Gas evolution characteristics of three kinds of no-bake resin-bonded sands for foundry in production

No-bake resin-bonded sand is commonly used in casting production.However,its air pollution is relatively serious,especially in the molding and pouring process.For this reason,it is necessary to study the gas evolution characteristics of no-bake resin-bonded sand from room temperature to high temperatures,and not only the amount of gaseous products,but also the composition of the gaseous products.No-bake furan resin-bonded sand(#1),phenolic urethane no-bake resin-bonded sand(#2),and alkaline phenolic no-bake resin-bonded sand(#3)are the three most common no-bake resin-bonded sands in casting.The gas evolution volume and rate of these three no-bake resin-bonded sands were studied.Thermogravimetry-mass spectrometer(TG-MS),headspace-gas chromatography/mass spectrometer(HS-GC/MS),and pyrolysis-gas chromatography/mass spectrometer(PY-GC/MS)were used to measure the composition of the gaseous products emitted from binders at room temperature and high temperatures.The differences between formaldehyde,heterocyclic aromatic compounds(HAC),monocyclic aromatic hydrocarbons(MAH),and polycyclic aromatic hydrocarbons(PAHs)gaseous products from the three types of no-bake resin-bonded sands during the molding and casting process were compared.From the perspective of environmental protection,alkaline phenolic no-bake resin-bonded sand and no-bake furan resin-bonded sand are better than phenolic urethane no-bake resin-bonded sand.

Development of a new instrument for measurement of high temperature mechanical properties of resin-bonded sand

The mechanical properties of resin-bonded sand mixtures at high temperatures significantly affect the quality of casting. However, the existing instruments for high-temperature performances testing mainly focus on inorganic binder-bonded sands no matter the test items or the atmospheric protection, while the instrumentss specially designed for resin-bonded sand are not yet available. A new instrument for testing the hightemperature performance of resin sand was designed including the confirmation of the testing parameters, loading, measurement and control systems, and the design of the frame shape and heating furnace. This instrument can test the compressive strength, heat tolerance time and restraining load of phenol-formaldehyde resin coated sand, self-hardened furan resin sand, and trimethylamine(TEA)-based resin bonded sand at high temperatures. The developed instrument has a high accuracy offering smaller than 0.3% deviation at a full scale in the measurement of the high temperature compressive strength and the restraining load over the range of 0-6.8 MPa and 0-2,000 N, respectively. The high temperature heat tolerance time range is 0-300 s and its measurement accuracy is ±1 s.

Mechanical Properties of Railway High-strength Manufactured Sand Concrete: Typical Lithology, Stone Powder Content and Strength Grade

In order to achieve the large-scale application of manufactured sand in railway high-strength concrete structure,a series of high-strength manufactured sand concrete(HMC)are prepared by taking the manufactured sand lithology(tuff,limestone,basalt,granite),stone powder content(0,5%,10%,15%)and concrete strength grade(C60,C80,C100)as variables.The evolution of mechanical properties of HMC and the correlation between cubic compressive strength and other mechanical properties are studied.Compared to river sand,manufactured sand enhances the cubic compressive strength,axial compressive strength and elastic modulus of concrete,while its potential microcracks weaken the flexural strength and splitting tensile strength of concrete.Stone powder content displays both positive and negative effects on mechanical properties of HMC,and the stone powder content is suggested to be less than 10%.The empirical formulas between cubic compressive strength and other mechanical properties are proposed.

Prediction of intrusive gas pores caused by resin burning in sand core for iron castings

In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occurs due to the intrusion of gases generated during the resin burning of the sand core into castings during the casting process.Therefore,a gas generation and flow constitution model was established,in which the gas generation rate is a function of temperature and time,and the flow of gas is controlled by the gas release,conservation,and Darcy's law.The heat transfer and gas flow during casting process was numerically simulated.The dangerous point of cores is firstly identified by a virtual heat transfer method based on the similarity between heat transfer and gas flow in the sand core.The gas pores in castings are predicted by the gas pressure,the viscosity and state of the melt for these dangerous points.Three distinct sand core structures were designed and used for the production of iron castings,and the simulated gas pore results were validated by the obtained castings.

