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The problems of establishing a new foundry in Kazakhstan utilizing Lost-foam casting technology are discussed in this article. The study’s main objectives are to determine the technical and financial viability of arranging such production in the country. Calculations of the manufacturing program were carried out as part of the study, and a financial- economic model of the project was developed. The research shows that establishing such a foundry is feasible, and the project may be recommended for execution.

The problems of establishing a new foundry in Kazakhstan utilizing Lost-foam casting technology are discussed in this article. The study's main objectives are to determine the technical and financial viability of arranging such production in the country. Calculations of the manufacturing program were carried out as part of the study, and a financial-economic model of the project was developed. The research shows that establishing such a foundry is feasible, and the project may be recommended for execution. [ABSTRACT FROM AUTHOR]

Recycling has become a top priority research task in highly developed countries, addressed from the perspective of environmental protection as well as cost-effectiveness of products. In many countries, including Poland, landfilling is still commonly accepted as a method of choice for waste neutralisation. This paper presents results of studies on the environmental impact of iron-bearing foundry waste in the event of its landfill disposal.

Polysaccharides constitute a wide group of important polymers with many commercial applications, for example food packaging, fibres, coatings, adhesives etc. This review is devoted to the presentation of polysaccharide application in foundry industry. In this paper the selected properties of foundry moulding sand and core sand containing modified polysaccharides as binders are presented according to foreign literature data. Also, author’s own research about effect of using moulding sand binder consisting of modified polysaccharide (modified starch) or its composition with non-toxic synthetic polymers are discussed. Based on technologies taken under consideration in this paper, it could be concluded that polysaccharides are suitable as an alternative for use as binder in foundry moulding applications.

The industrial activity in non-ferrous alloys foundries leads to the elimination of the pollutants in the atmosphere that may have adverse effects on the environment and human health. This paper presents an evaluation of the pollutantemissions resulting from an aluminium foundry starting from data on concentrations and pollutant massflow rates estimated for each phase of the technological process and on measured ambient levels for the area of influence of the objective to study.

Although new moulding processes for manufacture of high quality castings have been developed and introduced into foundry practice in recent years, the green-sand moulding in bentonite mixture still remains the most widely used technology. Higher utility properties of bentonite binders are achieved through their activation. This contribution is aimed at finding a suitable activating agent. A number of sodium salts and MgO based agents has been chosen. In the framework of the experiment the swelling volume of chosen agents was tested and technological parameters of a bentonite mixture with a binder activated with the studied agents were determined.

The results of preliminary tests of selected properties of the moulding sands with the binder in the form of a 5 % water solution of the sodium salt of carboxymethyl starch (with a degree of substitution (DS) of 0,2 and 0,87) arepresented in this study. The moulding sand properties such as permeability, abrasion resistance, tensile and bendingstrength - after curing - are shown in series of tests. The cure process was conducted in a field of electromagnetic radiation within the microwave range. The effect of the microwave treatment on the moulding sand was evaporating of water (solvent in a binder) and cross-linking of the polymeric binder. As a result the cured moulding sands with particular properties, essential in the context of its application in the mould technology in the foundry industry, were obtained.

The application of thermogravimetric analysis can be very useful in the method since an extensive range of resins is used in founding. The thermal analysis performed for three different binders indicated the similar destruction mechanism.Along with the temperature increase the mass decrease of samples is related to the organic compounds decomposition and proceeds in a similar fashion regardless of the atmosphere in which the process occurs. However, for each of the tested binders,a certain critical temperature exists, above which - in the oxygen presence - the burning process of the majority of organic compounds forming the given substance occurs.

Currently offered devices for the hardness measuring or indices of the mould strength, are presented in the hereby paper. The presented results allow to compare approximately the indications of individual devices of different types.The description of the author’s own microprocessor tester for the quality assessment of the sand foundry moulds, is shown. On the bases of the measurements results it is possible, to evaluate indirectly, the mould apparent density in the selected points, as well as several other properties.

The behaviour of non-metallic particles in the selected composites was analysed, in the current study. The calculations of particles floating in liquids differing in viscosity were performed. Simulations based on the Stokes equation were made for spherical SiC particles and additionally the particle size influence on Reynolds number was analysed.The movement of the particles in the liquid metal matrix is strictly connected with the agglomerate formation problem.Some of collisions between non-metallic particles lead to a permanent connection between them. Creation of the two spherical particles and a metallic phase system generates the adhesion force. It was found that the adhesion force mainly depends on the surface tension of the liquid alloy and radius of non-metallic particles.

