The aim of this study is the evaluation of the parameters of core mixtures using different binder systems with regard to the collapsibility of cores after casting and the resulting product quality of castings reflecting surface requirements based on non-ferrous alloys. The research compares organically bonded core mixtures based on phenol-formaldehyde resins for the production of cores with the shell molding (resin coated sand), currently used in the production of aluminum alloy castings in the Brembo Czech s.r.o., and mixtures using innovative inorganic binder systems based on geopolymers; GEOPOL^® W. The aim of the research is to compare the advantages and disadvantages of these binder systems in order to evaluate the potential of inorganically bonded mixtures to replace organically bonded mixtures, which would lead to a significant reduction in the environmental impacts of industrial production of castings.

The aim of this paper is to summarize the possibilities of foundry methods for the production of metallic foams. At present, there are a number of production technologies for this interesting material, to which increasing attention has been paid in recent years. What is unique about metallic foams is the combination of their physical and mechanical properties. As part of our research, we designed and verified four main methods of metallic foam production by the foundry technology, whose products are metallic foam castings with regular and irregular arrangements of internal cavities. All these methods use materials and processes commonly used in conventional foundry technologies. The main idea of the research is to highlight such technologies for the production of metallic foams that could be provided by manufacturing companies without the need to introduce changes in production. Moreover, foundry methods for the production of metallic foams have the unique advantage of being able to produce even complex shaped parts and can thus be competitive compared to today’s established technologies, the output of which is usually only a semi-finished product for further processing. This fact was the main motivation for the research.

In the foundry industry, silica sands are the most commonly used type of sands for the production of sand foundry moulds using various types of binders. Their greatest disadvantage is their significant volume changes at elevated temperatures, which are associated with the formation of many foundry defects from stress, such as veining, and thus have a direct influence on the final quality of the casting. In the case of non-silica sands and synthetic sands, the volume stability is more pronounced, but this is accompanied by a higher purchase price. Therefore, a combination of silica sand and synthetic sand CERABEADS is considered in order to influence and reduce the thermal expansion. The hybrid mixtures of sands, and their most suitable ratios, were evaluated in detail using sieve analysis, log W and cumulative curve of granularity. It was found that the addition of 50% CERABEADS achieves a 32.2% reduction in dilatation but may increase the risk of higher stresses. The measurements showed a significant effect of the granulometric composition of the sand on the resulting thermal expansion, where the choice of grain size and sorting can achieve a significant reduction in dilatation with a small addition of CERABEADS.

Satisfactory tensile properties, even at elevated temperatures, are very important for thermally stressed parts in car structures (e.g. cylinder heads and engine blocks). This condition is satisfied also by magnesium-based alloys containing st...

The constant effort of all metal alloy manufacturing technologies and processes is to improve the resulting quality of the processed part. Not only the metallographic structure of the material is monitored, but also the final quality of the cast surface. In foundry technologies, in addition to the quality of the liquid metal, external influences, such as the behaviour of the mould or core material, significantly affect the cast surface quality. As the core is heated during casting, the resulting dilatations often lead to significant volume changes causing stress foundry defects such as veining, penetration and surface roughness. In the experiment, various amounts of silica sand were replaced with artificial sand and a significant reduction in dilation and pitting of up to 52.9% was observed. An important finding was the effect of the granulometric composition and grain size of the sand on the formation of surface defects from brake thermal stresses. The specific mixture composition can be considered as an effective prevention against the formation of defects instead of using a protective coating.