1. Introduction
2. Sands of moulding mixtures: Silica sand – chemical and mineralogical composition, modification changes of SiO2, defects caused by restrained thermal expansion (scabs, veinings). Cristobalite expansion and its impact on casting quality and the collapsibility of mixtures with alkaline silicates. Non-silica sands, artificial metallic and non-metallic sands – classification, characteristics, applications, and binder selection.
3. Methods of sand evaluation. Influence of sand on the physical properties of the mixture. Structure of the moulding mixture, granulometric composition, grain size criterion, optimal ratio of two fractions, specific surface area, and angularity of sand. Porosity and permeability of the moulding mixture, the effect of compaction and dust content. Thermal-physical properties of the foundry mould. Thermal conductivity, binder selection.
4. Sand reclamation and the binding capacity of moist sands: Activation of the SiO2 surface, methods, and significance of activation. Adhesive-cohesive forces of binders. The effect of binder content on mixture degradation and reclamation. Sand reclamation – methods, procedures, properties of reclaimed sand, significance of reclamation, and its impact on the environment. Waste moulding mixtures and their utilization. Activation of synthetic resins through silanization, the effect of silanization using sands of different surface qualities (reclaimed materials).
5. Structure and properties of I. generation clay binders. Clays in natural sands, montmorillonite. Water-clay interaction, determination of optimal moisture content. Properties of bentonite (green sand) mixtures, thermal degradation. Ion exchange in bentonites and sodium activation. Homogeneous green sand mixtures (JBS) and their property control. Oolitization. Additives in moulding mixtures, lustrous carbon carriers, and their significance.
6. Chemization of mould and core production. II. generation binders – alkaline silicates, basic characteristics, colloidal solutions, modulus, density, gelation process. Water glass-based technologies. Reversible and irreversible curing processes of alkaline silicates – CO2 process, ST mixtures. Collapsibility of water glass mixtures and its solutions. Reclamation of mixtures with alkaline silicates. Ecological binder systems based on alkaline silicates, modified water glasses, geopolymers, salt cores.
7. II. generation organic-based binders. Overview of phenol-formaldehyde resin-based binders, basic classification of technologies by preparation method and curing principles (C-method, HOT-BOX, COLD-BOX resol, Alpha set, furan binders, carbohydrate binders). Preparation of coated mixtures, shell moulding. Typical casting defects, sand selection, influence of moisture. Collapsibility and reclamation of mixtures, chromite reclaimed materials, combination with HBM moulds. Issues of waste from core mixtures and development trends.
8. Binderless systems (III. generation): Magnetic mould, vacuum method, EFF-SET process, LOST FOAM. Surface protection of moulds and cores: sprays, washes, coatings. IV. generation binders.
9. History and present of cast iron production. Theoretical foundations of crystallization and structure formation of cast irons, basic types of cast iron. Iron-carbon equilibrium diagram. Influence of chemical composition and cooling rate on microstructure. Eutectic crystallization. Degree of graphite formation in cast irons. Volumetric and linear changes during cast iron solidification. Dimensioning of feeders and gating systems. Castability of cast iron casting design.
10. Classification of cast irons by graphite shape, mechanical, and physical properties. Basic types of cast irons and their industrial applications. Inoculation – thermodynamic basis of inoculation, mechanism, and methods. Modification, conditions, Mg losses. Modification technology, control methods. Alloyed cast irons and modern trends.
11. Introduction to the history of iron production up to the present. Iron-carbon equilibrium diagram. Structure of cast steels. Standards and range of cast steels. Structural cast steels. Special cast steels – corrosion-resistant. Special cast steels – wear-resistant. Volumetric changes during the solidification of cast steels, castability of cast steel designs. Modern trends.
12. Furnace units for melting cast irons and steels. Furnace linings. Charge materials, changes in the chemical composition of the charge. Principles and technology of desulfurization of cast irons and steels, dephosphorization, deoxidation of steels, holding furnaces, secondary metallurgy. Oxygen solubility in cast iron. Carbon-silicon interaction and thermal analysis of cast irons. Contemporary development trends in cast steel and cast iron production.
13. Microstructural defects of cast iron. Shrinkage cavities, microshrinkage, gas porosity, slag inclusions. Unsatisfactory mechanical and physical properties. Defects in steel castings. Causes of individual defect types and possibilities for their elimination.
