The herein paper contains the results of investigations on a new type of cellulose blend used for the manufacture of profiles applied in the process of making gating systems in the foundry industry. A standard cellulose profile was subjected to an experiment. During the experiment the profile was filled with a liquid cast iron and at the same time the temperatures of the liquid metal crystallizing inside the profile were measured as well as the temperature of the outer layer of the profile was controlled. Further, the microstructure of the cast iron, which crystallized out inside the cellulose profile, was analysed and the cellulose, thermally degraded after the experiment, was verified with the use of the chemical analysis method. Moreover, a quality analysis of the original as well as the degraded cellulose profile was run with the use of the FTIR infrared spectroscopy. The presented results revealed that the cellulose blend is aluminium silicate enriched and contains organic binder additives. The cast iron, which crystallized out, tended to have an equilibrium pearlitic structure with the release of graphite and carbides. The generation of disequilibrium ausferrite phases was also observed in the structure.
Liquid metal when filling sand casting mould while pouring it out from ladle at the first moment comes across the sprue/gate system of the mould the purpose of which is to transfer liquid metal and feed the mould recess. The materials presently used for the elements of the sprue/gate systems are based on ceramics or the mixtures based on paper pulp. In this study the use of alternative mineral additions such as expanded perlite, expanded vermiculite, and microspheres as the fillers to paper pulp acquired from waste-paper for the use for the elements of mould sprue/gate systems or also other applications for the contact with liquid metal are presented. Experimental mould tube shapes made on the basis of the paper pulp based mixture patented by the authors were poured over with liquid metal. For the comparison, ceramic shapes and commercially available cellulose shapes were investigated in the same way. In order to compare the crystallization processes, a measurement of the cooling off liquid metal was carried out for all the analysed tube samples. From the so obtained metal samples metallographic microsections were made to compare cast iron microstructures. The results obtained from the investigations carried out have shown that the patented paper pulp based mixture may well be applied as an alternative material used for the elements of the sprue/gate systems for disposable sand moulds.
This paper presents the findings of a study of gas emissivity and the volumetric gas flow rate from a patented modified cellulose mix used in production of disposable sand casting moulds. The modified cellulose mix with such additives as expanded perlite, expanded vermiculite and microspheres was used as the study material. The results for gas emissivity and the gas flow rate for the modified cellulose mix were compared with the gas emissivity of the commercial material used in gating systems in disposable sand casting moulds. The results have shown that the modified cellulose mix is characterized by a lower gas emissivity by as much as 50% and lower gas flow rate per unit mass during the process of thermal degradation at the temperature of 900°C, compared to the commercial mix. It was also noted that the amount of microspheres considerably affected the amount of gas produced.
This article presents a gas evolution study of a novel, cellulose-based mixture with such mineral additives as expanded perlite, expanded vermiculite and microspheres. Inorganic alumina-silica binder was used to produce an uniform, bound mixture. The results have shown that the novel, cellulose-based mixture, obtained from waste paper, with mineral additives, emits smaller amounts of gas, while retaining the same thermal resistance.
This paper presents the application of mineral additives, such as expanded perlite, expanded vermiculite and microspheres in items used in founding. Mixed with paper pulp and aluminosilicate resin as a binder, these additives are the base of a mixture patented by the authors, which can be used in the production of pipe shapes and connectors with a circular cross-section in casting systems in the founding industry. These mixtures were subjected to TG thermal degradation during which a quantitative analysis of the emitted fumes was carried out. The analysis did not detect any other compounds than those formed by the combustion of cellulose materials, which indicated that no chemical reaction took place between the applied additives and cellulose at high temperatures.
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