Dehydroxylation of Perlite and Vermiculite: Impact on Improving the Knock-Out Properties of Moulding and Core Sand with an Inorganic Binder

Abstract

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.

3D Printed (Binder Jetting) Furan Molding and Core Sands—Thermal Deformation, Mechanical and Technological Properties

“…Therefore, in recent years, much attention has been paid to inorganic molding and core sand systems [7][8][9][10][11][12]. Their significant advantage is their low emissivity, but they are not without disadvantages, including poor knockout properties [13,14], a limited reclamation ability, and unfavorable effects on bentonite (deactivation). Resin-coated sands are a widely used alternative that guarantees a very good surface with minimal defects in gray and ductile iron castings, according to [15][16][17].…”