EP3225327B1 - Système de liant inorganique pour fonderies - Google Patents
Système de liant inorganique pour fonderies Download PDFInfo
- Publication number
- EP3225327B1 EP3225327B1 EP17163617.8A EP17163617A EP3225327B1 EP 3225327 B1 EP3225327 B1 EP 3225327B1 EP 17163617 A EP17163617 A EP 17163617A EP 3225327 B1 EP3225327 B1 EP 3225327B1
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- EP
- European Patent Office
- Prior art keywords
- weight
- sodium silicate
- aqueous solution
- powder composition
- moulds
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000011230 binding agent Substances 0.000 title claims description 43
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 126
- 239000000203 mixture Substances 0.000 claims description 98
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 91
- 239000004115 Sodium Silicate Substances 0.000 claims description 87
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 87
- 239000007864 aqueous solution Substances 0.000 claims description 63
- 239000000843 powder Substances 0.000 claims description 61
- 239000000377 silicon dioxide Substances 0.000 claims description 44
- 239000004576 sand Substances 0.000 claims description 39
- 238000000465 moulding Methods 0.000 claims description 35
- 238000004519 manufacturing process Methods 0.000 claims description 25
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 claims description 24
- 239000000654 additive Substances 0.000 claims description 23
- 229910000503 Na-aluminosilicate Inorganic materials 0.000 claims description 19
- 239000000429 sodium aluminium silicate Substances 0.000 claims description 19
- 235000012217 sodium aluminium silicate Nutrition 0.000 claims description 19
- 229910052681 coesite Inorganic materials 0.000 claims description 18
- 229910052906 cristobalite Inorganic materials 0.000 claims description 18
- 239000011819 refractory material Substances 0.000 claims description 18
- 229910052682 stishovite Inorganic materials 0.000 claims description 18
- 229910052905 tridymite Inorganic materials 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 17
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 6
- 239000000243 solution Substances 0.000 description 25
- 230000008569 process Effects 0.000 description 14
- 239000000126 substance Substances 0.000 description 11
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 9
- 235000013339 cereals Nutrition 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 238000002156 mixing Methods 0.000 description 7
- 238000003860 storage Methods 0.000 description 7
- 238000005266 casting Methods 0.000 description 6
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 5
- 150000001875 compounds Chemical class 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 230000009257 reactivity Effects 0.000 description 4
- 239000011734 sodium Substances 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 229910000323 aluminium silicate Inorganic materials 0.000 description 3
- 239000012298 atmosphere Substances 0.000 description 3
- 230000015556 catabolic process Effects 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- HXLAEGYMDGUSBD-UHFFFAOYSA-N 3-[diethoxy(methyl)silyl]propan-1-amine Chemical compound CCO[Si](C)(OCC)CCCN HXLAEGYMDGUSBD-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- 229930006000 Sucrose Natural products 0.000 description 2
- CZMRCDWAGMRECN-UGDNZRGBSA-N Sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 150000001720 carbohydrates Chemical class 0.000 description 2
- 235000014633 carbohydrates Nutrition 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000000571 coke Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- UHOVQNZJYSORNB-UHFFFAOYSA-N monobenzene Natural products C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 2
- 150000004756 silanes Chemical class 0.000 description 2
- DGSDBJMBHCQYGN-UHFFFAOYSA-M sodium;2-ethylhexyl sulfate Chemical compound [Na+].CCCCC(CC)COS([O-])(=O)=O DGSDBJMBHCQYGN-UHFFFAOYSA-M 0.000 description 2
- 239000005720 sucrose Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 2
- 208000016261 weight loss Diseases 0.000 description 2
- 230000004580 weight loss Effects 0.000 description 2
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 239000004111 Potassium silicate Substances 0.000 description 1
- IIDJRNMFWXDHID-UHFFFAOYSA-N Risedronic acid Chemical compound OP(=O)(O)C(P(O)(O)=O)(O)CC1=CC=CN=C1 IIDJRNMFWXDHID-UHFFFAOYSA-N 0.000 description 1
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 239000011400 blast furnace cement Substances 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 239000000404 calcium aluminium silicate Substances 0.000 description 1
- 235000012215 calcium aluminium silicate Nutrition 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 235000012241 calcium silicate Nutrition 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 231100001010 corrosive Toxicity 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000009313 farming Methods 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 235000013980 iron oxide Nutrition 0.000 description 1
- 239000002085 irritant Substances 0.000 description 1
- 231100000021 irritant Toxicity 0.000 description 1
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 description 1
- 229910052912 lithium silicate Inorganic materials 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910052914 metal silicate Inorganic materials 0.000 description 1
- 239000005300 metallic glass Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 229910052913 potassium silicate Inorganic materials 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 229910001415 sodium ion Inorganic materials 0.000 description 1
- 230000002269 spontaneous effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- -1 sucrose Chemical class 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 239000003440 toxic substance Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
- B22C1/188—Alkali metal silicates
Definitions
- the object of the present invention is a powder composition that acts as an activator in foundry binder systems comprising an aqueous solution of sodium silicate.
