Experimental Study and Drying Kinetics Modeling of an Alkali-Activated Sand-Based Porous Medium, Application to Drying of Inorganic Foundry Cores
Résumé
In the production of cast aluminum automotive parts, cores made of sand and binders are often used to create the complex features that cannot be formed by the mold, such as internal passages. Core binders can be grouped into two different categories: organic and inorganic, depending on the binder system used. Conventional organic binders use petroleum-based materials that are sources of harmful gases. In contrast, inorganic binders such as sodium silicates (water glass) are environmentally friendly. The fabrication of inorganic cores requires a drying step that involves thermal dehydration (using hot box and hot air injection) and chemical reactions (polymerization) to give the sand core the necessary strength to withstand the constraints developed during core storage and the casting process. This drying step increases the duration of the process and affects the production line. This study evaluated different thin layer drying models to understand the drying behavior of sand cores in the inorganic process that uses both hot air and warm box. The Page model was found to best describe the drying kinetics based on experimental measurements on a rectangular core. The sorption properties of the core were determined by characterizing the desorption isotherms at three different temperatures. The energy required to remove water from the core was estimated and it is found that the highest energy reached a theoretical maximum at a box temperature of around 135 °C.