ISSUE 2/2011

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Pabel, T.; Kneißl, C.; Schumacher, P.; Brotzki, J.; Müller, J.
Improved properties of aluminium cast parts through the use of inorganic cores

When foundries become interested in inorganic mould or core manufacturing methods, this is usually motivated by the possibility of reducing emissions. In fact, the use of inorganic binder systems is not only beneficial to the environment. For instance, advantages in productivity and quality can also be seen in application for series production. The use of the Inotec inorganic binder system not only increases tool availability, e. g. by reduced cleaning intervals for the core box and die mould, but also significantly reduces the cleaning costs for castings, where condensation e. g. of phenol binders is a key factor. However, one crucial observation was that castings manufactured using the Inotec method show less porosity. This was the starting point for a large-scale project in which the impact of the inorganic binder system on the material properties of typical cylinder head and block alloys were examined. Comprehensive series of investigations were designed in collaboration between Ashland-Südchemie-Kernfest GmbH, Hilden, Germany, and the Austrian Foundry Research Institute in Leoben, Austria. In addition to the simulation and construction of the tool developed specially for this Investigation, consisting of a core box and gravity die casting mould, metallographic examinations and the determination of static and dynamic material testing was also performed. The casting trials were conducted with Inotec cores and cold-box cores simultaneously,and the results were assessed in a comparative manner.

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