- the powder composition of the invention comprises sodium silicate having CAS Registry Number 1344-09-8 and a SiO 2 /Na 2 O molar ratio comprised between 3.0 and 3.6, preferably between 3.2 and 3.5, and sodium aluminosilicate having CAS Registry Number 1344-00-9 .
- the powder composition of the invention may furthermore comprise additives.
- Objects of the invention furthermore are the binder systems comprising the powder composition of the invention and aqueous solutions of sodium silicate, optionally comprising additives, the use of said binder systems for the production of foundry moulds, such as cores and/or moulds, and likewise the moulding material mixtures for the production of foundry cores and/or moulds comprising the binder systems of the invention and the silica sand and/or other granular refractory material.
- objects of the invention are a process for the production of said foundry moulds, such as cores and/or moulds, comprising a production step of the moulding material mixtures comprising the binder systems of the invention, together with silica sand and/or other granular refractory material, and a heating step of said moulding material mixtures, and the cores and/or moulds obtainable with said process.
- the foundry moulds such as cores and /or moulds into or around which the molten metal will be poured, are comprised of a granular refractory material, such as, for example silica sand, mixed with a binder system, normally composed of two or more components.
- a granular refractory material such as, for example silica sand
- the foundry moulds must meet various requirements.
- said moulds must furthermore feature stability against moisture present in the processing environment, so as to be usable even some time after the production thereof and after being subjected to the mechanical stress of transportation from the place of production to the place of use thereof.
- the hardening reaction which binds the inert material is accelerated by a chemical catalyst in a liquid or vapour form.
- inorganic foundry binders such as binder systems based on alkali silicate and, in particular, sodium silicate in an aqueous solution.
- the need for totally inorganic-based binder systems is given by the need for binder-based moulds that do not emit hazardous (i.e. harmful, toxic, corrosive, irritant, etc) substances, such as - for example - benzene, toluene, xylene, phenol formaldehyde, when the high-temperature molten metal is poured into (or around) the mould, resulting in the breakdown of the said mould.
- hazardous substances i.e. harmful, toxic, corrosive, irritant, etc
- the organic binder systems deposit a layer of a tarry substance on the metal surfaces, which leads to frequent cleaning, and as a result, a slowdown in production.
- the inorganic binder systems - which should only develop water as a result of the heat - can prevent this slowdown in production.
- the aqueous solutions of alkali silicates are obtained by melting the silica with an alkali carbonate and dissolving the obtained product in water.
- Sodium silicate is the most commonly used alkali silicate, above all for cost reasons. Only in special cases outside the foundry industry potassium silicate is used, for example, in binders for the farming industry, where sodium ion is an undesirable component. Lithium silicate is used in very specific applications, for example for sealing concrete surfaces.
