Environmentally Friendly Foundry Molding and Core Sands
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JMEPEG https://doi.org/10.1007/s11665-019-03947-x
Environmentally Friendly Foundry Molding and Core Sands K. Major-Gabrys´ (Submitted September 28, 2018; in revised form January 23, 2019) The paper describes the current state of knowledge in a field where change has been driven in foundry molding sand practice due to the increasing requirements regarding environmental protection. These trends must take into account not only the technological quality and economics of their production process, but also the increasingly stringent requirements related to environmental protection. As part of this study, tests were performed in relation to reducing the toxicity of current molding sands with organic binders, so as to develop new organic binders for foundry practice. Molding sands with binders having various contents of furfuryl alcohol were tested. It was shown that reducing the total furfuryl alcohol content in the binder results in lower strength properties of the molding sands in practice. It was also suggested to replace the use of a furfuryl binder with one based on alkyd resin. The final stage of the study was to demonstrate the desirability of using biomaterials as a component of organic binders for foundry molding sands. Compositions: typical synthetic resins and biodegradable materials were designed as binders to improve the quality of the organic binders used with molding sands. Keywords
foundry engineering, green industry, molding and core sands, organic binder, biomaterial
1. Introduction The contemporary economic situation requires the manufacture of products that meet the highest quality criteria. Such products include castings used in the automotive, construction, metallurgical and cement industries, as well as those for the art and jewelry industry. In the context of the Polish economy, the production of castings is significant. One of the basic factors affecting the quality of the finished castings, mainly in terms of dimensional accuracy and surface finish, is the quality of the molds and foundry cores. These in turn depend on the type and quality of the molding and core sands. Due to the variety of foundry alloys, casting technologies, and both mass and quality requirements, it is necessary to use a number of different molding and core sands. In terms of size, the greater the mass of the casting, the greater the effect of the casting alloy on the molding or core sand. The type of casting and its pour temperature affect the selection of a suitable molding sand, due to the potential for chemical reactions at the alloy–mold interface. Additionally, the quality class required
This article is an invited submission to JMEP selected from presentations at the 73rd World Foundry Congress and has been expanded from the original presentation. 73WFC was held in Krakow, Poland, September 23-27, 2018, and was organized by the World Foundry Organization and Polish Foundrymens Association. K. Major-Gabrys´, Department of Molding Materials, Mold Technology and Foundry of Non-ferrous Metals, Faculty of Foundry Engineerin
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