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The paper presents the results of the research on the impact of process parameters of high-pressure, cold-chamber die casting of an industrial casting made of aluminium alloy on the casting properties assessed macroscopically by measuring the casting average density and microscopically through the characteristics of the casting microstructure. The analysis covers the influence of three selected velocity settings of the pressing plunger, which determine the filling time, and three values of the compression pressure setting characteristic of the third phase of the casting process. The cooling and solidification simulations of the casting were performed using the ProCAST software. During the simulation tests, the impact of the filling rate of the alloy into the die cavity on the cooling rate and the alloy solidification path at selected points were determined. The conducted research allowed linking the process parameters with the parameters of the casting structure with different wall thicknesses. Metallographic examinations of the castings were carried out using a light microscopy, SEM, and EDS analysis. The fraction of the phases α(Al), the size of dendritic cells, and the size of silicon particles, in the cross-sections of the castings with wall thickness of 3, 6, and 11 mm, respectively, were determined.

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 process of metal casting indisposable sand molds is associated with the generation of large amounts of waste, mainly used molding and core sands, from which the molds and cores reproducing the external and internal shapes of the castings were made. It is estimated that about 600 kg of waste can come from the production of 1 ton of casting. The main component of the waste is quartz matrix, which after undergoing appropriate reclamation treatments can be recovered and reused in the production process. This article presents the theoretical foundations regarding the existing methods of quartz matrix recovery and an experimentally justified model of the regeneration process occurring in one of the varieties used in the practice of mechanical regenerators. The goal is to improve the quality of regenerated molding sand by means of liberating the sand grain&rsquo, s surface from the layer of the used binding component. The elastic-plastic material model characterized by the Drucker&ndash, Prager yield criterion was used to describe the deformation of the sand layer during treatment performed in a centrifugal regenerator. Conclusions based on the results of numerical calculations, obtained with the use of the software adopting the material point method, enable us to find out how to control the device in a way that ensures a permanent reclamation effect which is independent of the working components that wear out over time.

The paper presents the results of the experimental and numerical analysis of material destruction of honeycomb cellular structure. Based on the experimental research, the results of numerical calculations regarding the compression process were verified along with the correctness of used constitutive numerical model. The destruction was analyzed for the casting with no structural defects and for the casting with detected porosities. The results were compared to the structural strength of the honeycomb structure manufactured on the CNC machine. The metallic honeycomb structure was manufactured as a casting of Al alloy in the investment casting technology. For manufacturing purposes the honeycomb model was obtained in additive manufacturing process. The castings and the CNC honeycomb were used in the compression test trials. The process was controlled by the displacement and the results were registered as the changes of the height and the force value. Based on the experimental results the numerical model of honeycombs was introduced for the numerical analysis of the energy absorption and compression process. The results showed good correlation between the experiment and FEM (Finite Element Method) analysis.

The results of investigations of the influence of the matrix grain sizes on properties of cores made by the blowing method are presented in the hereby paper. Five kinds of matrices, differing in grain size compositions, determined by the laser diffraction method in the Analysette 22NanoTec device, were applied in investigations. Individual kinds of matrices were used for making core sands in the Cordis technology. From these sands the shaped elements, for determining the apparent density of compacted sands and their bending strength, were made by the blowing method. The shaped elements (cores) were made at shooting pressures being 3, 4 and 5 atn. The bending strength of samples were determined directly after their preparation and after the storing time of 1 hour.

The cumulative results of investigations of the possibility of using the reclaimed materials after the mechanical, thermal or mechanical-thermal reclamation for making cores by means of the blowing method in the alkaline CO2 technology, are presented in the paper. Three kinds of spent sands: with furfuryl resin, bentonite and alkaline phenolic resin, obtained from the foundry, were subjected to three kinds of reclamation: mechanical, thermal and combined mechanical-thermal, applying for this aim adequate experimental devices. The obtained reclaims were assessed with regard to the degree of the matrix liberation from the determined binding material. Reclaims of moulding sands with binders of the form of resin were assessed with regard to ignition loss values and pH reaction, while reclaims of moulding sands with bentonite with regard to the residual clay content and pH value. In all cases the results of the performed sieve analyses were estimated and the average characteristic diameter dl was determined. The reclaimed matrix was applied as a full substitute of the fresh high-silica sand in typical procedures of preparing core sands used for making shaped samples for bending strength investigations, Rgu.