Feasibility study on the suitability of dielectric barrier discharge plasma treatment of desert sand for concrete production purposes

Due to the continuously increasing building and construction industry,sand has become one of the most questioned raw materials worldwide.However,the available amount of sand suitable for concrete production is orders of magnitude lower that the demand and consumption.Even though desert sand is sufficiently available,it is not usable for realizing stable concrete due to its surface shape.Against this background,the suitability of energy-efficient‘cold'dielectric barrier discharge plasma operated at atmospheric pressure for improving the properties of concrete produced from desert sand was investigated in this contribution.It is shown that such plasma treatment allows for a certain roughening and re-shaping of sand grains.As a result,the mass flow of treated sand is decreased due to an improved wedging of sand grains.This leads to a certain increase in compressive strength of concrete samples.Even though this increase is marginal,the suitability of the applied type of plasma for modification of the geometry and surface chemistry of sand grains was proven,showing its basic potential for the treatment and preconditioning of sand used for concrete,mortar or plastering.

Effects of bacterial strains on undrained cyclic behavior of bio-cemented sand considering wetting and drying cycles

The microbial-induced calcite precipitation(MICP)technique has been developed as a sustainable methodology for the improvement of the engineering characteristics of sandy soils.However,the efficiency of MICP-treated sand has not been well established in the literature considering cyclic loading under undrained conditions.Furthermore,the efficacy of different bacterial strains in enhancing the cyclic properties of MICP-treated sand has not been sufficiently documented.Moreover,the effect of wetting-drying(WD)cycles on the cyclic characteristics of MICP-treated sand is not readily available,which may contribute to the limited adoption of MICP treatment in field applications.In this study,strain-controlled consolidated undrained(CU)cyclic triaxial testing was conducted to evaluate the effects of MICP treatment on standard Ennore sand from India with two bacterial strains:Sporosarcina pasteurii and Bacillus subtilis.The treatment durations of 7 d and 14 d were considered,with an interval of 12 h between treatments.The cyclic characteristics,such as the shear modulus and damping ratio,of the MICP-treated sand with the different bacterial strains have been estimated and compared.Furthermore,the effect of WD cycles on the cyclic characteristics of MICP-treated sand has been evaluated considering 5–15 cycles and aging of samples up to three months.The findings of this study may be helpful in assessing the cyclic characteristics of MICP-treated sand,considering the influence of different bacterial strains,treatment duration,and WD cycles.

Data-driven casting defect prediction model for sand casting based on random forest classification algorithm

The complex sand-casting process combined with the interactions between process parameters makes it difficult to control the casting quality,resulting in a high scrap rate.A strategy based on a data-driven model was proposed to reduce casting defects and improve production efficiency,which includes the random forest(RF)classification model,the feature importance analysis,and the process parameters optimization with Monte Carlo simulation.The collected data includes four types of defects and corresponding process parameters were used to construct the RF model.Classification results show a recall rate above 90% for all categories.The Gini Index was used to assess the importance of the process parameters in the formation of various defects in the RF model.Finally,the classification model was applied to different production conditions for quality prediction.In the case of process parameters optimization for gas porosity defects,this model serves as an experimental process in the Monte Carlo method to estimate a better temperature distribution.The prediction model,when applied to the factory,greatly improved the efficiency of defect detection.Results show that the scrap rate decreased from 10.16% to 6.68%.

