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Many years of foundry practice and much more accurate analytical methods have shown that sands with organic binders, in addition to their many technological advantages, pose risks associated with the emission of many compounds, including harmful ones (e.g., formaldehyde, phenol, benzene, polycyclic aromatic hydrocarbons, and sulfur), arising during the pouring of liquid casting alloys into molds, their cooling, and knock-out. The aim of this research is to demonstrate the potential benefits of adopting inorganic binders in European iron foundries. This will improve the environmental and working conditions by introducing cleaner and more ecological production methods, while also ranking the tested binders studied in terms of their harmful content. The article pays special attention to the analysis of seven innovative inorganic binders and one organic binder, acting as a reference for emissions of gases from the BTEX (benzene, toluene, ethylbenzene, and xylenes) and PAHs (polycyclic aromatic hydrocarbons) groups and other compounds such as phenol, formaldehyde, and isocyanates (MDI and TDI) generated during the mold pouring process with liquid metals. The knowledge gained will, for the first time, enrich the database needed to update the Reference Document on The Best Available Techniques for the Smitheries and Foundries Industry (SF BREF).

This article presents the results of tests of molding and core sands with inorganic binders incorporating a mineral in the form of raw perlite ore. This material serves to reduce the final strength, thereby improving the knock-out properties. The assumption was made that the selection of the optimal fraction of the loosening additive, tailored to the grain size of the matrix of the molding sand used in foundries, could significantly affect its mechanical and technological parameters. The tests were conducted on molding sands prepared using three quartz sands with the addition of perlite ore of different grain sizes. In addition to determining the final tensile strength, the permeability and grindability of the molding sands were assessed. The results indicated that the raw perlite ore significantly reduced the final strength of the molding sands in each considered system, with the best efficiency achieved when using finer fractions. Moreover, the mineral’s addition had a minor impact on the technological properties of the molding sands, such as permeability and grindability.

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.

The foundry industry generates large amounts of waste when casting metal into sand moulds. An important issue is the activities that are related to the re-recovery of the grain matrix (the main component of the moulding sand) for realising subsequent technological cycles. This process is particularly important in the case of the expensive chromite matrix that is necessary for use in manganese steel casting. The effects of the reclamation treatments of spent alkali-phenolic binder sand were evaluated by scanning electron microscopy with EDS, analysing the chemical composition in micro areas and proving the loss of binder on the surfaces of the matrix grains. Tests were also performed using the main criteria for evaluating a reclaimed organic binder: sieve analysis and ignition loss. A thermogravimetric analysis study was performed to assess the change in the chromite character of the grain matrix under the influence of temperature. The effects of the reclamation measures were verified by making moulding compounds on a matrix of reclaimed sand and a mixture of reclaimed and fresh sand. The tests and analyses that were carried out indicated the direction of an effective method for reclaiming used alkali-phenolic binder masses and the extent of the proportion of the regenerate in moulding sand in order to maintain the relevant technological parameters of the moulding sand.

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.

The article presents the results of research on the properties of molding sands in Alphaset technology (alkaline-phenolic). These sands are often used in steel foundries, producing large castings. However, knowledge about them, and especially about the changeability of their properties with the change of environmental conditions (seasons), is still insufficient. Various compositions of molding sand were analyzed based on fresh chromite sand and reclaimed sand. A binder and hardener in various mass ratios were used to prepare the mass. The research methodology included, among others, tests of tensile and bending strength, permeability, abrasion, gas emissivity, and ignition losses. These tests were carried out for summer and winter conditions. The results showed the optimal proportions of resin and hardener, showed the influence of ambient temperature on the properties of the molding sand, and the possible ratio of reclaimed sand in relation to fresh sand. However, you should always remember to verify them under the conditions of a specific foundry.