Out of moulding sands used in the foundry industry, sands with organic binders deserve a special attention. These binders are based on synthetic resins, which ensure obtaining the proper technological properties and sound castings, however, they negatively influence the environment. These resins in their initial state these resins are not very dangerous for people and for the environment, thus under an influence of high temperatures they generate very harmful products, being the result of their thermal decomposition. Depending on the kind of the applied resin, under an influence of a temperature such compounds as: furfuryl alcohol, formaldehyde, phenol, BTEX group (benzene, toluene, ethylbenzene, xylene), and also polycyclic aromatic hydrocarbons (PAHs) can be formed and released. The aim of the study was the development of the method, selection of analytical methods and the determination of optimal conditions of formation compounds from the BTEX and PAHs group. Investigations were carried out in the specially designed set up for the thermal decomposition of organic substances in a temperature range: 500 – 1 300°C at the laboratory scale. The object for testing was alkyd resin applied as a binding material for moulding sands. The qualitative and quantitative analyses of compounds were performed by means of the gas chromatography coupled with the mass spectrometry (GC/MS).

The aim of the hereby paper is to present the developed model of determining the volume and surface porosity based on the main fraction of polifractional materials, its experimental verification and utilisation for the interpretation of effects accompanying the formation of a moulding sand apparent density, porosity and permeability in the blowing processes of the core and moulds technology.

This article addresses the effects of six mold materials used for obtaining thin-walled compacted graphite iron castings with a wall thickness of 3 mm. During this research, the following materials were analyzed: fine silica sand, coarse silica sand, cerabeads, molohite and also insulated materials in the shape of microspheres, including low-density alumina/silica ceramic sand. Granulometric and SEM observations indicate that the sand matrix used in these studies differs in terms of size, homogeneity and shape. This study shows that molds made with insulating sands (microspheres) possess both: thermal conductivity and material mold ability to absorb heat, on average to be more than five times lower compared to those of silica sand. In addition to that, the resultant peak of heat transfer coefficient at the mold/metal interface for microspheres is more than four times lower in comparison with fine silica sand. This is accompanied by a significant decrease in the cooling rate of metal in the mold cavity which promotes the development of compacted graphite in thin-walled castings as well as ferrite fractions in their microstructure.

The investigation results of the reclamation of spent moulding sands with furfuryl resin are presented in this paper. The reclamation process was performed in the secondary reclamation chamber of the REGMAS 1.5 vibratory reclaimer. 70 kg portions of moulding sands, previously subjected to the primary reclamation and dedusting, were used. The secondary reclamation was performed in two stages: the first consisted of determining the reclaimer intensity at various reclamation times (5 min, 10 min and 15 min) and various electrovibrator frequencies (40 Hz, 50 Hz and 60 Hz), the second consisted of determining the influence of additional crushing elements on the intensity of processes.

The furan resin offers advantages such as high intensity, low viscosity, good humidity resistance and is suitable for cast different casting alloys: steel, cast iron and non-ferrous metal casting. For hardening furan resins are used different hardeners (acid catalysts). The acid catalysts have significant effects on the properties of the cured binder (e,g. binding strength and thermal stability) [1 - 3]. Investigations of the gases emission in the test foundry plant were performed according to the original method developed in the Faculty of Foundry Engineering, AGH UST. The analysis is carried out by the gas chromatography method with the application of the flame-ionising detector (FID) (TRACE GC Ultra THERMO SCIENTIFIC).

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 &deg, C were measured (according to the authors&rsquo, 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.