- the aqueous solution of alkali silicate is mixed with the sand and any other optional components/additives: the resulting moist mixture is placed into the core box or in the flask where, depending on the process used, it hardens by effect of the heat and/or a chemical reaction with an external agent.
- blast-furnace cements for the cold hardening of foundry moulds bonded with aqueous solutions of sodium silicate
- Use of blast furnace slag cements as hardening agents for silicate-bonded moulding sands Donald W. and D. Smith, The British Foundryman, January 1968, p. 34-40 , herein incorporated by reference.
- Patent US4226277 herein incorporated by reference, describes a foundry binder system consisting of an aqueous solution of sodium silicate, in which a flow of air, optionally heated, is forced through a mass of sand bonded with said system to accelerate the evaporation of the water contained in the sodium silicate solution and, consequently, accelerate the hardening thereof.
- Patent application WO98/49118 herein incorporated by reference, describes the controlled gelification and subsequent hardening of the sodium silicate solutions for use as adhesives, in particular for outdoor applications when weather-resistance is required.
- the hardening of said solutions is brought about by adding additives such as amorphous silica or an amorphous metal silicate, chosen from magnesium silicate, calcium silicate or aluminium silicate.
- patent application EP1802409 herein incorporated by reference, describes a foundry moulding mixture comprising a granular refractory material, a sodium silicate solution and a hardener consisting of a metal oxide in particulate form, chosen from silica, alumina, titanium oxide, and zinc oxide.
- Patent US3210267 relates to the catalytic conversion of a hydrocarbon charge into lower boiling normally liquid and normally gaseous products and to an improved cracking catalyst characterized by unusual attrition resistance, activity, selectivity and stability to deactivation by steam.
- the catalysts disclosed in said patent possess a porous matrix and a crystalline aluminosilicate zeolite the cations of which consist essentially of metal characterized by a substantial portion of rare earth metal, said aluminosilicate having a structure of rigid three-dimensional networks and uniform pore openings of a size greater than 4 angstroms and less than 15 angstroms.
- foundry moulds such as the cores and/or moulds obtained with the binder systems and/or moulding material mixtures of the invention, feature high moisture resistance during storage, thus allowing later use thereof, some time after the production thereof, including after the transportation from the place of production to other places for the subsequent use thereof.
- the binder systems and the moulding mixtures of the invention are totally inorganic-based and therefore furthermore meet recent environmental safety standards requiring limited release of hazardous and/or toxic substances into the environment.
- the object of the invention is therefore a powder composition comprising sodium silicate ( CAS Registry Number 1344-09-8 ) and a SiO 2 /Na 2 O molar ratio comprised between 3.0 and 3.6, preferably between 3.2 and 3.5, and a sodium aluminosilicate powder ( CAS Registry Number 1344-00-9 ).
- the sodium silicate powder has an average grain size comprised between 60 and 100 ⁇ m, preferably between 70 and 90 ⁇ m, and still more preferably of 80 ⁇ m, and/or the sodium aluminosilicate powder has an average grain size comprised between 2 and 15 ⁇ m, preferably between 5 and 10 ⁇ m, and still more preferably of 7 ⁇ m.
- Sodium silicate powder is scarcely soluble in cold water, but becomes soluble when warm. Therefore, this component does not negatively affect the storage potential (bench life) of the moulding material comprising said component, since, thanks to its high molar ratio, it acts as an accelerator during the subsequent heating process (baking).
- the sodium aluminosilicate powder is insoluble in water.
- the powder composition of the invention comprises 60 to 90% by weight of sodium silicate with a SiO 2 /Na 2 O molar ratio comprised between 3.0 and 3.6, preferably between 3.2 and 3.5, and 10 to 40% by weight of sodium aluminosilicate, wherein said percentages refer to the total weight of the powder composition.
- the powder composition may comprise additives.
