Biodegradable materials as binders for IVth generation moulding sands

This paper focuses on the possibility of using the biodegradable materials as binders(or parts of binders' compositions) for foundry moulding and core sands. Results showed that there is a great possibility of using available biodegradable materials as foundry moulding sand binders. Using biodegradable materials as partial content of new binders, or additives to moulding sands may not only decrease the toxicity and increase reclamation ability of tested moulding sands, but also accelerate the biodegradation rate of used binders, and the new biodegradable additive(PCL) did not decrease the strength and thermal properties. In addition, using polycaprolactone(PCL) as a biodegradable material may improve the flexibility of moulding sands with polymeric binder and reduce toxicity.

The Reduction in the Swelling Potential of the Foundation Ground of Togblécopéin Togo by the Stabilization with Binders and Sands

The present study aims at helping to search for preventive solutions to pathologies of constructions in Togblécopé in Togo, by the reduction in the withdrawal and swelling of foundation grounds through their stabilization. Togblécopé’s clay taken from 1 m, 2 m and 3 m deep, and mixed with four binding materials (cement, sea sand, silty sand and lime). Tests of identification and free swelling with odometer are carried out on pure and stabilized materials. What emerges from these tests is that the limits of liquidity and plasticity are rising along with the rate of stabilizers while the index of plasticity is falling. Cement and lime cause a reduction in the index value of plasticity by almost 50%. The more the sand’s grain size, the more the reduction in the plasticity index. The swelling potential is reduced by 60% for cement and lime, 30% for sea sand and 20% for silty sand. The present study is a contribution to the reduction in deflations from 20% to 60% of some parts of constructions in order to limit cracks.

Allyl Glycidyl Ether-modified Animal Glue Binder for Improved Water Resistance and Bonding Strength in Sand Casting

This paper aims to develop a modified animal glue sand binder for foundry casting with improved water resistance and bonding strength.An efficient method is reported by using sodium hydroxide as the catalyst to improve the operability of animal glue binder and allyl glycidyl ether as the modifier to improve the water resistance and bonding strength.Sand specimens prepared using allyl glycidyl ether-modified animal glue binder were cured by compressed air at room temperature.The proposed method saves energy and is environmentally friendly and inexpensive.Compared with unmodified animal glue binder,standard dog bone sand specimens with allyl glycidyl ether-modified animal glue binder had higher tensile strength of 2.58 MPa,flowability of 1.95 g,better water resistance(a lower decrease in tensile strength at 25°C and relative humidity of 60%),and good collapsibility.This allyl glycidyl ether-modified animal glue binder is suitable for practical application in the foundry industry.

Research,application and development of inorganic binder for casting process

Inorganic binder used in casting process has the advantages of low odor,labor-friendly conditions,and relatively low cost,which is one of the main development directions for casting molding materials in the future.However,compared to organic binders(such as resin binders),inorganic binders exhibit lower bonding strength and are more sensitive to environmental humidity.This sensitivity poses challenges,particularly in the reclamation of used sand,thus limiting their broader application.In this paper,the research and application status of inorganic binders(mainly silicate inorganic binders)and their curing methods are summarized.In addition,the research and application of phosphate inorganic binders and 3D printing inorganic binders that are being developed are introduced.Meanwhile,a detailed comparative analysis is conducted on the challenging issue of“reclamation for used sand”in the application of inorganic binders.Finally,the development direction of inorganic binders is clarified.

Pep-Set树脂砂和呋喃树脂砂特性对比研究

主要研究航空镁合金铸件铸造用Pep-Set树脂砂和呋喃树脂砂的工艺对比特性。通过在实验室进行对比试验,在等量树脂及硼酸加入情况下,对比分析两种树脂砂的抗拉强度、透气性、发气量等关键特性参数。

Technology and mechanism of a new protein-based core sand for aluminum casting

The protein based binding material is from natural products, which is nontoxic and recyclable. This kind of green binder is earnestly needed by aluminum casting products. The new protein based core possesses higher strength and easier shakeout. Its tensile strength is close to that of common resin sands. The micro mechanism of protein binder was investigated by using infrared spectrum, chemical element analysis, SEM and thermal lost mass analysis.

Influence of core sand properties on flow dynamics of core shooting process based on experiment and multiphase simulation

The influence of core sand properties on flow dynamics was investigated synchronously with various core sands, transparent core-box and high-speed camera. To confirm whether the core shooting process has significant turbulence, the flow pattern of sand particles in the shooting head and core box was reproduced with colored core sands. By incorporating the kinetic theory of granular flow(KTGF), kinetic-frictional constitutive correlation and turbulence model, a two-fluid model(TFM) was established to study the flow dynamics of the core shooting process. Two-fluid model(TFM) simulations were then performed and a areasonable agreement was achieved between the simulation and experimental results. Based on the experimental and simulation results, the effects of turbulence, sand density, sand diameter and binder ratio were analyzed in terms of filling process, sand volume fraction(αs) and sand velocity(Vs).

