material, obtained as a result of the mechanical reclamation of spent sands of the same type, is used as a grain matrix of the moulding sand, the amount of a binder left from the previous technological cycle is essential for the sound castings production. On the bases of investigations of the thermal analysis, ignition losses, dusts contents and pH values of the samples taken from the spent sand the conditions under which the process of gases displacing in the casting mould was realised as well as factors limiting the efficient mould degassing - were considered in this study. The possible reason of a periodical occurrence of an increased number of casting defects due to changing gas volume emission, being the reason of the realised technological process, was indicated.
8
Content available Assessment method of overheating degree of a spent moulding sand with organic binder, after the casting process
Dańko R.
Archives of Foundry Engineering
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2013
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Vol. 13, iss. 2
11--16
EN
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.
9
Content available Influence green sand system by core sand additions
Špirutová N., Beňo J., Bednářová V., Kříž J., Kandrnál M.
Archives of Foundry Engineering
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2012
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Vol. 12, iss. 1
105-110
EN
Today, about two thirds of iron alloys casting (especially for graphitizing alloys of iron) are produced into green sand systems with usually organically bonded cores. Separation of core sands from the green sand mixture is very difficult, after pouring. The core sand concentration increase due to circulation of green sand mixture in a closed circulation system. Furthermore in some foundries, core sands have been adding to green sand systems as a replacement for new sands. The goal of this contribution is: 'How the green sand systems are influenced by core sands?" This effect is considered by determination of selected technological properties and degree of green sand system re-bonding. From the studies, which have been published yet, there is not consistent opinion on influence of core sand dilution on green sand system properties. In order to simulation of the effect of core sands on the technological properties of green sands, there were applied the most common used technologies of cores production, which are based on bonding with phenolic resin. Core sand concentration added to green sand system, was up to 50%. Influence of core sand dilution on basic properties of green sand systems was determined by evaluation of basic industrial properties: moisture, green compression strength and splitting strength, wet tensile strength, mixture stability against staling and physical-chemistry properties (pH, conductivity, and loss of ignition). Ratio of active betonite by Methylene blue test was also determined.
10
Content available Charakterystyka tworzyw ceramicznych otrzymanych z udziałem zużytych mas odlewniczych ze spoiwem organicznym
Pytel Z.
Archives of Foundry Engineering
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2012
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Vol. 12, iss. 1s
153--162
PL
Referat zawiera wyniki badań tworzyw ceramicznych otrzymanych z mas plastycznych, w których składnikiem przeznaczonym do schudzania surowca ilastego były zużyte masy odlewnicze. Wprawdzie masy te pochodziły z różnych odlewni, to jednak wspólną ich cechą był rodzaj spoiwa wykorzystywanego do ich przygotowania. Spoiwa te należały do grupy spoiw organicznych, opartych na żywicach furanowych lub fenolowo-formaldehydowych. Ze względu na potencjalną możliwość emisji do atmosfery szkodliwych substancji gazowych w postaci wielopierścieniowych węglowodorów aromatycznych (WWA), mogących się uwalniać w warunkach wysokich temperatur charakterystycznych dla procesu wypalania wyrobów ceramicznych, podjęte badania stanowią próbę utylizacji jednego z najbardziej niebezpiecznych rodzajów zużytych mas odlewniczych. Koncepcja badań przewiduje otrzymanie zasadniczo dwóch rodzajów tworzyw ceramicznych. Pierwszy rodzaj stanowi tworzywo referencyjne otrzymane z masy ceramicznej, w której rolę dodatku schudzającego surowiec ilasty spełnia tradycyjny dodatek w postaci piasku kwarcowego pochodzenia naturalnego. Drugi rodzaj stanowią tworzywa eksperymentalne otrzymywane również z mas ceramicznych, lecz w tym przypadku dodatkiem schudzającym był materiał krzemionkowy otrzymany w wyniku odpowiedniego przetworzenia zużytych mas odlewniczych zawierających pozostałości spoiw organicznych, wprowadzany w ekwiwalentnej ilości w stosunku do piasku kwarcowego. Ocenę przydatności tego rodzaju surowca wtórnego we wspomnianym kierunku utylizacji, przeprowadzono w oparciu o wynik analizy porównawczej obu rodzajów tworzyw, obejmującej swym zakresem ich podstawowe cechy użytkowe oraz wybrane elementy mikrostruktury. Uzyskane wyniki badań świadczą o braku negatywnego oddziaływania na środowisko naturalne związane z potencjalną możliwością emisji WWA w trakcie produkcji tworzyw ceramicznych z udziałem zużytych mas odlewniczych zawierających pozostałości spoiw organicznych, jak również potwierdzają możliwość otrzymywania z ich udziałem tworzyw ceramicznych odznaczających się porównywalnymi właściwościami w stosunku do tworzyw referencyjnych.
