This article presents measurements of the thickness of alcohol-based coatings on sand foundry cores and moulds. These coatings were applied using two methods, the dipping method and the painting method. For the purposes of the study, a zircon alcohol-based coating was prepared with three different levels of nominal viscosity; very thin at 10s, average at 20s, and thick at 30s. The coating was applied to a core made of quartz sand and furan resin. The cores were made of sand with three different grain sizes; dL = 0.22 mm – fine sand, dL = 0.33 mm medium sand, and dL = 0.47 mm coarse sand. In the study, the thickness of the coating obtained to the core was measured immediately after application as well as after drying. Additionally, the extent of penetration into the intergranular spaces of the core matrix was measured. On the basis of this study, the impact of the grain size of the core matrix on the thickness of the coating and its penetration into the core was assessed. The thickness of coatings obtained using different application methods was also assessed.
The results of investigations of the rheological properties of typical ceramic slurries used in the investment casting technology – the lost wax technology are presented in the paper. Flow curves in the wide range of shear velocity were made. Moreover, viscosity of ceramic slurries depending on shearing stresses was specified. Tests were performed under conditions of three different temperatures 25, 30 and 35oC, which are typical and important in the viewpoint of making ceramic slurries in the investment casting technology. In the light of the performed investigations can be said that the belonging in group of Newtonian or Non – Newtonian fluid is dependent on content of solid phase (addition of aluminum oxide) in the whole composition of liquid ceramic slurries.
Measurements of the hardening process course of the selected self-hardening moulding sands with the reclaimed material additions to the matrix, are presented in the hereby paper. Moulding sands were produced on the „Szczakowa” sand (of the Sibelco Company) as the matrix of the main fraction FG 0,40/0,32/0,20, while the reclaim was added to it in amounts of 20, 50 and 70%. Regeneration was performed with a horizontal mechanical regenerator capacity of 10 t/h. In addition, two moulding sands, one on the fresh sand matrix another on the reclaimed matrix, were prepared for comparison. Highly-fluid urea-furfuryl resin was used as a binder, while paratoluensulphonic acid as a hardener. During investigations the hardening process course was determined, it means the wave velocity change in time: cL = f(t). The hardening process kinetics was also assessed (dClx/dt = f(t)). Investigations were carried out on the research stand for ultrasound tests. In addition strength tests were performed.
The investigation results of the kinetics of binding ceramic moulds, in dependence on the solid phase content in the liquid ceramic slurries being 67, 68 and 69% - respectively, made on the basis of the aqueous binding agents Ludox AM and SK. The ultrasonic method was used for assessing the kinetics of strengthening of the multilayer ceramic mould. Due to this method, it is possible to determine the ceramic mould strength at individual stages of its production. Currently self-supporting moulds, which must have the relevant strength during pouring with liquid metal, are mainly produced. A few various factors influence this mould strength. One of them is the ceramic slurry viscosity, which influences a thickness of individual layers deposited on the wax model in the investment casting technology. Depositing of layers causes increasing the total mould thickness. Therefore, it is important to determine the drying time of each deposited layer in order to prevent the mould cracking due to insufficient drying of layers and thus the weakening of the multilayer mould structure.
Measurements of the hardening process of the selected self-setting sands are presented in the hereby paper. Moulding sands were prepared on the matrix of „Szczakowa” sand of the Sibelco Company. Two resins: phenol-formaldehyde-furfuryl (FF/AF) and urea-formaldehydefurfuryl (MF/AF) were used for making moulding sands. – Methylbenzene-sulphonic acid was applied as a hardener for the moulding sand on FF/AF resin, while paratoluene-sulphonic acid for the moulding sand on MF/AF resin. Both hardeners were used in two concentrations: low – the so-called ‘slow’ hardener and high - ‘fast’ hardener. During investigations, the courses of the hardening process were determined, more accurately changes of the velocity of the ultrasound wave passage through the moulding sand cL = f(t) and changes of the moulding sand hardening degree versus time, Sx = f(t). In addition, the kinetics of the hardening process was determined. Measurements were performed on the research stand for ultrasound investigations.