Elaboration of a Road Material Based on Clayey Soil and Crushed Sand

To contribute to the enhancement of unconventional local materials used for road construction,this study characterizes a crushed sand 0/5,a clayey soil and the litho-stabilized material without and with hydraulic binder and determines their use in accordance with some reference specifications(CEBTP 1984).It is shown that the different components are not usable alone in pavement base.Indeed,the plasticity index obtained for the clayey soil is 21%,a value higher than the imposed standards.In addition,the grading of the 0/5 crushed sand does not fit into the range proposed by CEBTP.A combination of these two(02)components is therefore considered to obtain a suitable material usable for the sub-base.This new material does not enter any class of the CEBTP lateritic soils.In order to be used in base layer,a treatment with hydraulic binder is carried out with the intention to improve its mechanical performances.The optimal dosage of hydraulic binder to achieve the desired mechanical performance is obtained by studying the evolution of the mechanical characteristics of the mixture.After this treatment,the Bearing Ratio index of the mix increases from 37 to 223 for the optimal dosage and the dry compaction density decreases from 2.11 to 2.06 g/cm3 while the optimal water content increases from 9%to 10.1%.

Binder jetting 3D printing process optimization for rapid casting of green parts with high tensile strength

Binder jetting 3D printing is a rapid,cost effective,and efficient moulding/core making process,which can be applied to a large variety of materials.However,it exhibits a relatively low green-part strength.This may cause the collapse of the printed parts during de-caking and the pick-up procedure,especially in the case of small-scale structures,such as thin walls,tips,and channels.In this work,polyvinyl alcohol(PVA)was used as the additive in coated sand powder.By exploiting the binding effect between the two composites(thermoplastic phenolic resin and PVA)triggered by the binder,bonding necks firmly form among the sand particles,improving the green-part strength of the coated sand printed parts.Experiments based on the Taguchi method were used to investigate the relationship between the process parameters and the green-part tensile strength.The following set of optimal process parameters was identified:50wt.%alcoholicity of the binder,75%binder saturation,0.36 mm layer thickness and 4.5wt.%PVA content.Further,the effect of such parameters on the green-part tensile strength was determined via statistical analysis.The green part of an engine cylinder head sand pattern with complex cavity structures was printed,and the green-part tensile strength reached 2.31 MPa.Moreover,the ZL301 aluminum alloy impeller shape casting was prepared using sand molds printed with the optimal process parameters.The results confirm that the proposed binder jetting 3D printing process can guarantee the integrity of the printed green parts and of small-size structures during de-caking and the pick-up procedure.Furthermore,the casting made from the printed sand molds exhibits a relatively high quality.

Optimization of Animal-Glue Binders for Casting Applications

In typical metal foundry applications,sand casting is still the most used technology.The related binder plays a very important role as its performances can directly influence the quality of castings.Among many binders,glues of animal origin have attracted much attention in recent years due to their reduced environmental impact.How-ever,they display some drawbacks such as the tendency to coagulate easily at room temperature and a relatively low strength.In this study,a novel gas-hardening casting binder was prepared using an animal glue and anhy-drous potassium carbonate as a hydrolyzing agent to avoid undesired agglomeration.Moreover,sodium pyropho-sphate and furfuryl alcohol were exploited as modifiers to obtain a binder with a high compressive strength.The best modification conditions,determined by means of an orthogonal design matrix approach,were 4 g of Na2CO3,sodium pyrophosphate,furfuryl alcohol and animal glue with a ratio of 4:12:100,at 85°C and with a duration of 115 min,respectively.The viscosity of the mixture obtained under these optimized conditions was 1250 mPa⋅s.The compressive strength of the binder,hardened by CO_(2) gas,was 4.00 MPa.Its gas evolution at 850°C was 15 ml⋅g-1,and its residual strength after 10 min calculation at 800°C was 0.01 MPa,which is high enough to meet the requirement of core-making in foundry.Moreover,after hydrolysis and further modification,animal glue and modifiers displayed a grafting reaction and an esterification reaction,respectively,which made the adhesive network denser and improved its thermal stability.

