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Preliminary Tests of Innovative Eco-Friendly Furfuryl Resins and Foundry Sand Mixtures Based on These Resins

100%

Kamińska J. , Puzio S. , Angrecki M. , Stachowicz M. , Łoś A.

Journal of Ecological Engineering

2019

tom Vol. 20, nr 9

285--292

The foundry industry in Poland and EU member states is growing steadily. The alloys based on ferrous metals (cast steel and cast iron) largely contribute to this upward trend. Currently, foundries are facing the problem of increasing requirements, which enforce the production of castings characterized by high dimensional accuracy and surface smoothness with parallel elimination of casting defects. Castings are mostly made in moulding sand mixtures, which are also subject to more and more stringent requirements to meet the above-mentioned casting acceptance conditions. Additionally, moulding sands should ensure adequate mould stiffness to avoid the risk of dimensional deformations during the pouring of liquid metal to this mould and casting solidification. For these reasons, the production of this type of castings has been dominated by loose self-hardening sands with furfuryl resin, commonly called furan sands. In the group of self-hardening sands with synthetic resins, loose self-hardening sands with furfuryl resin enjoy the greatest popularity. What accounts for this fact is the high level of the reclamability of these sands, the possibility of obtaining castings with high dimensional accuracy, the ability to make intricate moulds and cores, the binding process taking place at ambient temperature, and low content of binder. Unfortunately, this technology also has some disadvantages, which include short lifetime of the sand mixture, harmful gases emitted from the sand, and currently also high cost of the sand mixture. The anticipated tightening of the environmental protection regulations in the EU countries, including limiting the content of free furfuryl alcohol in resins (<25% by mass) and reducing the emission of furfuryl alcohol, formaldehyde and BTEX compounds at workplaces, necessitated the development of a new generation of furfuryl resins friendly to the environment. The article compares the results of testing the strength properties of foundry moulding sands using two types of resins, i.e. the resin of a new generation synthesized by Grupa Azoty JRCh and a commercial resin used in the foundry industry. Additionally, derivatographic studies of the above mentioned sand mixtures were conducted, and the loss on ignition and the amount of gases emitted by the sand mixture were determined. Melting was also carried out to study the impact of the resin used on the surface quality of iron castings.

Nowe materiały jako zamienniki pyłu węglowego w masie formierskiej z lepiszczem bentonitowym, stosowanej do wytwarzania odlewów z żeliwa ciągliwego i stopów aluminium

58%

Stefański Z.

tom T. 48, z. 4

5-18

W artykule przedstawiono ważniejsze wyniki prac badawczo-rozwojowych i wdrożeniowych, zrealizowanych w ramach Projektów Celowych w latach 2006-2007, w dwóch krajowych odlewniach: Fabryce Łączników "Radom" w Radomiu oraz Odlewni MJM Jarosław Michalak w Ostrołęce. Celem projektów było opracowanie nowoczesnego, ekonomicznego oraz ekologicznego procesu produkcyjnego wykonywania odlewów. W Fabryce w Radomiu dotyczyło to odlewów łączników wykonywanych z żeliwa ciągliwego, w Odlewni MJM w Ostrołęce odlewów ze stopów aluminium (Al-Si) dla potrzeb energetyki. Opisano niektóre problemy odlewni związane z jakością produkowanych odlewów, zaproponowano optymalny sposób ich rozwiązania oraz przedstawiono wyniki badań dotyczących wprowadzonych rozwiązań, polegających na zastosowaniu w odlewniach nowego typu mas formierskich, zawierających w swoim składzie nowoczesny zamiennik odlewniczego pyłu węglowego o nazwie "kormix".

The article discusses the most important results of research, development and implementation works conducted under Target Projects in years 2006-2007 at the two Polish foundries, i.e. "Radom" Fittings Factory in Radom and MJM Jarosław Michalak Foundry Shop in Ostrołęka. The aim of the projects was to develop a modern, economical and ecological process for the casting manufacture. In "Radom" Foundry the investigations were carried out on fittings and pipe connections cast from malleable iron; in MJM Foundry in Ostrołęka the examined castings were made from aluminium-silicon alloys and assigned for use by the power industry. Some problems faced by the Foundries in respect of casting quality were described, optimum solutions were searched, and the results of these searches were stated. The proposed solutions suggest using in foundry practice the moulding sands of a new type, containing in their composition the recently developed foundry coal dust substitute of the trade name "kormix".