EP1800771B1 - A moulding material and a method for casting, and an additive for the moulding material - Google Patents

A moulding material and a method for casting, and an additive for the moulding material Download PDF

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Publication number
EP1800771B1
EP1800771B1 EP06126676A EP06126676A EP1800771B1 EP 1800771 B1 EP1800771 B1 EP 1800771B1 EP 06126676 A EP06126676 A EP 06126676A EP 06126676 A EP06126676 A EP 06126676A EP 1800771 B1 EP1800771 B1 EP 1800771B1
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EP
European Patent Office
Prior art keywords
weight
moulding material
carbonaceous material
moulding
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Application number
EP06126676A
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German (de)
English (en)
French (fr)
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EP1800771A1 (en
Inventor
Peter Nayström
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Swerea SWECAST AB
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Swerea SWECAST AB
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/14—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for separating the pattern from the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives

Definitions

  • the present invention relates to a moulding material and a method for casting iron, the moulding material containing sand and a carbonaceous material, which comprises pit coal.
  • the invention further concerns an additive for a moulding material, the additive containing a carbonaceous material which comprises pit coal.
  • moulding material that contains about 80-90% by weight of sand, about 5-11% by weight of binder (usually bentonite), about 3-4% by weight of water and about 2-6% by weight of carbonaceous material.
  • the carbonaceous material In commercially used moulding materials, the carbonaceous material consists mainly of powdered coal, or alternatively a coal dust replacement.
  • a problem associated with this kind of carbonaceous material is that it contains a certain amount, usually about 30% by weight, of volatile compounds (such as VOC - volatile organic compounds), which are set free as the moulding material is heated, and which cause emissions from the foundry plant.
  • volatile compounds such as VOC - volatile organic compounds
  • these volatile organic compounds have a beneficial effect on the casting performance by reducing the adherence of, for example, the moulding material to the cast object, thus reducing the amount of moulding sand that has to be removed from the cast object in subsequent production stages.
  • US 5,688,313 discloses an activated carbon and/or activated graphite foundry sand additive, and method of casting molten metal against a foundry sand containing the additive composition.
  • An object of the present invention is to provide a moulding material, a method for casting and an additive for such a moulding material, which partly or entirely eliminate the problems associated with prior art.
  • a particular object is to provide a moulding material, a casting process and an additive, which reduce the emissions of volatile organic compounds, in combination with a low adherence of sand to the cast article.
  • a moulding material for casting iron which moulding material contains sand and a carbonaceous material, the carbonaceous material constituting 0.5-10% by weight of the moulding material and containing pit coal.
  • the carbonaceous material contains, relatively to each of the components of the carbonaceous material, mainly coke in proportion by weight.
  • a moulding material of this kind can be made acceptable in terms of both emissions and the adherence of moulding material to the cast object.
  • 40% by weight or more, preferably 50% by weight or more, of the carbonaceous material can be coke.
  • the lower limit for the amount of coke is not critical for the performance of the moulding sand in terms of adherence, but can be chosen based on the permissible amount of emissions.
  • 60% by weight or more, preferably 70% by weight or more, of the carbonaceous material can be coke.
  • 99% by weight or less, preferably 95% by weight or less, 90% by weight or less, 80% by weight or less, 75% by weight or less or 70% by weight or less, of the carbonaceous material can be coke.
  • the remaining part of the carbonaceous material can be pit coal, or pit coal and coal dust replacement.
  • 30% by weight or less, preferably 20% by weight or less, 15% by weight or less, 10% by weight or less, of the carbonaceous material can be pit coal, or pit coal and coal dust replacement.
  • the moulding material can contain 25% by weight or less, preferably 6% by weight or less, 4% by weight or less or 2.5% by weight or less, of carbonaceous material.
  • the moulding material can contain 0.5% by weight or more, 1% by weight or more, 1.5% by weight or more, 2% by weight or more, 2.5% by weight or more, 3% by weight or more, 3.5% by weight or more, 4% by weight or more or 4.5% by weight or more, of carbonaceous material.
  • the moulding material can contain a binder, for example about 4-15% by weight, preferably 5-11% by weight, of binder.
  • the binder can be bentonite.
  • the moulding material can contain graphite, preferably in an amount of up to about 0.5-2% by weight of the moulding material. By adding graphite the moulding material is made more fluid and thus becomes easier to handle.
  • the remaining part of the moulding material in addition to the components referred to above, can be sand, which part preferably constitutes 80-95% by weight, preferably 80-90% by weight of the moulding material.
  • a process for casting iron in a moulding material containing sand and a carbonaceous material, which constitutes 0.5% by weight of the moulding material and comprises pit coal.
  • the process comprises mixing coke into the moulding material, so that the main component by weight of the carbonaceous material, in proportion to each of the components of the carbonaceous material, is coke.
  • an additive for a moulding material intended for casting iron contains a carbonaceous material comprising pit coal and is distinguished in that the carbonaceous material, relatively to each of the components of the carbonaceous material, mainly contains coke in proportion by weight.