The paper determines the range and form of a surface layer of a spheroid cast iron founding. It presents proofs of the possibility to form an operative surface of a product in the range of an intermediate surface layer of the cast. Based on research and experience, one has stated that the hardness spread and structures in cross sections of the wall of a cast are the most representative parameters determining the range of the surface layer of the iron cast.

Investigation results of the drying rate of the selected protective coatings (water and alcohol) are presented in the article. Coating drying rate was determined for the first and second layers. The coating was applied to moulding sand cores. The rate of drying coatings were tested for three coating apparent viscosities estimated by means of the Ford 4 mm cup. Drying rates of the protective coating were examined by using the gravimetric technique and ultrasonic technique. Measurements were carried out in a continuous way under controlled conditions: constant ambient temperature and air humidity. Research shows that the drying time of the second coating layer is longer by 20 – 30 % than the first layer.

The paper presents the results of the research on the used moulding sands subjected to mechanical and thermal reclamation at different stages of the process in the foundry. The research on thermal treatment was carried out in an experimental thermal reclamation appliance. The effects of the process were evaluated with the use of a range of criteria, e.g. loss in roasting, sieve analysis, strength, the acidic reaction (pH). The performed investigations indicate that the thermal reclamation, of spent moulding sands knocked-out from the mould supplying reclaimed materials of the proper quality, can fully substitute the mechanical reclamation.

This article addresses the effect of mold filling and wall thickness on the flake graphite layer in ductile iron. The research was conducted for castings with different wall thickness (3-8 mm) and using molding sand with furan resin. A thermal analysis has been performed along the length of the castings to determine the initial temperature of the metal in the mold cavity and the contact time of the liquid metal with the mold. Results demonstrated the strong influence of the temperature decrease of the metal in the mold cavity on the occurrence and the thickness of the flake graphite in the surface layer in ductile iron.

Recycling has become a top priority research task in highly developed countries, addressed from the perspective of environmental protection as well as cost-effectiveness of products. In many countries, including Poland, landfilling is still commonly accepted as a method of choice for waste neutralisation. This paper presents results of studies on the environmental impact of iron-bearing foundry waste in the event of its landfill disposal. [ABSTRACT FROM AUTHOR]

Some of the foundries are in need of meeting production targets and due to the urgency they ignore the rejections. The objective of this paper is to analyze the various defects, [1] from molding process in a cast iron foundry. The Failure Mode Effects Analysis (FMEA) in quality control [2-6] with suitable supply chain for mold making process considering rejection rates are identified and analyzed in terms of Risk Priority Number (RPN) to prioritize the attention for each of the problem. The optimum levels of selected parameters [7] are obtained in this analysis.

The management systems in the Foundry in question were integrated by means of a quality management system according to ISO 9001 standard. This means that the quality management system is a basic management structure in the enterprise, into which elements of environment management and work safety management have been incorporated. In pre4sented paper we describe some problems of management system integration in metallurgical industry.

In this paper, the research results of surveys which were conducted in an Indian foundry cluster which are potential members of such sectors are presented. These results indicate that there is an enough potential improvement in the energy use. The use of energy efficient practices can result in their energy use effectively as well as cost reduction. The key findings about the energy pattern are a lack of energy efficient practices. The suggested recommendations can contribute to an increase in energy efficiency in such cluster.

The article considers the process of manufacturing castings using sand-resin forms and alloying furnace. Were the optimal technological parameters of manufacturing shell molds for the manufacture of castings of heating equipment. Using the same upon receipt of castings by casting in shell molds furnace alloying and deoxidation of the metal will provide consumers with quality products and have a positive impact on the economy in general engineering.

The technology of obtaining nanostructural composite aluminum alloys consists in the plasma injection of refractory nanometric particles with simultaneous two-plane magnetic dynamic mixing of the melt. Particularly important in obtaining composite aluminum matrix alloys is the provision of the introduced particles wettability with the matrix melt for forming stable adhesive bonds. Nanostructured powder components can be considered not only to be a starting product for producing nanostructural composite aluminum alloys but as an independent commerce product. Nanostructural composite metal matrix alloys make one of the most prospective structural materials of the future, and liquid-phase technologies of their obtaining are the most competitive in producing products of nanostructural composite aluminum alloys in the industrial scale.

An easy hardening method of sodium silicate sands, ester-microwave composite hardening, could decrease the sands mould absorbing moisture and the mould materials requirement. And it was performed by hardening the sodium silicate sands with a little ester, and then demoulding, finally hardening the non-mold sands with microwave energy. The results showed that the 4h storage strength of composite hardening increases by 29,4 % compared with the common one, when the addition amount of ester was wt. 1,5 % according to the weight of sodium silicate binder. The humidity resistance of the sodium silicate sands was improved after the production of hydrophobic materials, glycerol and sodium acetate trihydrate by the ester.