The influence of the use of moulding sand with furan resin, prepared both with fresh sand and reclaimed matrix, on the formation of a flake graphite formation at the surface layer of ductile iron castings has been investigated. A series of experimental heats of ductile iron cast in moulds made of moulding sand characterised by different levels of surface active elements (sulphur, oxygen) were performed. The effect of the wall thickness and the initial temperature of the metal in the mould cavity on the formation of flake graphite in the surface layer of the casting is shown in the paper. Investigations carried out by means of scanning electron microscopy (energy dispersive X-ray spectroscopy and wavelength dispersive X-ray spectroscopy) showed concentration of gradient profiles of surface active elements in the castings surface layer, which are responsible for their quality. Finally, it has been shown that there exists a significant effect of the quality of the sand on the formation of the flake graphite ...

Experiments of filling the model moulds cavity of various inner shapes inserted in rectangular cavity of the casting die (dimensions: 280 mm (height) × 190 mm (width) × 10 mm (depth) by applying model liquids of various density and viscosity are presented in the paper. Influence of die venting as well as inlet system area and inlet velocity on the volumetric rate of filling of the model liquid - achieved by means of filming the process in the system of a cold-chamber casting die was tested. Experiments compared with the results of simulation performed by means of the calculation module Novacast (Novaflow&Solid) for the selected various casting conditions - are also presented in the paper.

The problem related to the management of post reclamation dusts generated in the reclamation process of waste moulding sands with organic binders is presented in the hereby paper. Waste materials generated in this process are products hazardous for the environment and should be utilised. The prototype stand for the utilisation of this dangerous material in its co-burning with coal was developed and patented in AGH in Krakow. The stand was installed in one of the domestic casting houses. As the utilisation result the transformed waste product is obtained and its management in the production of ceramic materials constitutes the subject of the presented publication.

The paper, especially dealt with problems of reclamation of used furan sand, carried out in new, vibratory sand reclamation unit REGMAS developed by researches from AGH-University of Science and Technology, Faculty of Foundry Engineering in Cracow (Poland). Functional characteristics of reclamation unit as well as the results of reclamation of used sand with furfuryl resin are discussed in the paper. The quality of reclaim was tested by means of the LOI and pH value, dust content in the reclaim and at least by the the quality of the castings produced in moulds prepared with the use of reclaimed matrix.

Larger and larger proportions of aluminium castings, especially those produced by the die casting process, can be observed during recent years in the automotive industry, house-hold articles and others. In case of the automotive industry, apart from the traditional elements produced by the die pressure method such as engine blocks or crank shaft bedplates, aluminium is displacing steel from structural parts of cars (‘body in white’). The current state and development directions of the structural solutions of cold-chamber die castings are analysed in this paper. These solutions drive the prospective development of these machines and die casting technology. The focus is mainly on essential functional systems such as: hydraulic drives of closing and locking units, as well as pressing in die machines of known companies present on the European market.

The harmfulness assessment of moulding sands with a geopolymer binder and a new hardener, in an aspect of the emission of substances from the BTEX group, was performed. Within the expedience project the new series of hardeners for the inorganic GEOPOL binder was developed. Before the introduction of the new system of moulding sands it was necessary to estimate their influence on the environment. To this aim the gasses emission from moulding sands subjected to the influence of liquid cast iron was tested with regard to the content of the gases from the BTEX group (benzene, toluene, ethylbenzene and xylenes). For the comparison the analogous investigations of the up to now applied moulding sands with the geopolymer binder, were performed. It was found that both systems of moulding sands binding emit similar amounts of gases, as well as similar amounts of substances from the BTEX group. Moulding sands with the GEOPOL binder are much more environmentally friendly than moulding sands with organic binders. The content of the BTEX group substances in gases emitted from moulding sands with the GEOPOL binder was approximately 10-times lower than in case of the moulding sands with organic binders.

The after reclamation dusts originated from various foundry plants, applying moulding sands with organic binding agents, mostly resins, are characterised by different properties in dependence of the used binders, reclamation systems, spent sands overheating degree and the efficiency of the system dedusting the reclaimed material operating in individual foundry plants.In the article the results of investigations of physicochemical properties and thermal utilisation possibility referring to six kinds of after reclamation dusts generated in the mechanical reclamation process of spent moulding sands with furfuryl resins and six other kinds of after reclamation dusts obtained from reclamation process of spent moulding sands with alkaline resins have been presented. All tested dusts originated from various Polish foundry plants of cast iron and cast steel applying the mechanical reclamation process of moulding sands with resins, obtained from different producers.