- additives are understood as substances and/or compounds which are useful for improving the flowability of the moulding material mixtures comprising the powder composition of the invention, such as for example mica and/or silver graphite, substances and/or compounds which are useful for improving the surface of the castings, such as - for example - iron oxides, or substances and/or compounds which are useful for improving the breakdown (shake-out) of cores or moulds after casting.
- carbohydrates are used, such as sucrose, cereal flours, coke powder, and/or wood powder.
- the powder composition of the invention comprises 1 to 25% by weight of additives, preferably 5 to 15 % by weight of additives, wherein said percentages refer to the total weight of the powder composition of the invention.
- the powder composition of the invention is obtained by mixing sodium silicate and sodium aluminosilicate and any optional additives, as defined above, in a powder mixer, preferably of the conical type, which is activated until a homogeneous powder is obtained.
- the powder composition of the invention enables the hardening of a moulding material mixture comprising aqueous solutions of sodium silicate and sand and/or other granular refractory material, thereby allowing foundry moulds to be obtained, such as cores and/or moulds, which are safe for the environment and for the workers in the industry, feature resistance to ambient moisture, and which extend the storage potential for use thereof for some time, subsequently to the time of production.
- the object of the invention is a binder systems comprising the powder composition of the invention, as defined hereinabove, and an aqueous solution of sodium silicate having a SiO 2 /Na 2 O molar ratio comprised between 1.9 and 2.5.
- the aqueous solution of sodium silicate comprises 25 to 50% by weight of sodium silicate, more preferably, 35 to 45% by weight of sodium silicate, and between 50 to 75% by weight of water, wherein said percentages refer to the total weight of the aqueous solution of sodium silicate.
- the aqueous solution of sodium silicate has a SiO 2 /Na 2 O molar ratio comprised between 2.0 and 2.4, and preferably between 2.1 and 2.3, and/or the aqueous solution of sodium has a density at 20°C comprised between 1.30 and 1.50 kg/dm 3 , preferably comprised between 1.35 and 1.45 kg/dm 3 .
- Particularly preferred are the aqueous solutions of sodium silicate which have a SiO 2 /Na 2 O molar ratio comprised between 2.1 and 2.3, with a density at 20°C comprised between 1.35 and 1.45 kg/dm 3 .
- the aqueous solution of sodium silicate is prepared by taking an aqueous solution of sodium silicate having a molar ratio within the above cited range easily available on the market, and appropriately diluting it with water in a mixer equipped with a stirrer, with no need of heating.
- aqueous solution of sodium silicate may furthermore comprise additives.
- the aqueous solution of sodium silicate comprises 0.1 to 10% by weight of additives, wherein said percentages refer to the total weight of the aqueous solution of sodium silicate.
- additives are understood as substances and/or compounds which are useful for improving the flowability of the moulding material mixture, for example sodium 2-ethylhexyl sulphate, which is preferably added in aqueous solution at 40% by weight, in an amount comprised between 0.1% and 1.0% by weight, preferably between 0.2% and 0.6% by weight, with respect to the total weight of the aqueous solution of sodium silicate, or monophenyl glycol, which is preferably added in an amount comprised between 0.5% and 5.0% by weight, preferably between 1.0 and 4.0% by weight, with respect to the total weight of the aqueous solution of sodium silicate.
- sodium 2-ethylhexyl sulphate which is preferably added in aqueous solution at 40% by weight, in an amount comprised between 0.1% and 1.0% by weight, preferably between 0.2% and 0.6% by weight, with respect to the total weight of the aqueous solution of sodium silicate
- monophenyl glycol which is preferably added in an amount comprised between 0.5% and 5.
- the aqueous solution of sodium silicate may furthermore comprise additives which improve bonding with the grains of refractory material with which said aqueous solution of sodium silicate is mixed and which improve the storage potential of the manufactured articles in a humid environment, such as, for example, silane compounds.