  • the remaining part of the carbonaceous material of the additive is pit coal, or pit coal and coal dust replacement.
  • the additive contains a binder.
  • the binder comprises bentonite.
  • the additive contains graphite.
  • Tests were made consisting in the casting of brake discs of grey cast iron with a weight of 6.2 kg.
  • a basic mixture for a moulding material consisting of synthetic moulding sand, mixed from virgin materials, was prepared, wherein quartz-felspar was mixed with 5% by weight of soda-treated calcium bentonite and water, and then stored for one month.
  • the amount of water was chosen so as to provide a suitable consistency of the moulding sand, and the amount of added water was about 2.3-3.1% by weight.
  • the basic mixture was mixed with different additives.
  • the final amount of sand (percentage by dry weight) can be calculated from the tables below, since it constitutes the remaining part not stated in the tables. All weight parts in the tables relate to the dry weight composition of the mixtures.
  • Example 1 a moulding material made up of a basic mixture and 4% by weight of coke was prepared.
  • the carbonaceous material in this moulding material thus consisted of 100% by weight coke.
  • Example 2 a moulding material made up of a basic mixture, 3% by weight coke and 1% by weight graphite.
  • the carbonaceous material in this moulding material thus consisted of 75% by weight coke and 25% by weight graphite.
  • Example 3 a moulding material made up of a basic mixture and 4% by weight of powdered coal.
  • the carbonaceous material in this moulding material thus consisted of 100% by weight of powdered coal.
  • sample 4 use was made of a commercially used circulating, i.e. recycled, moulding material, with a measured carbon content of about 4.5% by weight.
  • the carbonaceous material added in this moulding material was made up of powdered coal and coal dust replacement.
  • this moulding material contains, due to the circulation, a small amount of coke, which is formed when the moulding material is heated during casting and the powdered coal and coal dust replacement are converted into coke.
  • this moulding material contains carbonaceous rests from polymere-containing binders used during the manufacture of mould cores.
  • Example 5 a moulding sand made up of a basic mixture and 4% by weight coke and 1.5% by weight of powdered coal was prepared.
  • the carbonaceous material in this moulding material thus consisted of 73% by weight coke and 27% by weight powdered coal.
  • Example 6 the moulding material of Sample 2 was used, wherein 0.5% by weight powdered coal was added.
  • the carbonaceous material in this moulding material thus consisted of 67% by weight coke, 22% by weight graphite and 11% by weight powdered coal.
  • Example 7 the moulding material of Sample 2 was used, wherein a basic mixture was added to obtain a total amount of coke representing 1.5% by weight and a total amount of graphite representing 0.5% by weight. Furthermore, 0.5% by weight of powdered coal was added.
  • the carbonaceous material in this moulding material thus consisted of 60% by weight coke, 20% by weight graphite and 20% by weight powdered coal.
  • Example 8 a moulding material according to the EU project GO-APIC (Proj. No. G1RD-CT-2000-00235) was used.
  • the carbonaceous material in this moulding material was made up of a graphite-zeolite blend, and thus contained no coke.
  • the cast article Upon casting, the cast article was left to cool for 40 minutes in the mould, following which one form part was removed and placed on its end on the other form part for 20 minutes, to allow volatile organic compounds set free by the form parts to be collected by the ventilating hood and measured in the ventilating duct.
  • the cast article was separated from the moulds and vibrated on a separating device for one minute, and then left to cool completely.
  • samples 1-4 the volatile organic compounds were measured by means of a ventilating hood provided with FID instruments, which measure the content of volatile organic compounds in the ventilating duct. Furthermore, the amount of sand was measured after the first separation.
  • Table 1 shows the results of the measurements for Samples 1-4.
  • Table 1 Results for Samples 1-4 Sample 1 2 3 4 Bentonite [% by weight] 5.1 5.1 5.1 6.5 Coke [% by weight] 4 3 0 -* Pit coal/ Coal dust replacement [% by weight] 0 0 4 -* Graphite [% by weight] 0 1 0 -* Carbon content [% by weight] 3.2 2.9 3.0 4.5 VOC max [ppm] 0.05 0.01 24 19 Sand amount [% by weight] 8.5 6.2 1.7 2.2 * No content data available, since the sample was a reference sample with recycled moulding material.
  • Samples 1-4 and 8 are comparative examples and do not form part of the claimed invention.
  • Table 1 shows that a moulding material with no admixture of pit coal results in an unacceptably large amount of adhering moulding material. Thus, Samples 1 and 2 are unacceptable from the point of view of productivity, since an excessive amount of adhering sand is obtained.
  • Table 1 further shows that a moulding material in which pit coal constitutes a small proportion of the carbonaceous material results in low emissions of volatile organic compounds. Thus, Samples 3 and 4 are unacceptable from the point of view of emissions.
  • Table 2 illustrates the results of the measurements for Samples 5-8.
  • Table 2 Results for Samples 5-8 Sample 5 6 7 8 Bentonite [% by weight] 5.1 5.1 5.1 6.8 Coke [% by weight] 4 3 1.5 0 Hard coal/ Coal dust replacement [% by weight] 1.5 0.5 0.5 0 Graphite [% by weight] 0 1 0.5 ⁇ 2.0 Carbon content [% by weight] 4,1 3.2 1.9 ⁇ 1.0 Sand amount [% by weight] 1.3 3.0 6.6 6.0
  • Table 2 shows that a moulding material in which the main component of the carbonaceous material is coke, with the admixture of pit coal, results in an acceptable amount of adhering moulding material.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
EP06126676A 2005-12-22 2006-12-20 A moulding material and a method for casting, and an additive for the moulding material Active EP1800771B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
SE0502882A SE529710C2 (sv) 2005-12-22 2005-12-22 Formmassa, användning av formmassa samt förfarande för gjutning