自硬-微波加热复合硬化硅酸盐粘结剂砂性能研究

针对自硬硅酸盐粘结剂砂用于铸铁件时存在硬化速度慢、对环境湿度敏感、砂型(芯)强度低、溃散性差四个问题,本文选择一种新型硅酸盐粘结剂,以陶瓷砂为原砂,在采用固化剂自硬的基础上,还通过微波加热以及添加粉末促硬剂,进行了复合硬化工艺的研究。首先,研究了微波加热工艺参数对型砂试样性能的影响,确定了优化微波加热工艺:加热功率为900 W、加热时间为180 s;而后,选用了三种粉末促硬剂进行优化,得到的最佳粉末添加剂优化方案为粘结剂2.2%、微硅粉0.2%、氧化铝0.2%、石英粉0.06%。结果表明,该组优化方案相比较不加入粉末添加剂,使砂型(芯)1 h强度提高至1.86 MPa,24 h强度提高至2.17 MPa,98%RH吸湿强度提高至1.45 MPa,800℃残留强度降低至0.75 MPa,其常温强度值和残留强度值分别达到和接近自硬树脂砂的水平。

基于离散元的颗粒性质标定及铺砂过程模拟

喷墨打印中,砂床质量的高低直接影响最终打印零件的质量,在砂层铺设过程中砂粒的颗粒性质是影响砂床质量的关键因素之一。为研究喷墨打印中颗粒性质对砂床质量的影响,以原砂为研究对象,通过实验和离散元仿真相结合的方法完成了砂粒间接触参数进行标定,并对覆膜砂接触参数进行研究,使用颗粒间的表面能来描述砂粒流动性的变化,通过实验与仿真结合的方法得到了催化剂含量和表面能之间的关系。在砂粒颗粒性质确定的基础上,构建了喷墨打印工艺中砂床铺设过程的离散元模型,完成了颗粒性质对铺砂质量影响的仿真实验,结果表明:催化剂含量的增加会降低砂床质量,但过低的催化剂含量会导致制件的尺寸精度和力学强度变差。因此,为了平衡固化效率和砂床质量,可将催化剂含量控制在0.4%到0.6%之间;在层厚和落砂质量一定的条件下,粒径系数是影响砂床质量的主要参数,粒径系数的减小会导致砂床质量的下降。

新型硅酸盐自硬粘结剂砂性能的研究

以有机酯为固化剂的普通水玻璃自硬砂具有生产环境好、产生的有害气体少的优势,目前广泛应用于铸钢件的生产。但以硅砂为原砂的水玻璃自硬砂用于生产结构复杂、质量要求高的铸铁件,与树脂砂工艺相比,还存在硬化速度慢,型芯砂强度较低,使用性能对环境湿度敏感等问题。为此,本文以一种新型硅酸盐粘结剂为对象,选用球形陶瓷砂,在固化剂自硬工艺基础上,添加促硬剂和多种粉末改性剂,重点研究了常温强度和高温残留强度的变化规律。正交试验获得的复合粉末改性剂优化配方为:陶瓷砂∶促硬剂∶氧化锆∶氮化硅=1000∶4∶2∶1,粘结剂加入量2.2%,固化剂占粘结剂质量的20%,试样1h强度为0.98MPa,24h强度1.59MPa,800℃残留强度0.62MPa,其常温强度已达到自硬树脂砂的性能指标。

河砂与石英砂对蒸养超高性能混凝土(UHPC)性能的影响及机理

本研究分别选用颗粒粒径分布相近的河砂与石英砂制备了不同胶砂比的超高性能混凝土(UHPC),探究了两种细集料对不同胶砂比情况下UHPC性能的影响。结果表明:(1)采用河砂制备的UHPC的扩展度稍大于采用石英砂者;(2)采用河砂制备的胶砂比为1.0的UHPC的抗压强度和抗拉强度最高,表现出明显的应变硬化现象,采用石英砂所制备的胶砂比为0.8的UHPC的抗拉强度最低,几乎无应变硬化现象;(3)细集料种类及胶砂比对水泥水化反应和掺合料火山灰反应的影响有限,蒸养条件下,硬化浆体中几乎无Ca(OH)_2存在;(4)UHPC内孔隙的直径大多小于1μm,胶砂比相同时,采用石英砂制备的UHPC所含孔径小于1μm孔的数量多于采用河砂者;(5)与石英砂相比,河砂与硬化浆体的界面过渡区较为致密,且采用河砂制备的UHPC中浆体对纤维的包裹性也较好。