- Silane compounds of particular interest are, for example, 3-aminopropyltriethoxysilane, 3-aminopropylmethyldiethoxysilane, 3-(diethoxymethyl-silyl)propylamine, 3-glycidoxypropyltrimethoxysilane and mixtures thereof, which are preferably added in amounts of between 0.1% and 1.0% by weight, preferably between 0.2 and 0.6% by weight, with respect to the total weight of the aqueous solution of sodium silicate.
- the aqueous solution of sodium silicate may furthermore comprise additives which facilitate the breakdown (shake-out) of the cores and moulds after casting, said additives usually being carbohydrates, such as sucrose, which is preferably added in an amount comprising between 1.0% and 10.0% by weight, preferably between 3.0% and 6.0% by weight, with respect to the total weight of the aqueous solution of sodium silicate.
- additives which facilitate the breakdown (shake-out) of the cores and moulds after casting
- said additives usually being carbohydrates, such as sucrose, which is preferably added in an amount comprising between 1.0% and 10.0% by weight, preferably between 3.0% and 6.0% by weight, with respect to the total weight of the aqueous solution of sodium silicate.
- room temperature means a temperature comprised between approximately 0 °C and + 40 °C, preferably between +15°C and + 30°C
- the aqueous solution of sodium silicate as described above is very fluid and scarcely reactive and it provides the moulding mixture containing it, i.e. to the mixture comprising the aqueous solution of sodium silicate, the powder composition, and the sand and/or other refractory material, with good flowability and a long "bench life".
- the invention therefore relates to the use of binder systems as defined above for the production of foundry cores and/or moulds.
- the moulding material mixtures which furthermore represent an object of the invention, comprising the binder systems of the invention, as defined above, together with the silica sand and/or other granular refractory material, such as zirconium sand (zirconium silicate) or chromite, are obtained by mixing silica sand and/or other granular refractory material with the aqueous solution of sodium silicate, as defined above, and subsequently adding the powder composition of the invention.
- the moulding material mixtures of the invention can be obtained by mixing silica sand and/or other granular refractory material with the powder composition of the invention and subsequently adding the aqueous solution of sodium silicate as defined above.
- the moulding material mixtures of the invention which if stored out of direct contact with the air, are usable for up to ten hours from the production thereof, comprise from 1.6 to 2.4 parts by weight of the aqueous solution of sodium silicate and from 0.5 to 1.5 parts by weight of the powder composition of the invention, as defined above, and 100 parts by weight of silica sand and/or other granular refractory material.
- said mixtures comprise from 1.8 to 2.2 parts by weight of the aqueous solution of sodium silicate and from 0.7 to 1.2 parts by weight of the powder composition of the invention, as defined above, and 100 parts by weight of silica sand and/or other granular refractory material.
- the cores and/or moulds of the invention comprise a heating step (baking) of said moulding material mixtures comprising the binder system of the invention and the silica sand and/or other granular refractory material.
- the foundry cores and/or moulds thus obtainable which furthermore represent an object of the present invention, show good strength and do not degrade during storage in humid environments.
- the moulding material mixtures of the invention are placed, either manually or by means of compressed air systems, inside a core box already heated to 150 to 200 °C and/or treated with a flow of hot air at 150 to 180 °C, which quickly hardens said mixture.
- the mixtures were prepared in the laboratory, adding first the silica sand, then the aqueous solution of sodium silicate, and finally the powder composition of the invention, using a Kitchen Aid rapid mixer (Artisan model).
- the sand and the aqueous solution of sodium silicate were mixed for 1 minute and then the powder composition of the invention was added and mixed for 1 minute.
- Standard identical bars were prepared with each one of the mixtures. Each mixture was compacted with five strokes of a Georg Fischer rammer PRA model in the individual core box and the resulting standard bars had a 5 cm 2 square breakage section.
- the bars were placed on 220 x 60 mm rectangular steel plates with a thickness of 3 mm, and were baked for 6 minutes at 260 °C in a laboratory oven.
- the bars in the first group were stored for 24 hours in a dryer, while the bars in the second group were stored for 24 hours in a climate chamber ClimaCell 111 model manufactured by MM, which was set at 25 °C with 60% of relative humidity.