2. Sands of moulding mixtures: Silica sand – chemical and mineralogical composition, modification changes of SiO2, defects caused by restrained thermal expansion (scabs, veinings). Cristobalite expansion and its impact on casting quality and the collapsibility of mixtures with alkaline silicates. Non-silica sands, artificial metallic and non-metallic sands – classification, characteristics, applications, and binder selection.
3. Methods of sand evaluation. Influence of sand on the physical properties of the mixture. Structure of the moulding mixture, granulometric composition, grain size criterion, optimal ratio of two fractions, specific surface area, and angularity of sand. Porosity and permeability of the moulding mixture, the effect of compaction and dust content. Thermal-physical properties of the foundry mould. Thermal conductivity, binder selection.
4. Sand reclamation and the binding capacity of moist sands: Activation of the SiO2 surface, methods, and significance of activation. Adhesive-cohesive forces of binders. The effect of binder content on mixture degradation and reclamation. Sand reclamation – methods, procedures, properties of reclaimed sand, significance of reclamation, and its impact on the environment. Waste moulding mixtures and their utilization. Activation of synthetic resins through silanization, the effect of silanization using sands of different surface qualities (reclaimed materials).
5. Structure and properties of I. generation clay binders. Clays in natural sands, montmorillonite. Water-clay interaction, determination of optimal moisture content. Properties of bentonite (green sand) mixtures, thermal degradation. Ion exchange in bentonites and sodium activation. Homogeneous green sand mixtures (JBS) and their property control. Oolitization. Additives in moulding mixtures, lustrous carbon carriers, and their significance.
6. Chemization of mould and core production. II. generation binders – alkaline silicates, basic characteristics, colloidal solutions, modulus, density, gelation process. Water glass-based technologies. Reversible and irreversible curing processes of alkaline silicates – CO2 process, ST mixtures. Collapsibility of water glass mixtures and its solutions. Reclamation of mixtures with alkaline silicates. Ecological binder systems based on alkaline silicates, modified water glasses, geopolymers, salt cores.
7. II. generation organic-based binders. Overview of phenol-formaldehyde resin-based binders, basic classification of technologies by preparation method and curing principles (C-method, HOT-BOX, COLD-BOX resol, Alpha set, furan binders, carbohydrate binders). Preparation of coated mixtures, shell moulding. Typical casting defects, sand selection, influence of moisture. Collapsibility and reclamation of mixtures, chromite reclaimed materials, combination with HBM moulds. Issues of waste from core mixtures and development trends.
8. Binderless systems (III. generation): Magnetic mould, vacuum method, EFF-SET process, LOST FOAM. Surface protection of moulds and cores: sprays, washes, coatings. IV. generation binders.
9. History and present of cast iron production. Theoretical foundations of crystallization and structure formation of cast irons, basic types of cast iron. Iron-carbon equilibrium diagram. Influence of chemical composition and cooling rate on microstructure. Eutectic crystallization. Degree of graphite formation in cast irons. Volumetric and linear changes during cast iron solidification. Dimensioning of feeders and gating systems. Castability of cast iron casting design.
10. Classification of cast irons by graphite shape, mechanical, and physical properties. Basic types of cast irons and their industrial applications. Inoculation – thermodynamic basis of inoculation, mechanism, and methods. Modification, conditions, Mg losses. Modification technology, control methods. Alloyed cast irons and modern trends.
11. Introduction to the history of iron production up to the present. Iron-carbon equilibrium diagram. Structure of cast steels. Standards and range of cast steels. Structural cast steels. Special cast steels – corrosion-resistant. Special cast steels – wear-resistant. Volumetric changes during the solidification of cast steels, castability of cast steel designs. Modern trends.
12. Furnace units for melting cast irons and steels. Furnace linings. Charge materials, changes in the chemical composition of the charge. Principles and technology of desulfurization of cast irons and steels, dephosphorization, deoxidation of steels, holding furnaces, secondary metallurgy. Oxygen solubility in cast iron. Carbon-silicon interaction and thermal analysis of cast irons. Contemporary development trends in cast steel and cast iron production.
13. Microstructural defects of cast iron. Shrinkage cavities, microshrinkage, gas porosity, slag inclusions. Unsatisfactory mechanical and physical properties. Defects in steel castings. Causes of individual defect types and possibilities for their elimination.