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Full-Scale Air Emissions Monitoring and Casting Quality Demonstration of a Hybrid Hydrolyzed Collagen–Alkali Silicate Core Binder

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Abstract

When comparing a novel collagen and alkali silicate core binder system to a conventional phenolic urethane binder system during full-scale trials, the phenolic urethane incurred a 33.3 % higher emissions rate than did the novel binder system. This was chronicled during several hours of stack tests in a full-scale trial demonstration of 3500 novel cores at a high-volume automotive ductile iron foundry. Baseline phenolic urethane emissions were determined immediately prior to running the collagen and alkali silicate cores, when making an identical casting. Approximately 10 % of the demonstration iron castings were inspected for defects, of which none (0 %) were scrapped on account of core-related defects. Also, the novel core’s shakeout was complete. These favorable results were achieved with humidity-free storage of the cores over the 10 days that the cores were made. These novel demonstration cores required somewhat longer curing time in the core-making machine, than did conventional phenolic urethane cores; and this curing rate was influenced by air flow and pressure into the core box. Also, tensile specimen tests of the collagen and alkali silicate-adhered system were higher than that of the conventional phenolic urethane system. When exposed to high humidity levels (80–95 % relative humidity) for prolonged periods of time (10 days), the collagen and alkali silicate-adhered tensile specimens degraded in terms of tensile strength and scratch hardness. These losses mostly rebounded when the tensile specimens were re-dried.

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Notes

  1. Collagen supplied by Entelechy.

  2. Tensile strength by Simpson Gerosa Universal Sand Strength Machine. Scratch hardness by Dietert scratch hardness tester.

  3. Mixing in a TinkerOmega Mega Mixer with high-speed mixer.

  4. Alkali silicate solution was Cast Clean Binder #1 by J.B. DeVenne, Inc.

  5. Core making machine by Harrison Machine Company. Super heater system by Furness-Newburge, LLC.

  6. Green sand molding system was by DISAmatic™.

  7. Stack testing by ARCADIS U.S., Inc. Branchburg, NJ.

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Acknowledgments

This research was funded in part by Ben Franklin Technology Partners and another part by the National Science Foundation 1338710. Additional facility support was provided by Hitachi Metals Automotive Components and technology support was provided by Furness-Newburge, Inc. Those assisting in the preparation of the cores include Zilong Zhao, Moses Ajemigbitse, Colin Cash, and Mike Morgan of Penn State; and Steve Sheetz and Alex Zook of Lehigh University. Important input from several industry personnel is also acknowledged: Jim Furness and Dave Paulsen of Furness-Newburge; Pat Farver and Dave Kidder of Harrison Machine Company, Bryan Bucklen, Bob Harter, Andrew Franks, Marty Heffner, Bob Miller, Brian Widener, and Darrin Steadman of HMAC foundry, Jim DeVenne of J.B. DeVenne and Associates; Paul Jacobson of Cross Creek Innovations, Larry Seibert of Ben Franklin Technology Partners, Mark S. Utter, Peter Marshall, and Jonathan S. Sobel of Arcadis U.S., Inc., Tom Weber and Brad Mallow of Avogadro Environmental Corporation.

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Authors and Affiliations

  1. The Pennsylvania State University, University Park, PA, USA

    Joshua F. Allen, Fred S. Cannon, Cesar Nieto-Delgado & Robert C. Voigt

  2. Lehigh University, Bethlehem, PA, USA

    John T. Fox

  3. Hitachi Metal Automotive Components, Lawrenceville, PA, USA

    Jim Lamonski

  4. ARCADIS U.S. Inc., Branchburg, NJ, USA

    John D. Kirby

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  1. Joshua F. Allen
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Correspondence to Joshua F. Allen.

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Allen, J.F., Cannon, F.S., Nieto-Delgado, C. et al. Full-Scale Air Emissions Monitoring and Casting Quality Demonstration of a Hybrid Hydrolyzed Collagen–Alkali Silicate Core Binder. Inter Metalcast 10, 172–189 (2016). https://doi.org/10.1007/s40962-016-0021-y

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