The investigation results of the mechanical reclamation of spent moulding sands from the Cordis technology are presented in the paper. The quality assessment of the obtained reclaim and the influence of the reclaim fraction in a matrix on the core sand strength is given. The reclaim quality assessment was performed on the basis of the determination of losses on ignition, Na2O content on reclaim grains and pH values. The reclaim constituted 100%, 75% and 50% of the core sand matrix, for which the bending strength was determined. The matrix reclamation treatment was performed in the experimental rotor reclaimer RD-6. Spent sands were applied in as-delivered condition and after the heating to a temperature of 140 °C. Shaped samples for strength tests were made by shooting and hardening of sands in the warmbox technology.

The paper presents the idea of the integrated recycling system of used moulding sands with organic resins. A combination of the method of forecasting averaged ignition loss values of moulding sands after casting and defining the range of necessary matrix reclamation treatments in order to obtain its full recycling constitutes the basics of this process. The results of own investigations, allowing to combine ignition loss values of spent moulding sands after casting knocking out with amounts of dusts generated during the mechanical reclamation treatment of such sands, were utilized in the system.

The effects of filling the core box cavity and sand compaction in processes of core production by blowing methods (blowing, shooting) depend on several main factors. The most important are: geometrical parameters of cavity and complexity of its shape, number, distribution and shape of blowing holes feeding sands as well as the venting of a technological cavity. Values of individual parameters are selected according to various criteria, but mostly they should be adjusted to properties of the applied core sand. Various methods developed by several researchers, including the authors own attempts, allow to assess core sands properties on the basis of special technological tests projecting the process into a laboratory scale. The developed criteria defining a degree or a filling ability factor provide a better possibility of assessing the core sand behavior during flowing and core box filling, which indicate the value and structure of the obtained compacting decisive - after hardening - for strength and permeability. The mentioned above aspects are analyzed - on the basis of authors’ own examinations - in the hereby paper.

Mechanical reclamation processes of spent moulding sands generate large amounts of post-reclamation dusts mainly containing rubbed spent binding agents and quartz dusts. The amount of post-reclamation dusts, depending in the reclamation system efficiency and the reclaim dedusting system, can reach 5%-10% in relation to the total reclaimed spent moulding sand. The proper utilization of such material is a big problem facing foundries these days. This study presents the results of investigations of physicochemical properties of post- reclamation dusts. All tested dusts originated from various Polish cast steel plants applying the mechanical reclamation process of moulding sands with alkaline resins, obtained from different producers. Different dusts, delivered from foundries, were tested to determine their chemical composition, granular characterization, physicochemical and energetic properties. Presented results confirmed assumptions that it is possible to utilize dusts generated during mechanical reclamation of used sands with organic resins as a source of energy.

Castings constitute important installation elements in the traditional coal, gaseous or nuclear power plants. Cast elements are also used in installations of the so-called renewable energy. Utilising nanoparticles in the foundry industry leads to improvements in the quality of produced castings and thus to the cost production lowering. Better properties of moulds and cores were achieved as a result of utilisation of nanoparticles in sand technologies. Works carried out in the Faculty of Foundry Engineering, AGH-UST, concerned the water-glass binder modification by nanoparticles of metal oxides (zinc oxide and magnesium oxide) in alcoholic solvents (methanol, ethanol and propanol). Nanoparticles were synthesised in the electrochemical process by anodic dissolution of metals as well as by the thermal method. The nanoparticles of zinc oxide obtained in the electrochemical process are of the structure of equiaxial agglomerates of various sizes depending on the applied alcohol. The largest nanoparticles were obtained from the methyl alcohol solution (~50 nm), while the smallest (≤20 nm) from the propyl alcohol solution. The highest tensile strength (above 25% larger than the strength of the moulding sand with no modified water-glass) was obtained by the moulding sand in which water-glass was the binder modified by the colloidal solution of zinc oxide nanoparticles in propyl alcohol.