Numerical simulation on sand sedimentation and erosion characteristics around HDPE sheet sand barrier under different wind angles

For the safety of railroad operations,sand barriers are utilized to mitigate wind-sand disaster effects.These disasters,characterized by multi-directional wind patterns,result in diverse angles among the barriers.In this study,using numerical simulations,we examined the behavior of High Density Polyethylene(HDPE)sheet sand barriers under different wind angles,focusing on flow field distribution,windproof efficiency,and sedimentation erosion dynamics.This study discovered that at a steady wind speed,airflow velocity varies as the angle between the airflow and the HDPE barrier changes.Specifically,a 90°angle results in the widest low-speed airflow area on the barrier’s downwind side.If the airflow is not perpendicular to the barrier,it prompts a lateral airflow movement which decreases as the angle expands.The windproof efficiency correlates directly with this angle but inversely with the wind’s speed.Notably,with a wind angle of 90°,wind speed drops by 81%.The minimum wind speed is found at 5.1H(the sand barrier height)on the barrier’s downwind side.As the angle grows,the barrier’s windproof efficiency improves,extending its protective reach.Sedimentation is most prominent on the barrier’s downwind side,as the wind angle shifts from 30°to 90°,the sand sedimentation area on the barrier’s downwind side enlarges by 14.8H.As the angle grows,sedimentation intensifies,eventually overtakes the forward erosion and enlarges the sedimentation area.

Flow field, sedimentation, and erosion characteristics around folded linear HDPE sheet sand fence: Numerical simulation study

Wind and sand hazards are serious in the Milan Gobi area of the Xinjiang section of the Korla Railway. In order to ensure the safe operation of railroads, there is a need for wind and sand protection in heavily sandy areas. The wind and sand flow in the region is notably bi-directional. To shield railroads from sand, a unique sand fence made of folded linear high-density polyethylene(HDPE) is used, aligning with the principle that the dominant wind direction is perpendicular to the fence. This study employed field observations and numerical simulations to investigate the effectiveness of these HDPE sand fences in altering flow field distribution and offering protection. It also explored how these fences affect the deposition and erosion of sand particles. Findings revealed a significant reduction in wind speed near the fence corner;the minimum horizontal wind speed on the leeward side of the first sand fence(LSF) decreased dramatically from 3 m/s to 0.64 m/s. The vortex area on the LSF markedly impacted horizontal wind speeds. Within the LSF, sand deposition was a primary occurrence. As wind speeds increased, the deposition zone shrank, whereas the positive erosion zone expanded. Close to the folded corners of the HDPE sand fence, there was a notable shift from the positive erosion zone to a deposition zone. Field tests and numerical simulations confirmed the high windproof efficiency(WE) and sand resistance efficiency(SE) in the HDPE sand fence. Folded linear HDPE sheet sand fence can effectively slow down the incoming flow and reduce the sand content, thus achieving good wind and sand protection. This study provides essential theoretical guidance for the design and improvement of wind and sand protection systems in railroad engineering.

Experimental and simulation research on hollow AZ31 magnesium alloy three-channel joint by hot extrusion forming with sand mandrel

Magnesium alloy is one of the lightest metal structural materials.The weight is further reduced through the hollow structure.However,the hollow structure is easily damaged during processing.In order to maintain the hollow structure and to transfer the stresses during the high temperature deformation,the sand mandrel is proposed.In this paper,the hollow AZ31 magnesium alloy three-channel joint is studied by hot extrusion forming.Sand as one of solid granule medium is used to fill the hollow magnesium alloy.The extrusion temperatures are 230℃ and 300℃,respectively.The process parameters(die angle,temperature,bottom thickness,sidewall thickness,edge-to-middle ratio in bottom,bottom shape)of the hollow magnesium alloy are analyzed based on the results of experiments and the finite element method.The results are shown that the formability of the hollow magnesium alloy will be much better when the ratio of sidewall thickness to the bottom thickness is 1:1.5.Also when edge-to-middle ratio in bottom is about 1:1.5,a better forming product can be received.The best bottom shape in these experiments will be convex based on the forming results.The grain will be refined obviously after the extrusion.Also the microstructures will be shown as streamlines.And these lines will be well agreement with the mold in the corner.

