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.