The casting production is considered of the main factors influencing the development of World economy. Actual capacity of the world’s casting production, which is about 101 mln metric ton per year (2012), is strongly diversified. 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, moreover the globalization of economy is regarded not only as a chance but also as a menace for European foundries.

In this paper, the results of decomposition of a moulding sand with furfuryl resin also on a quartz matrix and with additions of a reclaimed material, under industrial conditions, are presented. 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 dependence of the emitted PAHs and BTEX group substances and ignition losses on the reclaim fraction in a moulding sand are of a linear character of a very high correlation coefficient R2. On the bases of the derived equations, it is possible to determine the amount of the emitted hazardous substances from the moulding sand containing the known fraction of the reclaim.

This article deals with improvement of design properties of molded plastic parts. It can be achieved by modifying construction of metal injection mold and optimization of parameters in injection process. The subject of our examination was depressions formed on molded plastic parts which are inacceptable in the process of approval. The problem which has arisen was solved in two phases. The first phase consisted in alteration of injection mold design – enlargement of injection molding gate. In the second phase, we have changed the location of injection molding gate. After performing constructional modifications, new molded plastic parts were manufactured and assessed.

A new method to treat four solid wastes of sodium silicate used sands, dewatered municipal sludge, clay sands sludge and waste polyethylene, was discussed. About wt/ 50 % sodium silicate used sands and wt/ 50 % dewatered sludge were mixed, and then cured by microwave with a certain thickness film of clay sands sludge and waste plastic of polyethylene in the surface. The results showed that the compression strength of granulation sample with the size of Ф 50 × 50 mm was over 0,45 MPa. The waste plastic was the key factor for the durability, and curing temperature must be over melting temperature, so the thicker film could be coated in the surface of used sands and sludge.

Integrating environment development, as the objective of the research in this paper, is to define a model to implement and monitor the key indicators of energy use efficiency as an instrument of an effective environmental and energy management in the metal sector in Bosnia and Herzegovina (B&H). The used environmental data contribute to a more efficient use of energy as well as to a reduction of emissions and effects on the environment.

The subject-matter of the paper covers a very topical problem of possible restriction of shortcomings like poor knocking-out properties of castings and hard reclaimability of this type sandmixes by proper selecting their components and using innovative microwave heating. It was proved that the sandmixes subject to quick dielectric process of drying/hardening show significantly lower residual strength, which gives this method priority over traditional energy-consuming processes of casting core manufacture.

The paper presents results of preliminary examinations of possibility to measure binder content in traditional moulding sands using a new method employing electromagnetic waves. The presented examinations were carried-out with use of an innovative test station, the so-called microwave slot line. The measurements of binder content in moulding sand were based on the results of power balance investigation of microwaves affecting the specimen. An advantage of the suggested, new method of binder content measurement is short measuring time.

The paper presents a semi-industrial reactor designed for microwave utilization of waste moulds and cores made of moulding sands prepared in furane resin technology. It was found that a possibility exists of effective incinerating this way prepared residues of cores separated from moulding sands or waste moulds left after casting. The preliminary tests evidenced that microwave heating is an effective way of disposing waste moulding sands and the applied apparatus permits effective control of the microwave heating process.

Possibilities of cross-linking of new polymer binders from the BioCo group, their hardening in moulding sands at the application of cross-linking agents both physical and chemical are presented. Their thermal stability was determined. It was proved, that moulding sands bound by the BioCo binders are characterised by the compression strength (Ruc) of an order of 2 MPa, and the bending strength (Rug) of 1 MPa, after 1 hour of a sample curing. The worked out BioCo binders are biodegradable and renewable in the part which was not completely burned. The investigated moulding sands with the BioCo binders are easily knocked out and have a good susceptibility for mechanical reclamation processes.

Procedures have been developed to determine the volume, rate and composition (particularly BTEX: benzene, toluene, ethylbenzene and xylenes and PAHs (polycyclic aromatic hydrocarbons)) of gas evolution from moulds and cores prepared with various binders as a means of harmfulness of moulding sands. The rate of gas evolution from green sands with four different lustrous carbon carrier and BTEX content were determined. The gas evolution rates are highest in the range of about 20 to 30 s after contact with molten metal. In practice during the first 200-250 s the total emission of gases generated in investigated samples occurred. The main emitted component from the BTEX group was benzene.

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.