Microscopic Analysis of Cementitious Sand and Gravel Damming Materia

The mechanical properties of cementitious sand and gravel damming material have been experimentally determined by means of microscopic SEM(Scanning Electron Microscopy)image analysis.The results show that the combination of fly ash and water can fill the voids in cemented sand and gravel test blocks because of the presence of hydrated calcium silicate and other substances;thereby,the compactness and mechanical properties of these materials can be greatly improved.For every 10 kg/m^(3) increase in the amount of cementitious material,the density increases by about 2%,and the water content decreases by 0.2%.The amount of cementitious material used in the sand and gravel in these tests was 80-110 kg/m^(3),the water-binder ratio was 1-1.50.Moreover,the splitting tensile strength was 1/10 of the compressive strength,and the maximum strength was 7.42 MPa at 90 d.The optimal mix ratio has been found to be 50 kg of cement,60 kg of fly ash and 120 kg of water(C50F60W120).The related dry density was 2.6 g/cm^(3),the water content was 6%,and the water-binder ratio was 1.09.

Effect analysis of biomineralization for solidifying desert sands

The sand-dust weather has become an environmental hazard in the world.However,it is still a challenge to control sandstorms and decrease sand-dust weather.The biomineralization technology for solidifying desert sands has been developed as a novel method in recent years.In this study,the wind erosion tests and verification tests of the sand solidification system were conducted via a series of laboratory experiments.The effects of sand barriers,injecting volume and concentration of the biochemical solution in the sandstorm protection were studied.Moreover,a field test of 60,000 square metres was conducted in the solidification area on both sides of the Wuma Highway in the Tengri Desert.The biomineralization technique was used to solidify sand to prevent the wind from blowing quicksand onto the newly built highway and causing accidents.Results demonstrated that the biomineralization sand solidification method had a good solidification==effect,improved the survival rate,and promoted the growth of plants in the desert.This innovative biomineralization technology is an environmentally responsible technology to control sandstorm disasters.

基于P2PSand模型的水库土石坝坝基地震液化影响分析

为了解决水库土石坝坝基地震液化导致严重坝体变形和边坡失稳等灾害,从而对水库土石坝长效安全运行造成严重威胁的问题,以某水库土石坝为例,利用有限差分软件FLAC3D 7.0及其内置P2PSand模型(practical two-surface plastic sand model),对存在地震液化地基的水库土石坝进行地震动力响应分析。结果表明:地震强度与相对密实度对水库土石坝坝基地震液化趋势影响较大,超孔压比随着地震过程的进行而逐渐增大,增大幅度约为10.46%;随着坝基地震液化程度的提高,坝体变形更明显,并且坝基边坡稳定性劣化。

Protective benefits of HDPE board sand fences in an environment with variable wind directions on Gobi surfaces:wind tunnel study

The Golmud-Korla Railway in the Gobi area faces operational challenges due to sand hazards,caused by strong and variable winds.This study addresses these challenges by conducting wind tunnel tests to evaluate the protective benefits of High Density Polyethylene(HDPE)board sand fences,focusing on their orientation relative to various wind directions(referred to as'wind angle').This study found that the size of the low-velocity zone on the leeward side of the sand fences(LSF)expanded with an increase in the wind angle(WA).At 1H(the height of the sand fence)and 2H positions on the LSF,the wind speed profiles(WSP)exhibited a segmented logarithmic growth,constrained by Z=H at varying WAs.The efficacy of the sand fence in obstructing airflow escalated as WA increased.The size of the WA has a significant impact on the protective efficiency of HDPE board sand fences.Furthermore,compared to typical sandy surfaces,the rate of sand transport across the Gobi surface diminishes more slowly with height,attributed to the gravel's rebound effect.This phenomenon allows some sand particles to bypass the fences,rendering them less effective at blocking wind and trapping sand than in sandy environments.This paper offers scientific evidence supporting the practical use and enhancement of HDPE board sand fences in varied wind conditions.

