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Foundry Molds and Molding mixtures

* Exchange students do not have to consider this information when selecting suitable courses for an exchange stay.

Course Unit Code618-2022/02
Number of ECTS Credits Allocated5 ECTS credits
Type of Course Unit *Compulsory
Level of Course Unit *First Cycle
Year of Study *Third Year
Semester when the Course Unit is deliveredWinter Semester
Mode of DeliveryFace-to-face
Language of InstructionCzech
Prerequisites and Co-Requisites Course succeeds to compulsory courses of previous semester
Name of Lecturer(s)Personal IDName
BEN001Ing. Jaroslav Beňo, Ph.D.
The subject is focused on theoretical and practical aspects of moulding mixtures manufacture and control. The attention is devoted to mutual interaction of sand – binder system and to individual technologies of moulds and cores manufacture.
General methods of testing and control of moulding mixtures is also presented here.
Learning Outcomes of the Course Unit
Acquired knowledge:
- student will be able to characterize individual technologies for molding and core mixture manufacture
- student will be able to define basic methods for testing of molds and cores mixtures together with their regulation based on their physical – chemistry and technological properties.

Acquired skills:
- student will be able to predict mutual interactions of sand – binder system
-student will be able to apply their theoretical knowledge in order to control quality of molding mixture in relation to selected technology
Course Contents
1. Moulding and core mixtures. Basic components of moulding mixtures, their definition and classification. Basic characterization and division of sands. Evaluation of quality of natural and artificial sands
2. Silica sands, physical – chemistry properties, disadvantages of silica sands and their elimination
3. Artificial sands. Classification, general characterization and possibility of their utilization. Structure of moulding mixture. Porosity and permeability of moulding mixtures
4. Thermo-physical properties of moulding mixtures. Specific surface area, methods of its determination, Coefficient of angularity and its influence on technological properties of moulding mixture
5. Activation of sand grains. Reclamation of sands, methods and evaluation of quality reclaim
6. Binder systems of the I.-IV. Generation, general characterization. Clay binders of foundry technology. Role of water in clay minerals. Bentonites
7. Activation of bentonites. Changes of bentonite binder after thermal exposition. Control of green sand systems
8. Additives of green sand system. Carriers of Pyrolysis Carbon. Other additives of green sand systems.
9. Chemicization of mould and core manufacture. Binder system of the II. Generation – alkali silicates, general characterization. Methods and principles of alkali silicates curing
10. CT – and ST – mixtures with alkali silicates. CO2 – process. Self-setting mixtures with liquid hardeners. Problems with collapsibility of mixtures with water glass
11. Binder systems of the II. Generation based on organic resins. Moulding and cores mixtures based on phenol – formaldehyde resins. Croning method. HOT-BOX method and its versions. Gisag COLD-BOX method (No - bake )
12. Moulding and cores mixtures based on furan resins. Self-settings mixtures with catalyst. Self-hardening mixture (SO2 – process), Resol – CO2 process
13. Chemistry of polyurethane binders. Alkyd-oil polyurethanes. Phenol polyurethanes. Methods of core manufacture PUR COLD-BOX, PEP-SET. Saccharide binders and additives.
14. Binders systems of the III. And IV. Generation, application of physical and biological ways of binding for mould manufacture.
Recommended or Required Reading
Required Reading:
Sand Binder Systems III - XIII. Foundry Management and Technology. Cleveland:Penton, 1995, roč. 124. ISSN 0360-8999
Mold & core test handbook. 3rd ed. Des Plaines: American Foundry Society, c2001-2006. ISBN 0-87433-228-1.
JELÍNEK, Petr. Pojivové soustavy slévárenských formovacích směsí : chemie slévárenských pojiv. Ostrava: OFTIS, 2004. ISBN 80-239-2188-6.
JELÍNEK, Petr. Disperzní soustavy slévárenských formovacích směsí: Ostřiva. Ostrava: OFTIS, 2000. ISBN 80-238-6118-2.
Slévárenství. Brno: Svaz sléváren ČR, 2000-, roč.47-. ISSN 0037-6825
Mold & core test handbook. 3rd ed. Des Plaines: American Foundry Society, c2001-2006. ISBN 0-87433-228-1.

Recommended Reading:
GOODRICH, George M., ed. Iron castings engineering handbook. Rev. and repr. Schaumburg: American Foundry Society, 2006. ISBN 0-87433-260-5.
ELBEL, Tomáš. Vady odlitků ze slitin železa: (klasifikace, příčiny a prevence). Brno: MATECS, 1992.
GOODRICH, George M., ed. Casting defects handbook: iron & steel. Schaumburg: American Foundry Society, c2008. ISBN 978-0-87433-314-5.
Planned learning activities and teaching methods
Lectures, Individual consultations, Tutorials
Assesment methods and criteria
Task TitleTask TypeMaximum Number of Points
(Act. for Subtasks)
Minimum Number of Points for Task Passing
Credit and ExaminationCredit and Examination100 (100)51
        CreditCredit30 15
        ExaminationExamination70 36