- Solution A aqueous solution of sodium silicate with a density of 1.42 kg/dm 3 at 20° C, SiO 2 content of 25.77% and Na 2 O content of 11.91%, SiO 2 /Na 2 O weight ratio of 2.16 and SiO 2 /Na 2 O molar ratio of 2.23.
- Solution A dry, after 15 minutes at 650 °C had a sodium silicate content equal to 37.68%.
- Solution A1 a variant of Solution A containing additives and having the following percentage composition: Solution A 99.3% by weight of the weight of Solution A1 Sodium 2-ethylhexyl sulphate in 40% aqueous solution 0.2% 3-glycidoxypropyltrimethoxysilane 0.5%
- the sodium silicate powder used in the composition in the examples is a sodium silicate with the following chemical-physical characteristics: - SiO 2 /Na 2 O molar ratio: 3.2-3.5 - SiO 2 : 61.7-66.1 % by weight - Na 2 O: 18.0-20.3% by weight - loss on ignition, 800 ° C: ⁇ 20% by weight - average grain size: 80 ⁇ m
- the sodium aluminosilicate powder used in the composition in the examples is a sodium aluminosilicate with the following chemical-physical characteristics: - SiO 2 (on ignited substance): ⁇ 80% by weight - Al (on ignited substance): 6.0% by weight - Na (on ignited substance): 5.5% by weight - loss on ignition: ⁇ 10.0% by weight - average particle size: 7 ⁇ m
- Table 1 below provides a summary of the results obtained in Examples 1-9: Table 1 Flexural strength in N/cm 2 24 hours at 25°C, dry 24 hours at 25°C and 60% RH Mixture in Example 1. 510 90 Mixture in Example 2. 565 60 Mixture in Example 3. 500 105 Mixture in Example 4. 0 0 Mixture in Example 5. 435 430 Mixture in Example 6. 470 395 Mixture in Example 7. 510 385 Mixture in Example 8. 475 400 Mixture in Example 9. 395 360
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- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Claims (15)
- Composition de poudre comprenant de 60 à 90 % en poids de silicate de sodium ayant le numéro de registre CAS 1344-09-8 et un rapport molaire SiO2/Na2O compris entre 3,0 et 3,6, de préférence entre 3,2 et 3,5, et de 10 à 40 % en poids d'aluminosilicate de sodium ayant le numéro de registre CAS 1344-00-9, dans laquelle lesdits pourcentages sont sur la base du poids total de la composition de poudre.
- Composition de poudre selon la revendication 1, comprenant en outre des additifs.
- Composition de poudre selon la revendication 2, comprenant de 1 à 25 % en poids d'additifs, de préférence de 5 à 15 % en poids d'additifs, dans laquelle lesdits pourcentages sont sur la base du poids total de la composition de poudre.
- Composition de poudre selon l'une quelconque des revendications précédentes, dans laquelle le silicate de sodium a une taille de grain moyenne comprise entre 60 et 100 µm, de préférence entre 70 et 90 µm, et encore plus préférablement de 80 µm, et/ou l'aluminosilicate de sodium a une taille de grain moyenne comprise entre 2 et 15 µm, de préférence entre 5 et 10 µm, et encore plus préférablement de 7 µm.
- Système de liant de fonderie, comprenant la composition de poudre selon l'une quelconque des revendications 1 à 4 et une solution aqueuse de silicate de sodium ayant un rapport molaire SiO2/Na2O compris entre 1,9 et 2,5.
- Système de liant selon la revendication 5, dans lequel la solution aqueuse de silicate de sodium comprend de 25 à 50 % en poids de silicate de sodium, de préférence de 35 à 45 % en poids de silicate de sodium, et de 50 à 75 % en poids d'eau, dans lequel lesdits pourcentages sont sur la base du poids total de la solution aqueuse de silicate de sodium.