Rapid prototyping is an important technique for manufacturing. This work refers to the manufacture of hollow patterns made of polymeric materials by rapid prototyping technologies for its use in the preparation of ceramic molds in the investment casting process. This work is focused on the development of a process for manufacturing patterns different from those that currently exist due to its hollow interior design, allowing its direct use in the fabrication of ceramic molds; avoiding cracking and fracture during the investment casting process, which is an important process for the foundry industry.

A comparison and estimation of usefulness of a quantitative analysis of montmorillonite in foundry bentonites, was the aim of this research. The investigations were made by means of three different techniques: methylene blue (MB) adsorption method, Cu(II)-triethylenetetramine complex (Cu(II)-TET) adsorption method, and infrared spectroscopy (FTIR) method. Tests were performed for 9 kinds of bentonites originated from various producers. The achieved results indicated that, the results obtained by the FTIR method were, in general, even 10% lower than the ones obtained by other methods. The best correlation with the data given by the producers were obtained for the Cu(II)-TET method. In addition, this method was characterised by the smallest value of standard deviations. A very essential advantage of the Cu(II)-TET method is a much shorter time needed for the analysis and its easier execution, which is important under production conditions.

The paper presents the results of applying microwaves to support the drying, redrying and hardening process of molding and core sands made of different types of matrix. In the tests of the microwave heating process a slot line measuring stand was used. Being based on the dielectric parameter measurement it enabled the evaluation of power losses of microwaves penetrating: chromite, magnesite, corundum, zircon and silica molding matrix samples. The survey revealed an impact of humidity and chemical compound of sands on microwave absorption. The study enabled the systematization of knowledge about the influence of selected types of matrix on the effectiveness of the microwave heating process.

It is investigated the possibility to be accounted the raw material’s quantity for each casting on the basis of design draft and mass of casting. To precisely determine the quantity of raw materials is necessary to technological procedure is preliminary accomplished. This task can be reached if correlations between kind of castings, shape complexity of castings, relations between total and net mass of castings, relations between mass of cores and mass of net casting will be established, with all respect toward applied technology and production methods of cores, the molding box and models.

Polysaccharides constitute a wide group of important polymers with many commercial applications, for example food packaging, fibres, coatings, adhesives etc. This review is devoted to the presentation of polysaccharide application in foundry industry. In this paper the selected properties of foundry moulding sand and core sand containing modified polysaccharides as binders are presented according to foreign literature data. Also, author's own research about effect of using moulding sand binder consisting of modified polysaccharide (modified starch) or its composition with non-toxic synthetic polymers are discussed. Based on technologies taken under consideration in this paper, it could be concluded that polysaccharides are suitable as an alternative for use as binder in foundry moulding applications. [ABSTRACT FROM AUTHOR]

The industrial activity in non-ferrous alloys foundries leads to the elimination of the pollutants in the atmosphere that may have adverse effects on the environment and human health. This paper presents an evaluation of the pollutant emissions resulting from an aluminium foundry starting from data on concentrations and pollutant mass flow rates estimated for each phase of the technological process and on measured ambient levels for the area of influence of the objective to study. [ABSTRACT FROM AUTHOR]

The results of preliminary tests of selected properties of the moulding sands with the binder in the form of a 5 % water solution of the sodium salt of carboxymethyl starch (with a degree of substitution (DS) of 0,2 and 0,87) are presented in this study. The moulding sand properties such as permeability, abrasion resistance, tensile and bending strength - after curing - are shown in series of tests. The cure process was conducted in a field of electromagnetic radiation within the microwave range. The effect of the microwave treatment on the moulding sand was evaporating of water (solvent in a binder) and cross-linking of the polymeric binder. Asa result the cured moulding sands with particular properties, essential in the context of its application in the mould technology in the foundry industry, were obtained. [ABSTRACT FROM AUTHOR]

Although new moulding processes for manufacture of high quality castings have been developed and introduced into foundry practice in recent years, the green-sand moulding in bentonite mixture still remains the most widely used technology. Higher utility properties of bentonite binders are achieved through their activation.This contribution is aimed at finding a suitable activating agent. A number of sodium salts and MgO based agents has been chosen. In the framework of the experiment the swelling volume of chosen agents was tested and technological parameters of a bentonite mixture with a binder activated with the studied agents were determined. [ABSTRACT FROM AUTHOR]

The behaviour of non-metallic particles in the selected composites was analysed, in the current study. The calculations of particles floating in liquids differing in viscosity were performed. Simulations based on the Stokes equation were made for spherical SiC particles and additionally the particle size influence on Reynolds number was analysed. The movement of the particles in the liquid metal matrix is strictly connected with the agglomerate formation problem. Some of collisions between non-metallic particles lead to a permanent connection between them. Creation of the two spherical particles and a metallic phase system generates the adhesion force. It was found that the adhesion force mainly depends on the surface tension of the liquid alloy and radius of non-metallic particles. [ABSTRACT FROM AUTHOR]

