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Abstract

This paper deals with the complete technology of inorganic geopolymer binder system GEOPOL® which is a result of long term research and development. The objective of this paper is to provide a theoretical and practical overview of the GEOPOL® binder system and introduce possible ways of moulds and cores production in foundries. GEOPOL® is a unique inorganic binder system, which is needed and welcomed in terms of the environment, the work environment, and the sustainable resources. The GEOPOL® technology is currently used in the foundries for three basic production processes/technologies: (1) for self-hardening moulding mixtures, (2) sand mixtures hardened by gaseous carbon dioxide and (3) the hot box technology with hot air hardening. The GEOPOL® technology not only solves the binder system and the ways of hardening, but also deals with the entire foundry production process. Low emissions produced during mixing of sand, moulding, handling, and pouring bring a relatively significant improvement of work conditions in foundries (no VOCs). A high percentage of the reclaim sand can be used again for the preparation of the moulding mixture.

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Authors and Affiliations

M. Vykoukal
A. Burian
M. Přerovská
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Abstract

The foundry industry is looking for solutions that improve the quality of the finished product and solutions that reduce the negative impact of the industry on the natural environment [26]. This process leads to work on the use of new or previously unused materials for binders. Organic and inorganic foundry binders are replaced by renewable materials of plant origin to meet the requirements of both the foundry customers and the environmental and health and safety regulations. The aim of this work was to identify the applicability of renewable and organic malted barley binder in moulding sand technology. The influence of the malt binder content on dry tensile strength, dry bending strength, dry permeability, dry wear resistance and flowability were evaluated. The results show that the malted barley binder can be self-contained material binding the high-silica sand grains. Selected mechanical properties of moulding sands were found to increase with an increase in binder content. It was observed that malted barley binder creates smooth bonding bridges between high-silica sand grains.
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Bibliography

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[7] Chowdhury, S.I. Rashid, H. & Mumtaz, G.R. (2016) Comparison and CFD verification of binder effects in sand mould casting of aluminum alloy. ANNALS of Faculty Engineering Hunedoara - International Journal of Engineering. 14(1), 143-146.
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[12] Stachowicz, M. Granat, K. & Nowak, D. (2012). Bending strength measurement as a method of binder quality assessment on the example of water-glass containing moulding sands. Archives of Foundry Engineering. 12(1), 175-178. (in Polish).
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Authors and Affiliations

B. Samociuk
1
ORCID: ORCID
B. Gal
1
D. Nowak
1
ORCID: ORCID

  1. Department of Foundry Engineering, Plastics and Automation, Wroclaw University of Technology, ul. Smoluchowskiego 25, 50-372 Wrocław, Poland
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Abstract

Binder jetting (BJ) sand printing is a 3D printing process in which a sand mould or sand core is produced from an STL file. A single layer of a sand matrix consisting of one or more grains in height of sand is applied to a worktable, and then a liquid resin or binder is applied to bond the grains together. This process is repeated until the final result matches the CAD model. The sand matrix is the main component of ceramic cores and moulds. The present study aims to demonstrate the influence of the matrix used on the properties of the resulting moulding sand. Three types of sand matrices were selected for the study. The first was a quartz matrix for 3D printing with binder jetting; this is characterised by a sharp geometry that allows for proper layering during printing. Ordinary quartz sand was also used for the study; this type of sand is usually used for the production of sand cores in the hotbox process, among other things. The shape of this sand is irregular. The last matrix to be tested was Cerabeads sand; this was selected because its spherical geometry clearly distinguishes it from the other two matrices. The matrices were analysed for their grain sizes. Scanning electron microscope images were also taken to compare the geometries and chemical compositions of the respective matrices. In presented research utilises a sand matrix for the production of self-curing compounds with furan resin dedicated for binder jetting 3D printing. The moulding masses were produced in a laboratory circulation mixer. The laboratory moulds were produced with wooden core boxes and pre-compacted by vibration. The samples from the matrix for the 3D printing were produced using the binder jetting method. The samples were produced to determine the flexural strength, tensile strength, gas permeability, hot distortion, and apparent density. It was not possible to carry out tests for the Cerabeads sand, as the obtained moulds were too brittle to perform adequate tests. Tests with the other matrices have shown that the shape and size of the matrix affect the apparent density and gas permeability.
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Bibliography

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[11] Dobosz, S.M., Grabarczyk, A., Major-Gabryś, K. & Jakubski, J. (2015). Influence of quartz sand quality on bending strength and thermal deformation of moulding sands with synthetic binders. Archives of Foundry Engineering. 15(2), 9-15. DOI:10.1515/afe-2015-0028.
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Authors and Affiliations