The assessment of the harmfulness of moulding and core sands is mainly based on investigations of compositions of gases emitted by liquid casting alloys during the mould pouring. The results of investigations of moulding sands obtained under industrial conditions are presented in this paper. A unique research stand was designed and built for this aim. It allowed us to determine emissions of gases at individual stages of casting a mass up to 50 kg. This approach enables simulation of foundry conditions. Moulding sands bound by organic binders (phenol-formaldehyde; furan), inorganic binders and green sand, were subjected to investigations. The composition of gases that evolved during the individual stages, pouring, cooling and knocking out, was tested each time, and the contents of Polycyclic Aromatic Hydrocarbons (PAHs) and benzene, toluene, ethylbenzene, and xylenes (BETX) were analysed. Investigations indicated that the emission of gases from sands with inorganic binders is negligible when compared with the emission of gases from sands with organic binders. The emission of gases from green sand is placed in the middle of the scale. As an example: the sand with furan resin emitted 84 mg of BTEX (in recalculation for 1 kg of sand) while from sands with inorganic binders there was a maximum of 2.2 mg (for 1 kg of sand). In the case of sands with inorganic binders, MI and MC sands indicated comparable and very low emissions of gases from the PAHs group, at the level of 0.018 mg and 0.019 mg for 1 kg of sand, respectively. The higher emission of PAHs from MG sand is the result of its different way of hardening (a binder was of an organic character) than of sands MI and MC.

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.

Increasingly strict regulations, as well as an increased public awareness, are forcing industry, including the foundry industry, to develop new binders for molding sands, which, while being more environmentally friendly, would simultaneously ensure a high quality of castings. Until recently, binders based on synthetic resins were considered to be such binders. However, more accurate investigations indicated that such molding sands subjected to high temperatures of liquid metal generated several harmful, even dangerous substances (carcinogenic and/or mutagenic) from the benzene, toluene, ethylbenzene and xylenes (BTEX) and polycyclic aromatic hydrocarbons groups (PAHs). An assessment of the most widely used molding sands technologies at present with organic binders (synthetic resins) from the no-bake group (furan no-bake and phenolic-ester no-bake) and their harmfulness to the environment and work conditions is presented in this paper. In the first stage of this research, gases (from the BTEX and PAHs groups) emitted when the tested molds were poured with liquid cast iron at 1350 °C were measured (according to the authors’ own method). The second stage consisted of measuring the emission of gases released by binders subjected to pyrolysis (the so-called flash pyrolysis), which simulated the effects occurring on the boundary: liquid metal/molding sand. The gases emitted from the tested binders indicated that, in both cases, the emission of harmful and dangerous substances (e.g., benzene) occurs, but, of the given binder systems, this emission was lower for the phenolic-ester no-bake binder. The obtained emission factors of BTEX substances show higher values for furan resin compared to formaldehyde resin; for example, the concentration of benzene per 1 kg of binder for furan no-bake (FNB) was 40,158 mg, while, for phenol-formaldehyde no-bake (PFNB), it was much lower, 30,911 mg. Thus, this system was more environmentally friendly.

This article presents the results of experiments related to the process of replacement of the currently used furfuryl resin molding sand technology with a new alkali-phenolic technology. The new binder is characterized by a set of technological advantages and is considered more ecological compared to the furfuryl resin. However, the molding sand produced on the basis of the alkali-phenolic resin features lower strength compared to the sands containing furfuryl resin. This article presents a comparative study of sands made using various alkali-phenolic binders, aimed at the selection of a resin with strength parameters and other features that are both desirable and useful for new technology applied in a foundry.

This paper presents results of thermoanalytical and structural research on phenolic binder used in foundry for the preparation of moulding sand. The binder has been prepared based on resole type phenolic resin with the addition of ester hardener. The aim of the study was to determine the structural changes taking place in the phenolic binder under the influence of temperature. Results show that in the investigated range of temperatures,phenolic binder exhibits three exothermic thermal effects accompanying the decomposition process. The test results using the Diffuse Reflectance Infrared Fourier Transform Spectroscopy (DRIFTS) technique show that the addition of a hardener stabilizes the binder structure within methylene bridges. The reduction in the reaction rate observed in the DTA curve at about 330 癈 can be associated with the formation of gaseous products by decomposition of the binder or, as suggested by the literature data, the formation of triple bonds and CN-HCN groups.