The application of thermogravimetric analysis can be very useful in the method since an extensive range of resins is used in founding. The thermal analysis performed for three different binders indicated the similar destruction mechanism. Along with the temperature increase the mass decrease of samples is related to the organic compounds decomposition and proceeds in a similar fashion regardless of the atmosphere in which the process occurs. However, for each of the tested binders, a certain critical temperature exists, above which - in the oxygen presence - the burning process of the majority of organic compounds forming the given substance occurs. [ABSTRACT FROM AUTHOR]

Currently offered devices for the hardness measuring or indices of the mould strength, are presented in the hereby paper. The presented results allow to compare approximately the indications of individual devices of different types. The description of the author's own microprocessor tester for the quality assessment of the sand foundry moulds, is shown. On the bases of the measurements results it is possible, to evaluate indirectly, the mould apparent density in the selected points, as well as several other properties. [ABSTRACT FROM AUTHOR]

The paper presents the results of the research on the used moulding sands subjected to mechanical and thermal reclamation at different stages of the process in the foundry. The research on thermal treatment was carried out in an experimental thermal reclamation appliance. The effects of the process were evaluated with the use of a range of criteria, e.g. loss in roasting, sieve analysis, strength, the acidic reaction (pH). The performed investigations indicate that the thermal reclamation, of spent moulding sands knocked-out from the mould supplying reclaimed materials of the proper quality, can fully substitute the mechanical reclamation. [ABSTRACT FROM AUTHOR]

The paper determines the range and form of a surface layer of a spheroid cast iron founding. It presents proofs of the possibility to form an operative surface of a product in the range of an intermediate surface layer of the cast. Based on research and experience, one has stated that the hardness spread and structures in cross sections of the wall of a cast are the most representative parameters determining the range of the surface layer of the iron cast. [ABSTRACT FROM AUTHOR]

Investigation results of the drying rate of the selected protective coatings (water and alcohol) are presented in the article. Coating drying rate was determined for the first and second layers. The coating was applied to moulding sand cores. The rate of drying coatings were tested for three coating apparent viscosities estimated by means of the Ford 4 mm cup. Drying rates of the protective coating were examined by using the gravimetric technique and ultrasonic technique. Measurements were carried out in a continuous way under controlled conditions: constant ambient temperature and air humidity. Research shows that the drying time of the second coating layer is longer by 20 - 30 % than the first layer. [ABSTRACT FROM AUTHOR]

This article addresses the effect of mold filling and wall thickness on the flake graphite layer in ductile iron. The research was conducted for castings with different wall thickness (3-8 mm) and using molding sand with furan resin. A thermal analysis has been performed along the length of the castings to determine the initial temperature of the metal in the mold cavity and the contact time of the liquid metal with the mold. Results demonstrated the strong influence of the temperature decrease of the metal in the mold cavity on the occurrence and the thickness of the flake graphite in the surface layer in ductile iron. [ABSTRACT FROM AUTHOR]

The wear effect of silica sands is usually joined with many foundry processes during the fresh sand preparation. The significant effect of silica grains destruction by means of crushing, abrasion and attrition is caused by most of mechanical reclamation treatments, which leads to a higher sand consumption. The experimental reclaimer was equipped with two different peripheral rings, which enabled both impact and impact-free way of the reclamation treatment of silica grains. In each case the duration of treatment and the rotational speed as well as the number of reclamation cycles were changed and effects were checked by multiple sieve analyses of the sand.

The casting production is considered of the main factors influencing the development of World economy. Actual capacity of the world's casting production, which is about 101 mln metric ton per year (2012), is strongly diversified. 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, moreover the globalization of economy is regarded not only as a chance but also as a menace for European foundries. [ABSTRACT FROM AUTHOR]

The technology of obtaining nanostructural composite aluminum alloys consists in the plasma injection of refractory nanometric particles with simultaneous two-plane magnetic dynamic mixing of the melt. Particularly important in obtaining composite aluminum matrix alloys is the provision of the introduced particles wettability with the matrix melt for forming stable adhesive bonds. Nanostructured powder components can be considered not only to be a starting product for producing nanostructural composite aluminum alloys but as an independent commerce product. Nanostructural composite metal matrix alloys make one of the most prospective structural materials of the future, and liquid-phase technologies of their obtaining are the most competitive in producing products of nanostructural composite aluminum alloys in the industrial scale. [ABSTRACT FROM AUTHOR]