Sand control mechanism of radial well filled with phase change material in hydrate reservoir

Radial well filled with phase change material has been proposed as a novel sand control method for hydrate exploitation.In order to reveal the sand control mechanism,CFD-DEM coupling method is applied to simulate the migration,settlement,and blockage processes of sand particles in the radial well.The obtained results indicate that three scenarios have been recognized for sand particles passing through sand control medium,based on the diameter ratio of sand control medium to sand particle(D_(d)):fully passing(D_(d)=8.75-22.5),partially passing and partially blocked(D_(d)=3.18-5.63),and completely blocked(D_(d)=2.18-3.21).After being captured by the sand control medium,sand particles can block pores,which increases fluid flow resistance and causes a certain pressure difference in the radial well.The pressure in the radial well should be lower than the hydrate phase equilibrium pressure during sand control design,for the purpose of promoting hydrate decomposition,and sand capture.The length of the radial well should be optimized based on the reservoir pore pressure,production pressure difference,bottom hole pressure,and the pressure gradient in the radial well.It should be noticed that the sand control medium leads to a decrease in permeability after sand particles captured.Even the permeability is reduced to several hundred millidarcy,it is still sufficient to ensure the effective flow of gas and water after hydrate decomposition.Increasing fluid velocity reduces the blocking capacity of the sand control medium,mainly because of deterioration in bridging between sand particles.

Study on the clogging mechanism of punching screen in sand control by the punching structure parameters

As an independent sand control unit or a common protective shell of a high-quality screen,the punching screen is the outermost sand retaining unit of the sand control pipe which is used in geothermal well or oil and gas well.However,most screens only consider the influence of the internal sand retaining medium parameters in the sand control performance design while ignoring the influence of the plugging of the punching screen on the overall sand retaining performance of the screen.To explore the clogging mechanism of the punching screen,this paper established the clogging mechanism calculation model of a single punching screen sand control unit by using the computational fluid mechanics-discrete element method(CFD-DEM)combined method.According to the combined motion of particles and fluids,the influence of the internal flow state on particle motion and accumulation was analyzed.The results showed that(1)the clogging process of the punching sand control unit is divided into three stages:initial clogging,aggravation of clogging and stability of clogging.In the initial stage of blockage,coarse particles form a loose bridge structure,and blockage often occurs preferentially at the streamline gathering place below chamfering inside the sand control unit.In the stage of blockage intensification,the particle mass develops into a relatively complete sand bridge,which develops from both ends of the opening to the center of the opening.In the stable plugging stage,the sand deposits show a“fan shape”and form a“V-shaped”gully inside the punching slot element.(2)Under a certain reservoir particle-size distribution,The slit length and opening height have a large influence on the permeability and blockage rate,while the slit width size has little influence on the permeability and blockage rate.The microscopic clogging mechanism and its law of the punching screen prevention unit are proposed in this study,which has some field guidance significance for the design of punching screen and sand prevention selection.

Distribution, health and ecological risk assessments of trace elements in Nigerian oil sands

The Nigerian oil sands represent the largest oil sand deposit in Africa, yet there is little published information on the distribution and potential health and ecological risks of trace elements in the oil resource. In the present study, we investigated the distribution pattern of 18trace elements(including biophile and chalcophile elements) as well as the estimated risks associated with exposure to these elements. The results of the study indicated that Fe was the most abundant element, with a mean concentration of 22,131 mg/kg while Br had the lowest mean concentration of 48 mg/kg. The high occurrence of Fe and Ti suggested a possible occurrence of ilmenite(Fe TiO_(3)) in the oil sands. Source apportionment using positive matrix factorization showed that the possible sources of detected elements in the oil sands were geogenic, metal production, and crustal. The contamination factor, geo-accumulation index, modified degree of contamination, pollution load index, and Nemerow pollution index indicated that the oil sands are heavily polluted by the elements. Health risk assessment showed that children were relatively more susceptible to the potentially toxic elements in the oil sands principally via ingestion exposure route(HQ > 1E-04). Cancer risks from inhalation are unlikely due to CR < 1E-06 but ingestion and dermal contact pose severe risks(CR > 1E-04). The high concentrations of the elements pose serious threats due to the potential for atmospheric transport, bioaccessibility, and bioavailability.

