Moulding Materials and Ecology (FSI-PFM)

Academic year 2021/2022
Supervisor: prof. Ing. Milan Horáček, CSc.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The aim of the course is to familiarise students with chemical and mechanical properties of moulding materials, which will be applied in other courses on technologies. The course will extend the knowledge of basic kinds of binders and sands,as well as principles of recycled waste sands.
Learning outcomes and competences:
Students will gain experience in the physical and chemical hardening of moulding sands,and will be made familiar with the problem of the influence of moulding sands on the environment in foundry shops and waste deposits.
Prerequisites:
Students are expected to be familiar with following: Basic mineralogy, organic and inorganic chemistry, heat transfer, fluidity and filtration of gaseous media, interaction between melt and foundry mould.
Course contents:
The course gives an integral overview of the properties of moulding materials, sand and binder types, ceramic moulding materials, principles of recycling the moulding mixtures and the application of recycled mixtures. Also dealt with subjects of green sand moulding with a bentonite binder, sodium silicate sands, sand with synthetic resins, hot box and cold box systems, moulding sands with biogenic binders on the base of proteins. For individual technologies their effects on the environment are discussed.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.
Assesment methods and criteria linked to learning outcomes:
Attendance in lectures is recommended, attendance in exercises is obligatory.
Credit for exercises: semestr project - obligatory
Examination : written and oral exam.
Controlled participation in lessons:
Attendance at laboratory seminars is compulsory. Absence from 3 seminars may be compensated for.
Type of course unit:
    Lecture  13 × 3 hrs. optionally                  
    Laboratory exercise  13 × 2 hrs. compulsory                  
Course curriculum:
    Lecture Properties of moulding sands
Dispersal of sands grains
Moulding sands with clay binders
Cement sands
Ceramic sands
Plaster sands
Moulding sands with sodium silicates
Moulding sands with resin binders
Moulding sands with oil bindres
Moulding sands with polysacharides
Coating materials for moulds and cores
Recycling of moulding sands
Safety and working condition with moulding materials
    Laboratory exercise The way of a grain size determination,integral curve of grains, Stokes law, etc. Testing of bentonite sands - green sands properties, compactibility properties, influenced bentonite sands after contacts with fluid metals. Technological properties of sodium silicate sands, CO2 process, Ester hardening process, dicalcium silicate process, FeSi process. Plasters moulding sands for Art casings. Polycondensation of urea-formaldehyde resins in acid environment, selfhardening furane sands, Cold Box system catalysed with di/triethylamine,interaction on the interface mould/metal.
Literature - fundamental:
1. Lewandowski J.L: Tworzywa na formy odlewnicze, , 0
2. Kolektiv: Formstoffe und Formverfahren in der Giesereitechnik, , 0
3. Kolektiv: Operating guide to high-density molding, , 0
4. Rusín,K: Formovací materiály a směs
Literature - recommended:
1. Rusín K.: Slévárenské formovací materiály, , 0
2. Jelínek P.: Slévárenské formovací směsi a materiály, , 0
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
N-SLE-P full-time study --- no specialisation -- Cr,Ex 7 Compulsory 2 1 W