The results of investigations of the influence of the matrix grain sizes on properties of cores made by the blowing method are presented in the hereby paper. Five kinds of matrices, differing in grain size compositions, determined by the laser diffraction method in the Analysette 22NanoTec device, were applied in investigations. Individual kinds of matrices were used for making core sands in the Cordis technology. From these sands the shaped elements, for determining the apparent density of compacted sands and their bending strength, were made by the blowing method. The shaped elements (cores) were made at shooting pressures being 3, 4 and 5 atn. The bending strength of samples were determined directly after their preparation and after the storing time of 1 hour.
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 realization, 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.
The results of investigations of thermal reclamation of spent moulding sands originating from an aluminum alloy foundry plant are presented in this paper. Spent sands were crushed by using two methods. Mechanical fragmentation of spent sand chunks was realized in the vibratory reclaimer REGMAS. The crushing process in the mechanical device was performed either with or without additional crushing-grinding elements. The reclaimed material obtained in this way was subjected to thermal reclamations at two different temperatures. It was found that a significant binder gathering on grain surfaces favors its spontaneous burning, even in the case when a temperature lower than required for the efficient thermal reclamation of furan binders is applied in the thermal reclaimer. The burning process, initiated by gas burners in the reclaimer chamber, generates favorable conditions for self-burning (at a determined amount of organic binders on grain surfaces). This process is spontaneously sustained and decreases the demand for gas. However, due to the significant amount of binder, this process is longer than in the case of reclaiming moulding sand prepared with fresh components.
The aim of the hereby paper is to present the developed model of determining the volume and surface porosity based on the main fraction of polifractional materials, its experimental verification and utilisation for the interpretation of effects accompanying the formation of a moulding sand apparent density, porosity and permeability in the blowing processes of the core and moulds technology.
The cumulative results of investigations of the possibility of using the reclaimed materials after the mechanical, thermal or mechanical-thermal reclamation for making cores by means of the blowing method in the alkaline CO2 technology, are presented in the paper. Three kinds of spent sands: with furfuryl resin, bentonite and alkaline phenolic resin, obtained from the foundry, were subjected to three kinds of reclamation: mechanical, thermal and combined mechanical-thermal, applying for this aim adequate experimental devices. The obtained reclaims were assessed with regard to the degree of the matrix liberation from the determined binding material. Reclaims of moulding sands with binders of the form of resin were assessed with regard to ignition loss values and pH reaction, while reclaims of moulding sands with bentonite with regard to the residual clay content and pH value. In all cases the results of the performed sieve analyses were estimated and the average characteristic diameter dl was determined. The reclaimed matrix was applied as a full substitute of the fresh high-silica sand in typical procedures of preparing core sands used for making shaped samples for bending strength investigations, Rg u .
Emission of gases under high temperature after pouring molten metal into moulds, which contain the organic binder or other additives (solvents or curing agent), may be an important factor influencing both on the quality of the produced castings, and on the state of environment. Therefore, a comprehensive study of the emitted gases would allow to determine restrictions on the use of the moulding sands in foundry technologies, eg. the probability of occurrence of casting defects, and identify the gaseous pollutants emitted to the environment. The aim of the research presented in this paper was to determine the amount of gases that are released at high temperatures from moulding sands bonded by biopolymer binder and the quantitative assessment of the emitted pollutants with particular emphasis on chemical compounds: benzene, toluene, ethylbenzene and xylenes (BTEX). The water-soluble modified potato starch as a sodium carboxymethyl starch with low (CMS-NaL) or high (CMS-NaH) degree of substitution was a binder in the tested moulding sands. A tests of gases emission level were conducted per the procedure developed at the Faculty of Foundry Engineering (AGH University of Science and Technology) involving gas chromatography method (GC). The obtained results of the determination of amount of BTEX compounds generated during the decomposition process of starch binders showed lower emission of aromatic hydrocarbons in comparison with binder based on resin Kaltharz U404 with the acidic curing agent commonly used in the foundries.