The Influence of 3D Printing Core Construction (Binder Jetting) on the Amount of Generated Gases in the Environmental and Technological Aspect.

This article presents the findings of a study focusing on the gas generation of 3D-printed cores fabricated using binder-jetting technology with furfuryl resin. The research aimed to compare gas emission levels, where the volume generated during the thermal degradation of the binder significantly impacts the propensity for gaseous defects in foundries. The study also investigated the influence of the binder type (conventional vs. 3D-printed dedicated binder) and core construction (shell core) on the quantity of gaseous products from the BTEX group formed during the pouring of liquid foundry metal into the cores. The results revealed that the emitted gas volume during the thermal decomposition of the organic binder depended on the core sand components and binder type. Cores produced using conventional methods emitted the least gases due to lower binder content. Increasing Kaltharz U404 resin to 1.5 parts by weight resulted in a 37% rise in gas volume and 27% higher benzene emission. Adopting shell cores reduced gas volume by over 20% (retaining sand with hardener) and 30% (removing sand with hardener), presenting an eco-friendly solution with reduced benzene emissions and core production costs. Shell cores facilitated the quicker removal of gaseous binder decomposition products, reducing the likelihood of casting defects. The disparity in benzene emissions between 3D-printed and vibratory-mixed solid cores is attributed to the sample preparation process, wherein 3D printing ensured greater uniformity.

Thermostability of Organobentonite Modified with Poly(acrylic acid).

A new type of organobentonite foundry binder composed of a composite of bentonite (SN) and poly(acrylic acid) (PAA) was analyzed using thermal analysis (TG-DTG-DSC) and pyrolysis gas chromatography mass spectrometry (Py-GC/MS). The temperature range in which the composite retains its binding properties was identified using thermal analysis of the composite and its components. Results showed that the thermal decomposition process is complex and involves physicochemical transformations that are mainly reversible at temperatures in the ranges of 20-100 °C (related to evaporation of solvent water) and 100-230 °C (related to intermolecular dehydration). The decomposition of PAA chains occurs between 230 and 300 °C, while complete decomposition of PAA and formation of organic decomposition products takes place at 300-500 °C. Dehydroxylation of montmorillonite (MMT) in bentonite begins at about 500 °C, which leads to a drastic structural transformation. An endothermic effect associated with the remodeling of the mineral structure was observed on the DSC curve in the range of 500-750 °C. The produced SN/PAA composite was found to be thermostable during degradation in both oxidative and inert atmosphere, similar to the starting bentonite, and even maintained over a relatively higher and wider temperature range compared to organic binding materials used. At the given temperatures of 300 °C and 800 °C, only CO2 emissions occur from all the examined SN/PAA samples. There is no emission of compounds from the BTEX group. This means that the proposed binding material in the form of the MMT-PAA composite will not pose a threat to the environment and the workplace.

3D Printed (Binder Jetting) Furan Molding and Core Sands-Thermal Deformation, Mechanical and Technological Properties.

Casting cores produced in additive manufacturing are more often used in industrial practice, in particular in the case of the production of unit castings and castings with very complex geometry. The growing interest in the technology of 3D printing of cores and molds also brings emerging doubts related to their mechanical and technological properties. This article presents a comparison of the properties of cores made of sand with acid-curing furfuryl resin, made with 3D printing technology; the cores were prepared in a conventional way (mixing and compaction). The main purpose of this research was to determine the possibility of using shell cores as a substitute for solid cores, aimed at reducing the amount of binder in the core. The influence of the type of the binder and the size of the grain matrix fraction on the obtained mechanical and technological properties of the cores, with particular emphasis on abrasion and thermal deformation, as well as on the kinetics of their hardening, was demonstrated.

Organobentonite Binder for Binding Sand Grains in Foundry Moulding Sands.

A series of studies related to the production of organobentonite, i.e., bentonite-poly(acrylic acid), and its use as a matrix grain-binding material in casting moulding sand is presented. In addition, a new carbon additive in the form of shungite was introduced into the composition of the moulding sand. Selected technological and strength properties of green sand bond with the obtained organobentonite with the addition of shungite as a new lustrous carbon carrier (Rcw, Rmw, Pw, Pw, PD) were determined. The introduction of shungite as a replacement for coal dust in the hydrocarbon resin system demonstrated the achievement of an optimum moulding sand composition for practical use in casting technology. Using chromatographic techniques (Py-GC/MS, GC), the positive effect of shungite on the quantity and quality of the gaseous products generated from the moulding sand during the thermal destruction of its components was noted, thus confirming the reduced environmental footprint of the new carbon additive compared to the commonly used lustrous carbon carriers. The test casting obtained in the mould of the organobentonite moulding sand and the shungite/hydrocarbon resin mixture showed a significantly better accuracy of the stepped model shape reproduction and surface smoothness compared to the casting obtained with the model moulding sand.

Dehydroxylation of Perlite and Vermiculite: Impact on Improving the Knock-Out Properties of Moulding and Core Sand with an Inorganic Binder.