D.R. Gruszka
1
ORCID: ORCID
R. Dańko
1
ORCID: ORCID
M. Dereń
1
A. Wodzisz
1

  1. AGH University of Krakow, Faculty of Foundry Engineering, Poland
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Abstract

The publication presents a new shooting technique with reduced pressure in venting system for manufacturing foundry cores using inorganic sand mixture with Cordis binder. Traditional technologies for producing casting cores using blowing methods, despite their undeniable advantages, including the ability to produce cores in series, also come with some disadvantages. The primary drawbacks of the process involve uneven compaction structure of the cores, with denser areas primarily located under the blow holes, and under-shooting defects, which often occur in regions away from the blow hole or in increased core cross-sectional areas. In an effort to improve core quality, a concept was developed that involves incorporating a reduced pressure in the core box venting system to support the basic overpressure process. The solutions proposed in the publication with a vacuum method of filling the cavities of multi-chamber core boxes solve a number of technical problems occurring in conventional blowing technologies. It eliminates difficulties associated with evacuating the sand from the chamber to the shooting head and into technological cavity and increases the uniform distribution and initial degree of compacting of grains in the cavity. The additive role of this “underpressure” support is to enhance corebox venting by eliminating 'air cushions' in crevices and structural elements that obstruct the flow of evacuated air. The publication presents the results of studies on core manufacturing using blowing methods conducted in three variants: classic overpressure, utilizing the core box filling phenomenon by reducing pressure, and an integrated approach combining both these methods.
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Bibliography

[1] Dańko, J. (1992). Process of production of moulds and cores by mean of blowing methods. Theory and tests. Series Dissertations and Monography. AGH Publishing House. (in Polish).

[2] Dańko, R. (2019). Blowing Processes and Machines in Core making technologies for Foundrie. Katowice-Gliwice: Archives of Foundry Engineering. (in Polish).

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[4] Dańko, R., Dańko J. & Skrzyński, M. (2017). Assessment of the possibility of using reclaimed materials for making cores by the blowing method. Archives of Foundry Engineering. 17(1), 21-26. 10.1515/afe-2017-0004.

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[7] Fedoryszyn, A. Dańko, J., Dańko, R., Asłanowicz, M., Fulko, T. & Ościłowski. A. (2013). Characteristic of Core Manufacturing Process with Use of Sand, Bonded by Ecological Friendly Nonorganic Binders. Archives of Foundry Engineering. 13(3), 19-24. DOI: 10.2478/afe-2013-0052.

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[9] Budavári, I., Hudák, H., Fegyverneki, G. (2023). The role of acid hardener on the hardening characteristics, collapsibility performance, and benchlife of the warm-box sand cores. Archives of Foundry Engineering. 23(1), 68-74. DOI: 10.24425/afe.2023.144282.

[10] Czerwinski, F., Mir, M. & Kasprzak, W. (2015). Application of cores and binders in metal casting. International Journal of Cast Metal Research. 28(3), 129-139. https://doi.org/10.1179/1743133614Y.0000000140.

[11] Sivarupan, T., Balasubramani, N., Saxena, P., Nagarajan, D., El Mansori, M., Salonitis, K., Jolly, M. & Dargusch, M.S. (2021). A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting. Additive Manufacturing. 40, 101889, 1-17. https://doi.org/10.1016/j.addma.2021.101889

[12] Cheng, Y., Li, Y., Yang, Y,Tang, K., Jhuang, F., Li, K. & Lu. C. (2022). Greyscale printing and characterization of the binder migration pattern during 3D sand mold printing. Additive Manufacturing. 56, 102929, 1-13. https://doi.org/10.1016/j.addma.2022.102929.

[13] Liu, H., Lei, T. & Peng, F. (2023). Compensated printing and characterization of the droplet on the binder migration pattern during casting sand mold 3D printing. Journal of Manufacturing Processes. 108, 114-125. https://doi.org/10.1016/j.jmapro.2023.10.073.

[14] HA Group (2024). Additive Manufacturing. Retrieved February 20, 2024, from https://www.ha-group.com/pl/en/products-and-services/products/additive-manufacturing/

[15] Dajczer, G. (2024). Integrated process of making casting cores by blowing method using reduced pressure of venting the core box. PhD dissertation. AGH Krakow.

[16] Dańko, R., Dańko, J. (2023). Processes and mechanized systems for manufacturing casting core. In Chapter IV of Foundry's Guide, volume 2. Polish Kraków: Foundrymen’s Association.
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Authors and Affiliations

M. Skrzyński
1
R. Dańko
1
ORCID: ORCID
G. Dajczer
2

  1. AGH University of Krakow, Poland
  2. KPR PRODLEW-KRAKÓW Spółka z o.o., Alfreda Dauna 78, 30-629 Krakow, Poland

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