New Data on Coal, Gypsum, Iron and Silica Sand Deposits and Geochemical Exploration (Pakistan): Revision of 25 Years History of Dinosaur Discoveries from Pakistan

Discoveries of many coal seams at depths by drilling carried by Geological Survey of Pakistan in Sor Range and Harnai Gochina, extended the coal seams at depth which is challenge for mine owners to exploit feasibly. Bed to bed gypsum samplings (and their chemical analyses) of huge gypsum deposits from Sulaiman foldbelt is a base for industrialist and also planers to develop cement and gypsum industries to increase export and foreign exchange for the development of area and Pakistan. Low and high grade sedimentary iron deposits, silica sand and uranium host rocks and their extensions in Sulaiman and Kirthar foldbelts are presented. Anomalies of a few base metals arise as a result of geochemical exploration carried at part of Loralai District of Balochistan. Theropod dinosaurs were frequent in India, while Poripuchian titanosaurs (Sauropoda, Dinosauria) were frequent in Pakistan. Besides some ichnotaxa, many bone taxa such as 1 titanosauriform, 14 titanosaurian sauropod (including one new titanosaur), and 3 theropod dinosaurs are established from Pakistan. Among these 12 titanosaur species and 3 theropod species are named in about 10 km2 area of Vitakri dome and 2 titanosaur species are named in about a few hundred square meter area of Mari Bohri (Kachi Bohri) which is about 10 km westward from Vitakri dome. Pakistan is a unique country which discoverd 14 diversified titanosaurs in a short area and also in a short period (67 - 66 million years ago/Ma). About 400 bones found from a few meter thick upper part of upper shale horizon of latest Maastrichtian Vitakri Formation which is base for titanosaur taxa. Cranial material is in low fraction (but include significant diverse snouts), caudal vertebrae are prominent, the cervicals, dorsals and sacrals have significant numbers, forelimb and hind limb bones have balanced fraction. Humeri, femora and tibiae are most common. To know the position of Pakistani titanosaurs among titanosaurs and sauropods, there is a need to extend list of characters for phylogenetic analyses. This broad feature list should include main characters of titanosaurs from Pakistan and also from global world.

An Investigation into the Compressive Strength,Permeability and Microstructure of Quartzite-Rock-Sand Mortar

River sand is an essential component used as a fine aggregate in mortar and concrete.Due to unrestrained exploitation,river sand resources are gradually being exhausted.This requires alternative solutions.This study deals with the properties of cement mortar containing different levels of manufactured sand(MS)based on quartzite,used to replace river sand.The river sand was replaced at 20%,40%,60%and 80%with MS(by weight or volume).The mechanical properties,transfer properties,and microstructure were examined and compared to a control group to study the impact of the replacement level.The results indicate that the compressive strength can be improved by increasing such a level.The strength was improved by 35.1%and 45.5%over that of the control mortar at replacement levels of 60%and 80%,respectively.Although there was a weak link between porosity and gas permeability in the mortars with manufactured sand,the gas permeability decreased with growing the replacement level.The microstructure of the MS mortar was denser,and the cement paste had fewer microcracks with increasing the replacement level.

Fungi Associated with Sand and Plants from Marine Coastlines: Potential Relevance for Human Health

The fungal community associated with beach sand and plants located along marine coasts are an under-studied area of research despite its potential relevance to human health. In this study, we isolated and identified the cultivable mycobiota associated with sand and plants collected along the coast of Gran Canaria (Spain) using culture-dependent and -independent methods. Clinically relevant species belonging to Cryptococcus spp. and related genera such as Naganishia and Papilotrema were isolated and identified from shoreline plants. Moreover, Candida tropicalis was isolated from beach sand, and Aspergillus fumigatus and Aspergillus terreus strains were associated with both types of samples (i.e., plants and beach sand). We conclude that beach sand and shoreline plants are potential reservoirs of fungi of high clinical interest. We recommend including beach sand and plants from the environment when assessing the quality of marine coastal systems. Our results open a framework for studying the natural marine environment and its role in the epidemiology of infectious diseases in order to more accurately manage public health.