The article aims to verify the possibility of obtaining an organic–inorganic material acting as both a binder and a lustrous carbon carrier in bentonite-bonded molding sands. Due to the wide industrial application, organoclays can be considered as innovative materials supporting the foundry technology in meeting environmental requirements. In this study, the organic modification of montmorillonite in calcium bentonite (SN) was performed by poly(acrylic acid) (PAA) and its sodium salt (PAA/Na). Additionally, for the purpose of comparison, the sodium-activated bentonite/poly(acrylic acid) (SN-Na/PAA) composites were also prepared. The collective analysis of the research results used in the assessment of the mineral/polymer interaction mechanism indicates surface adsorption combined with the intercalation of PAA monolayer into the mineral interlayer spaces. Materials were characterized by the combination of Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), Brunauer–Emmett–Teller (BET) surface area analysis and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) methods. Based on the XRD analysis, the influence of PAA/Na on the aluminosilicate layered structure was found to be destructive, which may adversely affect the binding properties of SN/PAA/Na composites considered as a potential group of new foundry binders. The SN/PAA and SN-Na/PPA composites (with appropriate polymer content) can act as a binding agent in the synthetic molding sand technology, despite coating the bentonite particles with polymer molecules. The risk of losing the mineral′s binding capacity is reduced by the good binding properties of pol(acrylic acid) itself. The article is the first stage (preceding the thermal analysis and the strength tests of molding sands with the prepared organobentonites) in determining the possibility of obtaining a new full-value foundry binder in molding sands with bentonite.

This paper presents results of thermoanalytical and structural research on phenolic binder used in foundry for the preparation of moulding sand. The binder has been prepared based on resole type phenolic resin with the addition of ester hardener. The aim of the study was to determine the structural changes taking place in the phenolic binder under the influence of temperature. Results show that in the investigated range of temperatures, phenolic binder exhibits three exothermic thermal effects accompanying the decomposition process. The test results using the Diffuse Reflectance Infrared Fourier Transform Spectroscopy (DRIFTS) technique show that the addition of a hardener stabilizes the binder structure within methylene bridges. The reduction in the reaction rate observed in the DTA curve at about 330 °C can be associated with the formation of gaseous products by decomposition of the binder or, as suggested by the literature data, the formation of triple bonds and CN-HCN groups.

An attempt has been made to determine the effect of an addition of colloidal suspensions of the nanoparticles of magnesium oxide on the structure of water glass, which is a binder for moulding and core sands. Nanoparticles of magnesium oxide MgO in propanol and ethanol were introduced in the same mass content (5wt.%) and structural changes were determined by measurement of the FT-IR absorption spectra.