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Magnet Assisted Composite Manufacturing: A Flexible New Technique for Achieving High Consolidation Pressure in Vacuum Bag/Lay-Up Processes

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Fast-Setting Permeable Alkyd/Polyester Composites: Moulding Sands.

Wojciech Voytek S Gutowski^1,2, Andrzej K Błędzki²

¹Faculty of Science, The University of Melbourne, Parkville, VIC 3010, Australia.

|December 28, 2021

Summary

High-performance alkyd and polyester resins were developed for large castings, offering controlled properties and enhanced thermal resistance. This advanced binder technology minimizes defects and reduces binder content in moulding sands.

Keywords:

alkyd/polyester composites controlled cure core-/mould-making mixtures furan heavy castings industrial production low-gas emission moulding sands thermal stability

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Area of Science:

Materials Science
Polymer Chemistry
Foundry Technology

Background:

Development of high-performance binders is crucial for manufacturing large-size/complex-shape castings.
Existing alkyd and polyester resins have limitations in thermal stability and process control.
Heavy industry casting demands materials with specific properties like controlled strength development and high thermal resistance.

Purpose of the Study:

To develop high-performance alkyd and polyester resins for permeable composite materials in heavy casting.
To optimize resin crosslinking kinetics, shelf-life, thermo-mechanical stability, and gaseous emission.
To achieve defect-free castings with minimized binder content.

Main Methods:

Extensive research on alkyd and polyester resin formulations.
Optimization of crosslinkers and catalysts for composite materials.
Testing of material properties including shelf-life, stripping time, compressive strength, tensile strength, and thermal resistance.

Main Results:

Optimized formulations provide flexible control over material properties (shelf-life: 10-120 min, stripping time: 10 min-24 h).
Achieved compressive strength of 4-6 MPa (10-12 MPa post-cure) and tensile strength up to 3 MPa (post-cure).
Developed moulding sands exhibit thermal resistance up to 345 °C, exceeding commercial materials (280 °C), with a 2-3 times longer onset of thermal decomposition.

Conclusions:

The developed alkyd and polyester resin technology enables defect-free casting of heavy components.
Binder content was minimized to 1.2-1.5% for quartz and 1.2% for zirconium or chromite sand.
The technology offers superior thermo-mechanical stability and controlled processing for demanding industrial applications.