The paper presents the results of investigations of the influence of the quality of moulding sand with furfuryl resin hardened by paratoluenosulphonic acid, on the formation of microstructure and surface quality of ductile iron castings. Within the studies different moulding sands were used: moulding sand prepared with fresh sand and moulding sands prepared with reclaimed sands of a different purification degree, determined by the ignition loss value. Various concentrations of sulphur and nitrogen in the sand moulds as a function of the ignition loss were shown in the paper as well as the gas emission and gas evaporation rate from the moulding sands. A series of experimental melts of ductile iron in moulds made of moulding sand characterized by different levels of surface-active elements (e.g. sulphur) and different gas evolution rates were performed. It was shown that there exist a significant effect of the quality of the sand on the formation of the graphite degeneration layer.

Out of moulding and core sands used in the foundry industry, sands with organic binders deserve a special attention. These binders are based on synthetic resins, which ensure obtaining the proper technological properties and sound castings, however, they negatively influence the environment. Depending on the kind of the applied resin under an influence of a temperature such compounds as for example BTEX group and polycyclic aromatic hydrocarbons (PAHs) can be formed and released. During storing or economic utilization of used sand is possibility of eluting harmful substances into the environment. Therefore at assessing an influence of the used sand on the environment two above elements should be taken into consideration. Only such investigations provide the complete assessment of the given sand harmfulness.

The results of investigations of the reclamation of spent moulding and core sands, originated from one of the Polish foundry plants, are presented in the paper. Four mixtures consisting of two types of spent sands (spent moulding sand and spent core sand) were subjected to the regeneration process. Each tested mixture consisted of an inorganic type spent moulding sand and of an organic type spent core sand. Proportions of mutual fractions of spent moulding and core sands in mixtures was 70%-30% and was representative for the waste sands from the foundry, from which these sands originated.

The idea and experimental verification of assumptions of the integrated recycling process of matrices of uniform self-hardening moulding sands with synthetic resins, leading to obtaining moulding sands matrix of expected quality - is presented in the hereby paper. The basis of the presented process constitutes a combination of the method of forecasting averaged ignition losses of moulding sands after casting and defining the range of necessary matrix reclamation treatments in order to obtain its full recycling. Simultaneously, the empirically determined dependence of dusts amounts emitted during the reclamation process of the matrix from the given spent sand on the ignition loss values (which is the most proper assessment index of the obtained reclaimed material quality) was taken into account. The special experimental stand for investigations of the matrix recycling process was one of the elements of the conceptual approach and verification of its assumptions. The stand was equipped with the system of current on-line control of the purification degree of matrix grains from organic binder remains. The results of own investigations, allowing to combine ignition loss values of spent moulding sands after casting knocking out with amounts of dusts generated during the mechanical reclamation treatment of such sands, were utilized in the system.

Mechanization of the process of core making with the use of inorganic and organic binders is based, almost solely, on core blowing machines. Presently the core blowing machines are equipped with tools and devices that allow for application of different technologies of core making. Cold-box, hot-box and warm-air technologies require that core blowing machines shall be additionally equipped with either core-box pre-heating system or gas purging and neutralization system, or hot air purging systems. Considering the possibility of using varied, the most advantageous technologies of core making, the production of universal core blowing machines equipped with replaceable devices has been undertaken in Poland. The universal core blowing systems allow for mechanization of core making process also with the use of sand, bonded by modern, eco-friendly binder systems. The paper presents selected results-based evaluation of core blowing process showing the scope of conducted design and implementation works.

nvestigations of filling the model mould cavity (with perpendicular walls) of the casting die by model liquids of various density and viscosity are presented in the paper. Influence of localisation of the inlet system and inlet velocity on the flow character of model liquids of different viscosity in the system of a cold-chamber casting die was tested. Calculations performed by means of the calculation module NOVACAST (NOVAFLOW&SOLID) for the selected models of cavities cast by the pressure method are also presented in the paper.

