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The article presents the results of gas emissions generated during heating of mineral additives – aluminosilicates (perlite ore and vermiculite). The test on a laboratory stand for a 1 g sample at 1 000 °C was carried out. It has been shown, that there is a correlation between the degree of fragmentation and the amount of gas generated. The finest fraction of perlite ore caused a similar quantitative gas emission as ground vermiculite. The presence of additives in molding sands, regardless of the size of fraction, should not affect the formation of casting defects. The addition of perlite ore and vermiculite does not effect the ecological properties of moulding sand.

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 CO 2 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.

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 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.

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., (Copyright © 2018 Elsevier B.V. All rights reserved.)

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)., (Copyright © 2018 Elsevier B.V. All rights reserved.)