This article investigates possible use of waste gypsum (synthetic), recovered via flue-gas desulfurization from coal-fired electric power plants, in foundries. Energy sector, which in Eastern Europe is mostly composed from coal-fired electric power plants, is one of the largest producers of sulfur dioxide (SO2). In order to protect the environment and reduce the amount of pollution flue-gas desulfurization (FGD) is used to remove SO2 from exhaust flue gases of fossil-fuel power plants. As a result of this process gypsum waste is produced that can be used in practical applications. Strength and permeability tests have been made and also in-depth analysis of energy consumption of production process to investigate ways of preparing the synthetic gypsum for casting moulds application. This paper also assesses the chemical composition, strength and permeability of moulds made with synthetic gypsum, in comparison with moulds made with traditional GoldStar XL gypsum and with ceramic molds. Moreover examination of structure of synthetic gypsum, the investigations on derivatograph and calculations of energy consumption during production process of synthetic gypsum in wet flue-gas desulfurization were made. After analysis of gathered data it’s possible to conclude that synthetic gypsum can be used as a material for casting mould. There is no significant decrease in key properties, and on the other hand there is many additional benefits including low energy consumption, decreased cost, and decreased environmental impact.
While analyzing shape accuracy of ferroalloy precision castings in terms of ceramic moulds physical anisotropy, low-alloy steel castings ("cover") and cast iron ("plate") were included. The basic parameters in addition to the product linear shape accuracy are flatness deviations, especially due to the expanded flat surface which is cast plate. For mentioned castings surface micro-geometry analysis was also carried, favoring surface load capacity tp50 for Rmax = 50%. Surface load capacity tp50 obtained for the cast cover was compared with machined product, and casting plate surface was compared with wear part of the conveyor belt. The results were referred to anisotropy of ceramic moulds physical properties, which was evaluated by studying ceramic moulds samples in computer tomography equipment Metrotom 800.
The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process, considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty.
This research presents comprehensive assessment of the precision castings quality made in the Replicast CS process. The evaluation was made based on quality of the surface layer, shape errors and the accuracy of the linear dimensions. Studies were carried out on the modern equipment, among other things a Zeiss Calypso measuring machine and profilometer were used. Obtained results allowed comparing lost wax process models and Replicast CS process.