Publications (2)

Publication Number Publication Date
EP1800771A1 EP1800771A1 (en) 2007-06-27
EP1800771B1 true EP1800771B1 (en) 2011-04-20

Family

ID=37812054

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06126676A Active EP1800771B1 (en) 2005-12-22 2006-12-20 A moulding material and a method for casting, and an additive for the moulding material

Country Status (4)

Country Link
EP (1) EP1800771B1 (sv)
AT (1) ATE506129T1 (sv)
DE (1) DE602006021383D1 (sv)
SE (1) SE529710C2 (sv)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE1650208A1 (sv) 2016-02-17 2017-06-27 Swerea Swecast Ab A carbonacous additive for a moulding material fo r casting iron

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2830913A (en) * 1955-10-11 1958-04-15 Exxon Research Engineering Co Carbonaceous molding material for foundry operations
SE413997B (sv) * 1977-01-17 1980-07-07 Westin & Backlund Ab Sett vid framstellning av gjutformar eller gjutkernor ur en vattenhaltig blandning av formsand, bindemedel och kolhaltigt material, som kan bilda sa kallad glanskol, samt formmassa avedd att anvendas vid settet
US5094289A (en) * 1990-09-19 1992-03-10 American Colloid Company Roasted carbon molding (foundry) sand and method of casting
US5893946A (en) * 1996-06-21 1999-04-13 Amcol International Corporation Combustible carbonaceous compositions and methods
US5695554A (en) * 1996-06-21 1997-12-09 Amcol International Corporation Foundry sand additives and method of casting metal, comprising a humic acid-containing ore and in-situ activated carbon or graphite for reduced VOC emissions
US5810918A (en) * 1996-06-21 1998-09-22 Amcol International Corporation Method of analyzing and/or treating foundry sands for reduced VOCs
US5769933A (en) * 1996-06-21 1998-06-23 Amcol International Corporation Activated carbon foundry sand additives and method of casting metal for reduced VOC emissions
US6860319B2 (en) * 2003-06-04 2005-03-01 American Colloid Company Acid activated clay for use in foundry sand

Also Published As

Publication number Publication date
EP1800771A1 (en) 2007-06-27
SE529710C2 (sv) 2007-10-30
SE0502882L (sv) 2007-06-23
DE602006021383D1 (de) 2011-06-01
ATE506129T1 (de) 2011-05-15

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