The study investigates the key aspects involved in the flow of the air-sand stream from the machine chamber and in the core box filling in the core shooting and core blowing processes. The prevailing tendency to manufacture thin-walled castings with intricate channel structures has become the major determinant of castings quality and production rates. An important parameter of most core sand used in the shooting processes is the ability to eject from the machine chamber and the core-box filling capability. These properties are the key factors determining the feasibility of manufacturing intricate cores and the process efficiency. The research work outlined in this study focuses on establishing the performance criteria of core sand ejection from the machine chamber and of core box filling and sand compaction. The results given below were obtained for several new-generation core sand types, containing organic and inorganic binders, and designed to be used in hot-box, warm box and warm air processes.

The paper presents the results of investigations of the influence of the quality of molding sand with furan resin hardened by paratoluenesulfonic acid, on the formation of microstructure and surface quality of ductile iron castings. Within the studies different molding sands were used: molding sand prepared with fresh sand and molding sands prepared with reclaimed sands of a different purification degree, determined by the ignition loss value. Various concentrations of sulfur and nitrogen in the sand molds as a function of the ignition loss were shown in the paper. A series of experimental melts of ductile iron in molds made of molding sand characterized by different levels of surface-active elements (e.g., sulfur) and different gas evolution rates were performed. It was shown that there exists a significant effect of the quality of the sand on the formation of the graphite degeneration layer.

Due to the presence of harmful substances in resins those mould sands may be hazardous to the natural environment and workers. The general assessment of harmfulness of sands used for molds and cores encompasses 2 basic points: emission of hazardous substances during processes of preparing sands, pouring mold with liquid metals (high temperatures), cooling and shaking-out; possibility of washing out hazardous substances from used sands to the environment, during storage or economic use outside foundries. We present the results of research on the emission of BTEX compounds from mould sands with phenolic resins during pouring liquid metal of different temperature (cast iron and Al alloy). The research was conducted according to the original method prepared by the authors, which has been used for years in cooperation with various foundries (Poland, abroad).

A proper management of sand grains of moulding sands requires knowing basic properties of the spent matrix after casting knocking out. This information is essential from the point of view of the proper performing the matrix recycling process and preparing moulding sands with reclaimed materials. The most important parameter informing on the matrix quality - in case of moulding sands with organic binders after casting knocking out - is their ignition loss. The methodology of estimating ignition loss of spent moulding sands with organic binder - after casting knocking out - developed in AGH, is presented in the paper. This method applies the simulation MAGMA software, allowing to determine this moulding sand parameter already at the stage of the production preparation.

A determination of the heating degree of the moulding sand with bentonite on the grounds of simulating investigations with the application of the MAGMA program, constitutes the contents of the paper. To this end the numerical simulation of the temperature distribution in the virtual casting mould was performed. It was assumed that the mould cavity was filled with a moulding sand with bentonite of a moisture content 3,2 % and bentonite content 8 %. A computer simulation can be used for predicting the heating degree of moulding sands with bentonite. Thus, prediction of the active bentonite (montmorillonite) content in individual layers of the overheated moulding sand can be done by means of the simulation. An overheating degree of a moulding sand with bentonite, and thus the bentonite deactivation depends on a temperature of a casting alloy, casting mass, ratio of: mass : masscasting, moulding sand amount in the mould and contact area: metal - mould (geometry of the casting shape). Generally it can be stated, that the bentonite deactivation degree depends on two main factors: temperature of moulding sand heating and time of its operation.

Theoretical problems concerning the determination of work parameters of the two-phase sand-air stream in the cores making process by blowing methods as well as experimental methods of determination of the main and auxiliary parameters of this process decisive on the cores quality assessed by the value and distribution of their apparent density are presented in the paper. In addition the results of visualisations of the core-box filling with the sand-air stream, from the blowing chamber, obtained by the process filming by means of the quick-action camera are presented in the paper and compared with the results of simulation calculations with the application of the ProCast software.