EN
This study summarises the properties of ceramic materials based on plastic mixes, containing used moulding sands as the leaning agent. Though the moulding sands came from several foundry plants, they contain the same binding agent. These bonding agents belong to the group of organic binders based on furane or phenol-formaldehyd resins. In the context of potential hazards associated with hazardous gas emissions in the form of polycyclic aromatic hydrocarbons (PAHs) released at high temperatures required during the burning of ceramic products, research work is undertaken to work out the method of disposal of one of the most hazardous types of used moulding mix. Two types of ceramic materials are going to be obtained. The first type is the reference material made of the ceramic mix containing the natural silica sand as the leaning agent. The second type of ceramic products are experimental materials produced from ceramic mixes too, but in this case, the leaning agent was silica raw material obtained as a result of waste foundry moulding mixes recycling. Those waste mixes contained some residues of organic binders. The waste raw material was introduced into the final mix in amount equivalent to quartz mass in reference mix. The usability of this type of recycled product is assessed by comparative analysis of the two materials, covering their functional parameters and selected elements of microstructural analysis. Results indicate there are no negative environmental impacts associated with potential PAHs emissions during the manufacturing process of the ceramic materials containing used sand mix with organic binders and show that thus obtained ceramic materials are comparable to the reference materials in terms of their functional qualities and parameters.
11
Przyszłość organicznych spoiw odlewniczych w Europie
Serghini A.
Przegląd Odlewnictwa
|
2011
|
Vol. 61,nr 11-12
548-553
12
Content available remote Gas evolution rate from heated moulding sands bonded with organic binders
Siewiorek A., Nowak R., Chojecki A., Mocek J.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 1
87-92
EN
This study is continuation of research on gas evolution rate from heated moulding sands used in the manufacture of foundry moulds. The first stage of the study described in [1] included bentonite-bonded sands. At the second stage, sands bonded with organic binders were tested. The composition of gases, evolved at a given temperature using mould heating system that simulates the process of mould pouring with molten metal, was determined. Metal was not used in these studies to prevent its reaction with gases formed as a result of moulding sand heating, since this effect would significantly impede the gas identification or even make it totally impossible.
13
Rola zagęszczania w technologii formy opartej na masach ze szkłem wodnym i spoiwami organicznymi
Zych J.
Przegląd Odlewnictwa
|
2005
|
Vol. 55, nr 2
88-97
PL
W pracy przedstawiono wyniki badań dotyczących wpływu gęstości pozornej utwardzonych mas ze spoiwami chemicznymi na ich właściwości wytrzymałościowe i technologiczne. Wskazano na ważną rolą zagęszczenia w podwyższaniu sztywności form i ich odporności na erozyjne działanie ciekłego metalu. Opisano ultradźwiękową metodę pomiaru gęstości pozornej masy w utwardzonych elementach form i rdzeni. W porozymetrii ultradźwiękowej mas ze spoiwami wykorzystuje się liniową zależność pomiędzy gęstością pozorną masy i prędkością fali.
EN
In the article results of research concerning the influence of the apparent density hardened sands with chemical binders on their tensile and technological properties. The important role of compactness in the increasing of the mould rigidity and their resistance to the erosive activity of the liquid metal was indicated. The ultrasonic method of determining the apparent density in the hardened elements of moulds and cores was described. By testing waterglass sands using the ultrasonic porosimetry the relationship between the apparent density of sand and the wave rate is utilised.
14
Content available remote Kierunki rozwoju mas formierskich i rdzeniowych ze spoiwami organicznymi
Holtzer M.
Archiwum Odlewnictwa
|
2003
|
R. 3, nr 9
189--196
PL
Przewiduje się, że rozwój spoiw stosowanych do mas formierskich i rdzeniowych będzie bardziej ewolucyjny niż rewolucyjny. Zmiany będą głównie spowodowane coraz ostrzejszymi wymaganiami w zakresie ochrony środowiska. Jednak nie bez znaczenia będzie nacisk na wysoką wydajność procesu oraz jakość otrzymywanych odlewów. W artykule omówiono najnowsze działania światowych firm w zakresie opracowywania nowych i modyfikacji już stosowanych spoiw organicznych. Szczególną uwagę zwrócono na zminimalizowanie oddziaływania poszczególnych etapów wykonywania form i rdzeni na środowisko. Istotne znaczenie ma w tym względzie wyeliminowanie rozpuszczalników aromatycznych i zastąpienie ich rozpuszczalnikami pochodzenia naturalnego lub wodą.
EN
The future for core and mould binder will be more evolutionary than revolutionary, as they react to the demands placed upon them rather than veering off in new directions. The driving force of those changes will be environmental regulations, as binders will have to become more environment-friendly to meet demands of lower air pollutant emission level while maintaining or exceeding the productivity demands of a competitive global marketplace. Some binders are compared with regard to productivity, casting quality and environmental acceptability. The purpose of this paper is to discuss a new technology, which provides foundries with new options for the casting process.
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