花岗岩尾矿砂制备砂浆的黏结性能研究

利用花岗岩尾矿砂(GTS)制备砂浆,研究了胶砂比、聚乙烯醇胶粉(PVAP)和聚乙烯醇纤维(PVAF)对砂浆黏结性能的影响规律,分析了砂浆破坏形式与拉伸黏结强度之间的关系,并通过SEM对其微观机理进行分析。结果表明,单掺聚乙烯醇胶粉或聚乙烯醇纤维对砂浆黏结性能均有提升,复掺聚乙烯醇胶粉和聚乙烯醇纤维时砂浆黏结性能最优。砂浆的胶砂比为1∶2,聚乙烯醇胶粉为0.9%(质量分数),聚乙烯醇纤维为1.5%(体积分数)时,黏结性能最优,28 d拉伸黏结强度最高可达1.75 MPa。砂浆破坏形式与拉伸黏结强度有关。未掺聚乙烯醇胶粉与聚乙烯醇纤维时破坏形式多为界面破坏,复掺聚乙烯醇胶粉与聚乙烯醇纤维时破坏形式多为基体破坏,单掺聚乙烯醇胶粉或聚乙烯醇纤维时破坏形式多为界面-基体破坏。

无机结合料稳定风积沙公路用的性能实践

水泥稳定风积沙技术的推出,使修路成本节约了30%以上,施工现场也智能环保,省时省力。将风积沙铸路技术应用对荒漠化综合治理当中,能够为国内外沙漠地区治理提供技术支撑,为沙产业的发展作出应有的贡献。石灰土干缩和温缩比较明显。水泥土干缩系数、干缩应变以及温缩系数的比较:粒料的系数小于土。二灰土:抗冻性比石灰土好。(因为有孔,羽绒服抗冻)。收缩性小于水泥土和石灰土。(因为有孔,结构具有一定的伸缩性)。本研究首先从干缩特性研究、温缩特性研究两个方面分析了半刚性基层收缩性能与规律研究现状,然后进行了原材料分析。

有机物HPMC和PAM对磷酸盐自硬砂性能影响探究

探究羟丙基甲基纤维素、聚丙烯酰胺两种辅料浓度及加入量对自硬砂性能的影响,讨论了两种辅料联合加入的影响,借助SEM-EDS和FTIR对影响机理进行了初步分析。结果表明,占粘结剂2%的0.7%羟丙基甲基纤维素水溶液和占粘结剂1%的0.8%聚丙烯酰胺水溶液联合加入能有效提高自硬砂干强度和抗吸湿性。相对湿度为40%~60%RH时,干强度由0.67 MPa提高到0.97 MPa,存放4天期间,平均强度提高24.58%;恒湿箱80%~85%RH时,砂样存放4天的平均强度提高43.27%,24~96 h内强度下降率由31.25%下降到25.00%。

一种改性公路水泥基纤维复材的综合性能研究

为了提升公路水泥基纤维复合材料的综合性能,研究了水胶比、砂胶比对水泥基纤维复合材料强度的影响,优化了柠檬酸缓凝剂掺量。结果表明,在复合材料中加入柠檬酸缓凝剂后,随着柠檬酸掺量的增加,初凝时间和终凝时间都逐渐增加。随着龄期增加,复合材料的抗压强度也表现为先快速增加而后趋于稳定,在相同龄期下,砂胶比越大则抗压强度越大,水胶比越大则抗压强度越小。随着龄期增加,复合材料的抗折强度先快速增加而后趋于稳定,在相同龄期下,砂胶比越大复合材料的抗折强度越大,水胶比越大则抗折强度越小。适宜的砂胶比为1.0或1.2,水胶比为0.22或0.24,龄期为14d。

绿色环保无机发泡砂的制备及性能

采用WJ-1无机粘结剂,加入发泡剂、发泡促进剂改性,并在混砂时加入FT-1添加剂,获得了具有较高强度和优异清砂性能的绿色环保无机发泡砂;通过挤压将发泡砂加入到预热模具中硬化,形成中空的砂型(芯);浇注铸件后,砂型(芯)具有优异的溃散性,能够通过振动和气流等低成本且简单方法实现砂型(芯)清除,省去以往所使用的如粉碎处理、热处理、喷砂处理等繁杂的清砂方法,简化砂型铸造后处理工艺。

不同添加剂配比对镁合金砂型铸造用树脂砂性能的影响研究

针对镁合金砂型铸造中使用的树脂砂,探讨了混砂时加入树脂、固化剂、阻燃剂、硅烷等添加剂的配方及作用。通过测定树脂砂的可使用时间、起模时间、抗压强度等参数,分析了不同添加剂配比对树脂砂性能的影响。研究结果表明,在确保树脂砂强度的基础上,尽量减少树脂和固化剂的配比量,可减少铸件气孔缺陷,改善高温性能,提高铸件质量,降低生产成本。该研究结果可为镁合金铸件的高质量生产提供技术支持。