Modern investigation methods and equipment for the quality estimation of the moulding sands matrices with organic binders, in their circulation process, are presented in the paper. These methods, utilising the special equipment combined with the authors investigation methods developed in the Faculty of Foundry Engineering, AGH the University of Science and Technology, allow for the better estimation of the matrix quality. Moulding sands systems with organic binders require an in-depth approach to factors deciding on the matrix technological suitability as well as on their environmental impact. Into modern methods allowing for the better assessment of the matrix quality belongs the grain size analysis of the reclaimed material performed by means of the laser diffraction and also the estimation of the moulding sand gas evolution rate and identification of the emitted gases and their BTEX group gases content, since they are specially hazardous from the point of view of the Occupational Safety and Health.

Suitability of the given binding agent for the moulding sands preparation depends on the one hand on the estimation of technological properties of the sand and the mould made of it and the obtained casting quality and on the other hand on the assessment of this sand influence on the natural and working environment. Out of moulding sands used in the foundry industry, sands with organic binders deserve a special attention. These binders are based on synthetic resins, which ensure obtaining the proper technological properties and sound castings, however, they negatively influence the environment. If in the initial state these resins are not very dangerous for people and for the environment, thus under an influence of high temperatures they generate very harmful products, being the result of their thermal decomposition. Depending on the kind of the applied resin (phenol-formaldehyde, urea, furfuryl, urea-furfuryl, alkyd) under an influence of a temperature such compounds as: furfuryl alcohol, formaldehyde, phenol, BTEX group (benzene, toluene, ethylbenzene, xylene), and also polycyclic aromatic hydrocarbons (PAH) can be formed and released. The aim of the study was the development of the method, selection of analytical methods and the determination of optimal conditions of formation compounds from the BTEX group. An emission of these components constitutes one of the basic criteria of the harmfulness assessment of binders applied for moulding and core sands. Investigations were carried out in the specially designed set up for the thermal decomposition of organic substances in a temperature range: 5000C - 13000C at the laboratory scale. The object for testing was alkyd resin applied as a binding material for moulding sands. Within investigations the minimal amount of adsorbent necessary for the adsorption of compounds released during the decomposition of the resin sample of a mass app. 15 mg was selected. Also the minimal amount of solvent needed for the desorption of compounds adsorbed in the column with adsorbent was found. The temperature range, in which the maximal amounts of benzene, toluene, ethylobenzene and xylenes are released from the resin, was defined. The qualitative and quantitative analyses of compounds from the BTEX group were performed by means of the gas chromatography combined with the mass spectrometry (GC/MS).

The casting production is considered as one of the main factors influencing the development of world economy. The state of art and foresight of world’s casting production is discussed in the paper on the basis of the latest statistical data. The progress gained during the last few years in foundry engineering is shown as a way to further development of foundry technology. The last decade brought significant changes in the world map of the greatest casting producers. Globalization and transformation of economic systems is reflected by variations of foundry production in different countries, more over the globalization of economy is regarded not only as a chance but also as a menace for the European foundries.

A review of the studies carried out on this subject so far was made, and the available mathematical models applicable at Phase I of the diecasing process were presented. Own model testing of the examined process phase was described. The tests were conducted on a laboratory station designed and constructed to serve this purpose. Basing on the obtained results, the fundamental Garber's model was modified and extended further to include the coefficient of liquid metal viscosity.

A study is reported in which cryogenic temperatures are applied to intensify the mechanical reclamation of used foundry sand in experimental equipment that reproduces the abrasion, rubbing and crushing found in industrial processing. Results for used silica sands with bentonite and silicate (water-glass plus ethylene glycol) binders carried out at approximately –70°C and ambient temperature are presented. The reclaimed material was characterised by pH value, ADV (acid demand value) and Na2O content, which usefully define ease of reclamation, bending sand strength and compressive sand strength. Mechanical–cryogenic reclamation clearly improved the output for both sand types, utilising the hygroscopic behaviour of moulding sands to intensify the release of sand from the binder. The presence of a 'freezing' agent changes the volume of both binder and sand grains, leading to increased stresses on the surface and inside the grains, combined with higher brittleness of the binder material. Compared with ...

