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K. Kaczmarska, A. Bobrowski, S. Żymankowska-Kumon and B. Grabowska

Abstract

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.

Open access

B. Grabowska, K. Kaczmarska and A. Bobrowskia

Abstract

In this paper the results of studies of polymeric binders on the example of the new BioCo2 binder, including the problem of its renewability, are presented. The results of structural studies (FT-IR) for the BioCo2 binder before and after crosslinking, and bending strength tests Rg u fresh and renewed cured molding sands with BioCo2 binder are discussed. The cross-linking binder and curring of moulding sand was carried out by physical agents (microwave radiation, temperature). On the basis of obtained results was shown that it is possible to restore the initial properties of the adhesive of BioCo2 binder. The initial properties of moulding sand can be achieved, after the cross-linking binders and after curing in the moulding sands with bioCo2 binder , by supplementing the moulding sand composition by the appropriate amount of water.

Open access

B. Grabowska, A. Bobrowski, E. Olejnik and K. Kaczmarska

Abstract

This publication describes research on the course of the process of cross-linking new BioCo polymer binders - in the form of water-based polymer compositions of poly(acrylic acid) or poly(sodium acrylate)/modified polysaccharide - using selected physical and chemical factors. It has been shown that the type of cross-linking factor used influences the strength parameters of the moulding sand. The crosslinking factors selected during basic research make it possible to obtain sand strengths similar to those of samples of sands bonded with commercial binders. Microwave radiation turned out to be the most effective cross-linking factor in a binder-matrix system. It was proven that adsorption in the microwave radiation field leads to the formation of polymer lattices with hydrogen bonds which play a major role in maintaining the formed cross-linked structures in the binder-matrix system. As a result, the process improves the strength parameters of the sand, whereas the hardening process in a microwave field significantly shortens the setting time.

Open access

B. Grabowska, K. Kaczmarska, A. Bobrowski, Ż. Kurleto-Kozioł and Ł. Szymański

Abstract

The spectroscopic FT-IR and FT-Raman methods allowed to identify the cross-linking process of the aqueous composition of poly(acrylic acid)/sodium salt of carboxymethyl starch (PAA/CMS-Na) applied as a binder for moulding sands (as a novel group binders BioCo). The cross-linking was performed by physical agent, applying the UV-radiation. The results of structural studies (IR, Raman) confirm the overlapping of the process of cross-linking polymer composition PAA/CMS-Na in UV radiation. Taking into account the ingredients and structure of the polymeric composition can also refer to a curing process in a binder - mineral matrix mixture. In the system of binder-mineral matrix under the influence of ultraviolet radiation is also observed effect of binding. However, the bonding process does not occur in the entire volume of the investigated system, but only on the surface, which gives some possibilities for application in the use of UV curing surface of cores, and also to cure sand moulds in 3D printing technology.

Open access

A. Bobrowski, S. Żymankowska-Kumon, D. Drożyński, B. Grabowska and K. Kaczmarska

Abstract

The paper presents the results of thermoanalytical studies by TG/DTG/DTA, FTIR and GC/MS for the oil sand used in art and precision foundry. On the basis of course of DTG and DTA curves the characteristic temperature points for thermal effects accompanying the thermal decomposition reactions were determined. This results were linked with structural changes occurred in sample. It has been shown that the highest weight loss of the sample at temperatures of about 320°C is associated with destruction of C-H bonds (FTIR). In addition, a large volume of gases and high amounts of compounds from the BTEX group are generated when liquid metal interacts with oil sand. The results show, that compared to other molding sands used in foundry, this material is characterized by the highest gaseous emissions and the highest harmfulness, because benzene emissions per kilogram of oil sand are more than 7 times higher than molding sand with furan and phenolic binders and green sand with bentonite and lustrous carbon carrier.

Open access

B. Grabowska, K. Kaczmarska, A. Bobrowski, D. Drożyński, S. Żymankowska-Kumon and S. Cukrowicz

Abstract

The effects of silica additive (Poraver) on selected properties of BioCo3 binder in form of an aqueous poly(sodium acrylate) and dextrin (PAANa/D) binder were determined. Based on the results of the thermoanalytical studies (TG-DTG, FTIR, Py-GC/MS), it was found that the silica additive results in the increase of the thermostability of the BioCo3 binder and its contribution does not affect the increase in the level of emissions of organic destruction products. Compounds from group of aromatic hydrocarbons are only generated in the third set temperature range (420-838°C). The addition of silicate into the moulding sand with BioCo3 causes also the formation of a hydrogen bonds network with its share in the microwave radiation field and they are mainly responsible for maintaining the cross-linked structures in the mineral matrix system. As a consequence, the microwave curing process in the presence of Poraver leads to improved strength properties of the moulding sand (Ru m). The addition of Poraver's silica to moulding sand did not alter the permeability of the moulding sand samples, and consequently reduced their friability. Microstructure investigations (SEM) of microwave-cured samples have confirmed that heterogeneous sand grains are bonded to one another through a binder film (bridges).