- Système de liant selon l'une quelconque des revendications 5 et 6, dans lequel la solution aqueuse de silicate de sodium comprend des additifs supplémentaires.
- Système de liant selon la revendication 7, dans lequel la solution aqueuse de silicate de sodium comprend de 0,1 à 10 % en poids d'additifs, dans lequel lesdits pourcentages sont sur la base du poids total de la solution aqueuse de silicate de sodium.
- Système de liant, selon l'une quelconque des revendications 5 à 8, dans lequel la solution aqueuse de silicate de sodium a un rapport molaire SiO2/Na2O compris entre 2,0 et 2,4, et de préférence entre 2,1 et 2,3.
- Système de liant, selon l'une quelconque des revendications 5 à 9, dans lequel la solution aqueuse de silicate de sodium a une masse volumique à 20 °C comprise entre 1,30 et 1,50 kg/dm3, de préférence entre 1,35 et 1,45 kg/dm3.
- Utilisation du système de liant selon l'une quelconque des revendications 5 à 10, pour la fabrication de noyaux et/ou moules de fonderie.
- Mélange de matériaux de moulage pour la fabrication de noyaux et/ou moules de fonderie contenant le système de liants selon l'une quelconque des revendications 5 à 10 et du sable siliceux et/ou un autre matériau réfractaire granulaire.
- Mélange de matériaux de moulage selon la revendication 12, comprenant :- de 1,6 à 2,4 parties, de préférence de 1,8 à 2,2 parties, en poids, de la solution aqueuse de silicate de sodium telle que définie selon l'une quelconque des revendications 5 à 10 ;- de 0,5 à 1,5 partie, de préférence 0,7 à 1,2 partie, en poids, de la composition de poudre telle que définie selon l'une quelconque des revendications 1 à 4 ; et- 100 parties en poids de sable siliceux et/ou un autre matériau réfractaire granulaire.
- Procédure de production de noyaux et/ou moules de fonderie, comprenant une étape de production du mélange de matériaux de moulage selon l'une quelconque des revendications 12 à 13, et une étape de chauffage dudit mélange de matériaux de moulage.
- Noyaux et/ou moules de fonderie, pouvant être obtenus selon la procédure de la revendication 14.
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CN114406181B (zh) * | 2022-01-21 | 2023-10-20 | 金耐源(河南)工业科技有限公司 | 一种温芯盒粘结剂及制备方法 |
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DE1190610B (de) * | 1956-02-27 | 1965-04-08 | Rudolf Stolle Dipl Ing | Verfahren zur Herstellung von Formen und Kernen nach dem Wasserglas-Kohlensaeureverfahren |
US3210267A (en) * | 1965-04-20 | 1965-10-05 | Socony Mobil Oil Co Inc | Catalytic cracking of hydrocarbons with the use of a crystalline zeolite catalyst containing rare earths and a porous matrix |
DD82809B1 (de) * | 1970-06-09 | 1973-06-20 | Formstoff für die herstellung von vorzugweise stahlformguss | |
US4226277A (en) | 1978-06-29 | 1980-10-07 | Ralph Matalon | Novel method of making foundry molds and adhesively bonded composites |
US5474606A (en) * | 1994-03-25 | 1995-12-12 | Ashland Inc. | Heat curable foundry binder systems |
US5743953A (en) * | 1996-12-11 | 1998-04-28 | Ashland Inc. | Heat curable alumino-silicate binder systems and their use |
GB9708831D0 (en) | 1997-04-30 | 1997-06-25 | Unilever Plc | Suspensions with high storage stability, comprising an aqueous silicate solution and filler material |
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DE102004042535B4 (de) | 2004-09-02 | 2019-05-29 | Ask Chemicals Gmbh | Formstoffmischung zur Herstellung von Gießformen für die Metallverarbeitung, Verfahren und Verwendung |
HUE029506T2 (en) * | 2006-10-19 | 2017-02-28 | Ask Chemicals Gmbh | Carbohydrate-containing molding compound |
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