A systematic approach to analyse the reclamation of used foundry sands is proposed. The development of an energetic model for dry mechanical reclamation of used foundry sands is described. The theoretical basis of the model is the Rittinger hypothesis for crushing minerals, which balances the energy input for reclamation against the energy consumed in creating additional surface area as the average size of the used sand agglomerates is reduced. The Rittinger number is known for pure silica, which has properties close to those of quartz sand grains. It is shown that information from routine grain size analysis, performed by sieving during reclamation, can be used to calculate the Rittinger number for binder materials, assisting in optimisation of the dry reclamation process. Processing at cryogenic temperatures (−80°C) increases dry reclamation efficiency and produces reclaimed sands with better technological parameters, but must be closely controlled to prevent excessive dusting.

Metalcasting involves having a molten metal poured in a hollow mould to produce metal objects. These moulds are generally made of sand and are chemically bonded, clay-bonded, or even unbounded. There are many binder systems used. Binders based on furfuryl resins constitute currently the highest fraction in the binders no-bake group. Moulding sand, after knocking out the cast, is partially reclaimed, and the remaining part, known as waste foundry sand is used or stored outside the foundry. In this case, the environment hazardous organic compounds and metals can be leached from the moulding sand, thus causing pollution of water and soil. Also during the casting moulds with molten metal, they emit pyrolysis gases containing many different compounds, often dangerous from the BTEX and PAH group, which has adverse impacts on the environment and workers. The article presents the results of research on the impact of the regenerate addition to the moulding sand matrix on emitted gases and the degree of threat to the environment due to leaching of hazardous components. Therefore, for the total assessment of the moulding sands harmfulness, it is necessary to perform investigations concerning the dangerous substances elution into the environment during their management and storage, as well as investigations concerning emissions of hazardous substances (especially from the BTEX and PAHs group) during moulds pouring, cooling, and casting knocking out. Both kinds of investigations indicated that reclaimed sand additions to moulding sands have significantly negative influence on the environment and working conditions.

This chapter presents the issue related to the morphology of graphite, namely, flake/compacted/spheroidal graphite that is the main controlling factor of the mechanical and physical properties of cast irons. It is presented that flake graphite in the surface layer can be regarded as a local source of stress concentration and thus the crack growth resistance of the cast iron with flake graphite is extremely poor. It has also been shown that the presence of flake graphite in the surface layer has a significant influence on the mechanical properties of spheroidal graphite cast iron (SGI) and compacted graphite cast iron (CGI), including firstly its plasticity, which decreases with the increasing thickness of the flake graphite layer. Moreover it was shown that the presence of flake graphite makes the surface layer brittle, non-plastic, which results in forming cracks. No flake graphite in the surface layer causes the specimen to deform uniformly, providing the most favorable combination of mechanical properties. Finally, the results of SGI iron corrosion resistance, performed in 0.1 M sodium chloride solution, are shown. It has been indicated that the presence of a thick layer of flake graphite in the surface layer of the castings significantly increases the cathode current, which stimulates the cathodic reaction and oxygen reduction.

This chapter on methods for assessing the quality of the matrix and molding sand presents the most important properties of these materials, from the point of view of the feasibility of using these molding sands for producing sound castings. In the case of matrix testing (both fresh and reclaimed), attention was drawn to the size and shape of the grain, which have a decisive influence on the permeability of the molding sand, on the content and the activity of the binder for the matrix used for the preparation of green sand, loss on ignition and the chemical nature of the matrix evaluated on the basis of the parameters such as ADV and pH. The next section presents complementary research methods of molding sand properties with reclaimed sand. Modern systems require evaluation and a careful approach to the factors that determine molding sand suitability for both technological use as well as the impact on the surrounding environment. In this context, a full evaluation of the quality of the reclaimed matrix goes beyond the usual instrumental methods and requires the addition of advanced apparatus research methods. This allows one to put the evaluation of the reclaimed matrix into perspective, both in terms of its use for the preparation of molding sand, as a substitute for fresh sand, and also in terms of environmental protection. Such modern methods may include, inter alia, an assessment of gas excretion in molding sand, identification of the type of emitted gases, the content of BTEX gases that are particularly dangerous to humans, and the evaluation of the surface of the casting made in molding sand with reclaimed sand.