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Optimisation of an Environmentally Friendly Foundry Inorganic Binder Core Making Process for the Replacement of an Organic Binder

Published online by Cambridge University Press:  27 April 2020

Farai Chrispen Banganayi ,
Didier Kasongo Nyembwe  and
Hartmut Polzin
Farai Chrispen Banganayi*
Affiliation:
Metal Casting Technology Station, University of Johannesburg, 37 Nind street Doornfontein Johannesburg, South Africa (e-mail: fcbanganayi@uj.ac.za)
Didier Kasongo Nyembwe
Affiliation:
Department of Metallurgy, University of Johannesburg, 37 Nind street Doornfontein, Johannesburg, South Africa (e-mail: dnyembwe@uj.ac.za)
Hartmut Polzin
Affiliation:
Metal Casting Technology Station, University of Johannesburg, 37 Nind street Doornfontein, Johannesburg, South Africa (e-mail: gp.polzin@icloud.com)
*
*(Email: fcbanganayi@uj.ac.za)
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Abstract

There is a need to introduce modern sand binder systems in the South African foundry industry as a means of improving its competiveness through the reduction of scrap castings and compliance to environmental regulations. According to the Industrial Policy Action Plan (IPAP). The foundry industry will play an important role with regards to the economic infrastructure priority advocated in the National Development Plan (NDP) of South Africa. In this study, a new generation water glass binder is introduced in a local foundry for production of cores for export plumbing casting production. The new water glass introduced is unique in that it contains an inorganic breakdown agent. The core making operating parameters including binder content, temperature and cycle time are optimised through core making trials without any alterations on the coremaking machines. Production data was evaluated using an optimization feature of Microsoft excel software. The results provided a set of optimum operating variables to manufacture 80-100% good quality sand cores for casting applications with an environmentally friendly binder. The most favourable binder content is above 2.60%.The most favourable operating temperature range is 160-174 0C. Therefore temperature and related energy costs can be reduced. The shortfall is reduction in cycle time.

Keywords

environmentcasting
Type
Articles
Information
MRS Advances , Volume 5 , Issue 25: African Materials Research Society 2019 , 2020 , pp. 1323 - 1330
Copyright
Copyright © Materials Research Society 2020

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