Skip to main content
SpringerLink
Log in

Development and Evaluation of a New Eco-friendly Sodium Silicate-Based Binder System

  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

Although sand systems containing Na-silicate binder present several environmental and economic advantages, technological applications are restricted due to their poor knock-out properties and low moisture resistance. Thus, many investigations have been performed recently to eliminate these undesirable handicaps of Na-silicate binder. In this study, the technological importance of a recently developed Na-silicate binder with a liquid hardener and its applicability in a mold/core system have been investigated. Further, a casting trial of a tank rear idler wheel has been performed by using the molds prepared with the current Na-silicate binder, and the observations have been evaluated. It has been determined that using Na-silicate binder results in more important advantages and benefits such as shorter period (10 s) for CO2 application, sound mold surface without cavity, good gas permeability, long shelf-life at high moisture environment (90% moisture at 23 °C for 24 h), and achieving silica sand-based mold/core systems with superior shakeout property than that of the conventional ones. It has been observed that the preparation of molds with the current Na-silicate binder hardened by CO2 process and the liquid Na-silicate hardener provides a practically odorless and fast process, and outstanding casting quality during the trials.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6

Similar content being viewed by others

References

  1. D. Warren, Br. Foundrym. 64(12), 52–56 (1971)

    Google Scholar 

  2. F. Czerwinski, M. Mir, W. Kasprzak, Int. J. Cast Metal Res. 28(3), 129–139 (2015)

    Article  CAS  Google Scholar 

  3. D. Drożyński, A. Bobrowski, M. Holtzer, Arch. Foundry Eng. 15(1), 138–142 (2015)

    Article  Google Scholar 

  4. G. Gigante, Int. J. Met. (2010). https://doi.org/10.1007/BF03355494

    Article  Google Scholar 

  5. M.B. Parappagoudar, D.K. Pratihar, G.L. Datta, Mater. Manuf. Process. 23, 59–67 (2009)

    Google Scholar 

  6. S. Robert E, W. Robert J, U.S. Patent No. 2, 765, 507, 9 Oct 1956

  7. H. E. Bergna, U.S. Patent No. 4, 316, 744, 23 Feb 1982

  8. M.A. Boyle, C.J. Martin, J.D. Neuner, in Neuner, in Epoxy Resins, ed. by B. Miracle, S.L. Donaldson (ASM International, Materials Park, 2001), p. 78

    Google Scholar 

  9. J.A. Heth, in Safety and Health Issues, ed. by S.T. Peters (Chapman & Hall, London, 1998), p. 832

    Google Scholar 

  10. R.K. Ohdar, P.T. Pushp, J. Eng. Manuf. (2003). https://doi.org/10.1243/095440503321628152

    Article  Google Scholar 

  11. F. Zitian, H. Naiyu, D. Xuanpu, Int. J. Cast Met. Res. 17(1), 51–56 (2004)

    Article  Google Scholar 

  12. R.M. Andrade, S. Cava, S.N. Silva, L.E.B. Soledade, C.C. Rossi, E.R. Leite, C.A. Paskocimas, J.A. Varela, E. Longo, J. Mater. Process. Technol. 159(1), 125–134 (2005)

    Article  CAS  Google Scholar 

  13. V. LaFay, Int. J. Met. (2012). https://doi.org/10.1007/BF03355530

    Article  Google Scholar 

  14. H.G.F. Kunsmann, AFS Trans. 79, 488–492 (1971)

    Google Scholar 

  15. S. A. Barker, N. Baggett, J. Stevenson, D. R. deCourcy, U.S. Patent No. 4,504,314, 12 Mar 1985

  16. W. Schumacher, AFS Trans. 63, 488–492 (1955)

    Google Scholar 

  17. H. Chang, E.L. Chen, R. Lindeke, AFS Trans. 96, 217–222 (1988)

    CAS  Google Scholar 

  18. W. Jina, F. Zitian, Z. Xiaolei, P. Di, China Foundry 6(3), 191–196 (2009)

    Google Scholar 

  19. L. Zaretskiy, Int. J. Met. (2016). https://doi.org/10.1007/s40962-015-0005-3

    Article  Google Scholar 

  20. L. Zaretskiy, Int. J. Met. (2017). https://doi.org/10.1007/s40962-017-0155-6

    Article  Google Scholar 

  21. Ala-Merset, Characterization Study of Casting Binders Information Sheet 26052015 (Alazan Casting Chemicals & Industry Metal Inc. Co., Kocaeli, Turkey, 2015)

  22. W.H. Moore, W.E. Gruver, Jr., U.S. Patent No. 2,883,723, 28 Apr 1959

  23. R.H. Cooper, U.S. Patent No. 3,230,099, 18 Jan 1966

  24. J.R. Brown (ed.), Foseco Ferrous Foundryman’s Handbook (Replika Press Pvt Ltd, Delhi, 2000), pp. 204–215

    Google Scholar 

  25. M. Holtzer, D. Drożyński, A. Bobrowski, W. Plaza, Arch. Foundry Eng. 14(1), 37–40 (2014)

    Article  Google Scholar 

  26. T.V.R. Rao, Metal Casting: Principles and Practice, 5th edn. (New Age International, New Delhi, India, 2010)

    Google Scholar 

  27. https://en.wikipedia.org/wiki/Permeability (foundry_sand). Accessed 25 May 2017

  28. R.E. Melcher, F.W. Schaefer, U.S. Patent No. 4,131,476, 26 Dec 1978

  29. GF Sand Testing Equipment Catalog, George Fischer Limited, Schaffhausen, Switzerland

  30. N. D. Miller, Patent WO1995015229 A1, 8 Jun 1995

Download references

Acknowledgements

Alazan Casting Chemicals & Industry Metal Inc. Co. is gratefully acknowledged for permission to publish this work. Corresponding author would like to thank the Editor and Reviewers of the International Journal of Metalcasting due to their highly valuable critical comments. Authors are also grateful to Anadolu Steel Casting Inc.Co., Kocaeli, Turkey, for their help during the casting trials of this study.

Author information

Authors and Affiliations

  1. Metallurgical and Materials Engineering Department, Istanbul Technical University, 34469, Maslak, Istanbul, Turkey

    Necip Ünlü

  2. Alazan Casting Chemicals and Industry Metal Inc. Co., 41400, Gebze, Kocaeli, Turkey

    Ahmet Odabaş

Authors
  1. Necip Ünlü
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ahmet Odabaş
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Necip Ünlü.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ünlü, N., Odabaş, A. Development and Evaluation of a New Eco-friendly Sodium Silicate-Based Binder System. Inter Metalcast 12, 765–771 (2018). https://doi.org/10.1007/s40962-018-0210-y

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40962-018-0210-y

Keywords

Search

Navigation