The article presents the results of research aimed at examining the type of swelling material introduced into moulding or core sand to improve their knock-out properties. Tests on Slovak perlite ore (three grain sizes), Hungarian perlite ore and ground vermiculite (South Africa) were carried out. For this purpose, thermal and structural analyses (FTIR-Fourier Transform Infrared Spectroscopy), a chemical composition test (XRF-X-Ray Fluorescence), phase analysis (XRD-X-Ray Diffraction), and scanning electron microscopy (SEM-Scanning Electron Microscope) as well as final strength tests of moulding sands with the addition of perlite ore and vermiculite were carried out. The results of thermal studies were related to IR (Infrared Spectroscopy) spectra and XRD diffractograms. It has been shown that the water content in the pearlite ore is almost three times lower than in vermiculite, but the process of its removal is different. Moreover, the chemical composition of the perlite ore, in particular the alkali content and its grain size, may influence its structure. The phenomena of expansion (perlite) and peeling (vermiculite) have a positive effect on the reduction of the final sand strength and eliminate technological inconveniences (poor knocking out) that significantly limit the wide use of moulding sands with inorganic binders.

Organobentonites Modified with Poly(Acrylic Acid) and Its Sodium Salt for Foundry Applications.

The article aims to verify the possibility of obtaining an organic-inorganic material acting as both a binder and a lustrous carbon carrier in bentonite-bonded molding sands. Due to the wide industrial application, organoclays can be considered as innovative materials supporting the foundry technology in meeting environmental requirements. In this study, the organic modification of montmorillonite in calcium bentonite (SN) was performed by poly(acrylic acid) (PAA) and its sodium salt (PAA/Na). Additionally, for the purpose of comparison, the sodium-activated bentonite/poly(acrylic acid) (SN-Na/PAA) composites were also prepared. The collective analysis of the research results used in the assessment of the mineral/polymer interaction mechanism indicates surface adsorption combined with the intercalation of PAA monolayer into the mineral interlayer spaces. Materials were characterized by the combination of Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), Brunauer-Emmett-Teller (BET) surface area analysis and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) methods. Based on the XRD analysis, the influence of PAA/Na on the aluminosilicate layered structure was found to be destructive, which may adversely affect the binding properties of SN/PAA/Na composites considered as a potential group of new foundry binders. The SN/PAA and SN-Na/PPA composites (with appropriate polymer content) can act as a binding agent in the synthetic molding sand technology, despite coating the bentonite particles with polymer molecules. The risk of losing the mineral's binding capacity is reduced by the good binding properties of pol(acrylic acid) itself. The article is the first stage (preceding the thermal analysis and the strength tests of molding sands with the prepared organobentonites) in determining the possibility of obtaining a new full-value foundry binder in molding sands with bentonite.

Effects of curing conditions on the structure of sodium carboxymethyl starch/mineral matrix system: FT-IR investigation.

Strength properties of the microwave cured molding sands containing binders in a form of the aqueous solution of sodium carboxymethyl starch (CMS-Na) are higher than the same molding composition cured by conventional heating. Finding the reason of this effect was the main purpose in this study. Structural changes caused by both physical curing methods of molding sands systems containing mineral matrix (silica sand) and polymer water-soluble binder (CMS-Na) were compared. It was shown, by means of the FT-IR spectroscopic studies, that the activation of the polar groups in the polymer macromolecules structure as well as silanol groups on the mineral matrix surfaces was occurred in the microwave radiation. Binding process in microwave-cured samples was an effect of formation the hydrogen bonds network between hydroxyl and/or carbonyl groups present in polymer and silanol groups present in mineral matrix. FT-IR studies of structural changes in conventional and microwave cured samples confirm that participation of hydrogen bonds is greater after microwave curing than conventional heating.

Effect of microwave treatment on structure of binders based on sodium carboxymethyl starch: FT-IR, FT-Raman and XRD investigations.

The paper deals with the influence of the microwave treatment on sodium carboxymethyl starch (CMS-Na) applied as a binder for moulding sands. The Fourier transformation infrared spectrometry (FT-IR), Raman spectroscopy (FT-Raman) and XRD analysis data of native potato starch and three different carboxymethyl starches (CMS-Na) with various degree of substitution (DS) before and after exposition to microwave radiation have been compared. FT-IR studies showed that polar groups present in CMS-Na structure take part in the formation of new hydrogen bonds network after water evaporation. However, these changes depend on DS value of the modified starch. The FT-Raman study confirmed that due to the impact on the samples by microwave, the changes of intensity in the characteristic bands associated with the crystalline regions in the sample were noticed. The X-ray diffraction data for microwave treated CMS-Na samples have been compared with the diffractograms of initial materials and analysis of XRD patterns confirmed that microwave-treated samples exhibit completely amorphous structure. Analysis of structural changes allows to state that the binding of sand grains in moulding sand with CMS-Na polymeric binder consists in the formation of hydrogen bonds networks (physical cross-linking).