Effects of Composition on the Physical Properties of Water-Soluble Salt Cores

Abstract

The demand for producing essential cast parts and the design requirements for superior engineering performance have increased in recent years. Sand cores used in conventional aluminum cast parts are harmful to the environment, which limits their application. Utilizing water-soluble cores in the aluminum casting industry is expected to be an environmentally friendly approach due to recyclability of the salt cores. In this study, water-soluble salt cores were made from chloride- and/or carbonate-containing salts in various amounts. The salts were melted and cast into steel molds to obtain salt cores. The salt cores were subjected to three-point bending tests to determine their mechanical strength, the melting points were determined with thermal analyses, and the water solubility was measured at room temperature and 50 °C. A maximum bending strength of 17.19 MPa, a maximum melting point of 776 °C and a maximum water solubility of 89 g salt/100 ml water were obtained for the samples with compositions of 75% KCl–25% K2CO3 and 25% Na2CO3–75% K2CO3, respectively. Fractographs of the samples used in bending tests were taken by a still camera in macro mode, and from these fractured surfaces, scanning electron microscopy studies were performed. The X-ray diffraction pattern of the sample exhibiting optimal properties (28.3% Na2CO3 and 71.7% K2CO3) also showed that K2CO3, NaKCO3 and KNaCO3 phases were present in the structure, as expected. An actual casting process with aluminum die casting of an automotive part was also performed. The diecast aluminum part was subjected to a leak-proof test, and X-ray images were used to check for porosity in the part.