Feasibility Study on Using Fly Ash Used as Part of Mold Sand in Furan Sand Molds

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Project title

Code/計畫編號

MOST106-2221-E019-031

Translated Name/計畫中文名

?喃砂模使用飛灰作為部分模砂之可行性研究

Project Coordinator/計畫主持人

Shuei-Wan Juang

Funding Organization/主管機關

National Science and Technology Council

Department/Unit

Department of Mechanical and Mechatronic Engineering

Website

https://www.grb.gov.tw/search/planDetail?id=12237846

Year

2017

Start date/計畫起

01-08-2017

Expected Completion/計畫迄

01-07-2018

Bugetid/研究經費

870千元

ResearchField/研究領域

機械工程

"飛灰為火力發電廠之燃煤廢棄物，研究發現飛灰具有廢物再利用的價值，例如土壤的穩定性、瀝青或混凝土的摻料、鋁基飛灰（ALFA, Aluminum Fly Ash）複合材料的產品等，以達到減廢的循環經濟模式。而飛灰中的三種主要成分，即氧化矽(SiO2)、氧化鋁(Al2O3)及氧化鐵(Fe2O3)，適合做為濕砂模或呋喃模的模砂，可有效增加砂模的耐火性、熱傳導性，並降低膨脹壓力，防止燒結點及氣孔疵病之產生。本計畫旨在利用田口法探討添加飛灰對提升呋喃模耐火性及避免產生鑄件砂孔、燒結等缺陷之可行性研究。研究方法係以不同比率（介於0~12 wt%）之飛灰加入不同粒徑（約0.16 ~1.18 mm）之矽砂中，使用相對於砂重不同比例（3~7 wt%）之呋喃樹脂及45 wt %之硬化劑（相對於樹脂重）添加至不同粒徑矽砂中混練後，倒入預置的標準試片模具內成形，待分別反應4~30 hrs 後，再分別以40~120 oC 烘烤20~100 mins。使用田口法探討不同比率飛灰、不同比率呋喃樹脂、不同粒徑矽砂及不同烘烤溫度與時間對呋喃砂模之抗壓強度、透氣性、表面安定性之影響及以飛灰混入砂模對於砂模耐火性之分析，藉以提升砂模鑄件外觀及功能性。預期以上實驗將能有效提升砂模耐火性，並大幅降低製程上之成本。" "Fly ash is a coal-fired waste from thermal power plants. Fly ash has been found to be valuable for recycling, such as soil stability, asphalt or concrete admixtures, aluminum-based fly ash (ALFA) composites Products, etc., to achieve waste recycling economy model. Three major compounds in the fly ash, namely SiO2, Al2O3 and Fe2O3, are suitable for molding sand used in green sand mold or Furan mold, which can effectively increase the fire resistance as well as thermal conductivity of sand molds, and reduce the expansion pressure to prevent the defects of sintering and pore flaw. The aim of this project is to explore the feasibility of adding fly ash to improve the fire resistance of Furan mold and to avoid the defects such as pore hole and sintering. The method was carried out by adding fly ash of different particle sizes (about 0.16 to 1.18 mm) in different ratios (0 to 12 wt%), using 3 to 7 wt% in different ratios of Furan resin with respect to sand weight and 45 wt.% hardener (relative to resin weight) were added to different sizes of silica sand and kneaded. The mixture was poured into a preset standard specimen mold and allowed to react for 4 to 30 hrs. Then baked at 40 ~ 120 oC for 20 ~ 100 mins. Taguchi method was used to investigate the effects of different ratios of fly ash, Furan resin, silica sand with different particle size and different baking temperature and time on compressive strength, permeability and surface stability and fire resistance of Furan molds, to enhance the appearance and function of sand castings. The above experiment is expected to effectively enhance the fire resistance sand mold and significantly reduce the cost of the process."

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Feasibility Study on Using Fly Ash Used as Part of Mold Sand in Furan Sand Molds

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