Pressure Casting Research Articles

Plastic Injection Molding Process Analysis: Data Integration and Modeling for Improved Production Efficiency

This paper presents a comprehensive analysis of the plastic injection molding process through the integration of data acquisition technologies and classification models. In collaboration with a company specializing in plastic injection, data were extracted directly from the machine during a specific period at the beginning of a shift change. These data were subjected to exploratory analysis to identify correlations between important variables, such as injection time, cycle time, and mold pressures. Additionally, classification models, including Random Forest and Logistic Regression, were constructed to predict and classify the process state based on these variables. The model results demonstrated high predictive performance, with 99.5% accuracy for Random Forest and 97% for Logistic Regression. These results provide a strong foundation for the early identification of potential problems and informed decision making to improve the efficiency of the plastic injection molding process. This study contributes to the advancement of the integration of intelligent technologies in industrial process optimization, aligned with the principles of Industry 4.0.

The Effect of Process Parameters on the Pore Structure of Lotus-Type Porous Copper Fabricated via Continuous Casting

The pores in lotus-type porous copper are formed due to the difference in hydrogen solubility between the liquid and solid phases of copper. In a pressurized hydrogen atmosphere, hydrogen gas is released at the gas release and crystallization temperature, which is the melting point of copper. This study systematically analyzes the effects of process parameters, including hydrogen ratio, total pressure, and continuous casting speed, on the pore structure of lotus-type porous copper, with the aim of identifying the most critical process parameters for controlling pore diameter and density. Within the hydrogen ratio up to 50%, it was observed that as the hydrogen ratio increases, the pores tend to increase in porosity, and the pore diameter increases. As the hydrogen ratio increased from 25% to 50%, the pore diameter increased from 300 μm to 400 μm, while the pore density decreased from 3.3 N·mm−2 to 2.8 N·mm−2. As the total pressure increased, the pore diameter tended to decrease, and the pore density increased. Specifically, when the total pressure increased from 0.2 MPa to 0.4 MPa, the pore diameter decreased from 1100 μm to 400 μm, while the pore density increased significantly from 0.5 N·mm−2 to 2.8 N·mm−2. In addition, as the continuous casting speed increased, 30 to 90 mm·min−1, the pore diameter decreased from 850 μm to 400 μm, and the pore density increased from 0.7 N·mm−2 to 2.8. N·mm−2. Specifically, the increase in total pressure led to a decrease in Gibbs free energy and a reduction in the critical pore nucleation radius, which promoted pore formation and resulted in the creation of more, smaller pores. These results suggest that total pressure is the primary factor influencing both pore diameter and density in lotus-type porous copper.

Tribological properties and related effects of compressed, thermally modified and wax-impregnated wood

AbstractThis paper develops a process for the preparation of modified wood with low friction and low wear for tribological applications such as self-lubricating bearings. Two types of wood, beech (Fagus sylvatica) and robinia (Robinia pseudoacacia), have been studied and the results compared with naturally lubricated native lignum vitae. The process developed consists of plasticisation followed by compression in a mould, thermal modification and subsequent wax impregnation. Plasticisation was carried out by conditioning the samples to a low equilibrium moisture content of 10%, followed by heating to a sample core temperature of 80 °C. This process protects the internal wood structure from mechanical damage during densification. After plasticisation, the wood was compressed in a press mould. A low springback effect (SBE), resulting in compression of up to 40%, was achieved by unloading the mould without opening it. This step optimises compressive strength and hardness. Subsequent heat treatment reduces thickness swelling by up to 85%. Finally, a wax impregnation was applied to reduce friction. Sliding wear tests on modified beech wood have shown that the lowest wear occurs in the cross-sectional orientation (load perpendicular to the fibre ends; rxt orientation). Sliding friction studies using a steel ball on a ball-on-disc tribometer showed that compressed and thermally modified samples impregnated with rapeseed wax or beeswax exhibited coefficients of friction in a range of 0.08 to 0.09. These values are almost four times lower than those of plain compressed wood and even lower than those of lignum vitae, which was used for plain bearings decades ago. This study clearly demonstrates the high potential of compressed, thermally modified and wax-impregnated wood.

Moulding Test and Process Parameter Optimization of Biomass Seedling Pots for Cow Dung and Corn Stover

In order to determine the optimal moulding process parameters of biomass seedling pots prepared from fermented cow dung mixed with corn stover, the moulding pressure, baking time, and baking temperature of biomass seedling pots were taken as the influencing factors, and the expansion rate, durability rate, wet swelling rate (48 h), and resistance to damage were taken as the evaluation indexes, and the Box–Behnken design of the response surface method was used to analyze the significance of interactions among the different influencing factors in the moulding process of biomass seedling pots and to optimize the moulding process. The experiment was conducted in the Biomass Laboratory of Heilongjiang Bayi Agricultural University. The response surface method Box–Behnken design was used to analyze the significance of the interaction between different influencing factors in the biomass seedling pots moulding process and optimize the moulding process. The results showed that the optimum moulding process conditions obtained using the Box–Behnken design were the following: a moulding pressure of 520.393 kN, baking temperature of 202.870 °C, and baking time of 8.573 min. The model was validated by testing and a response value of 10.522% was obtained for expansion, 99.598% for durability rate, 11.145% for wet swelling (48 h), and 4503.545 N for resistance to damage. The experimental verification showed that the deviation of the actual value obtained under this condition from the predicted value is less than 5%, indicating that the model reproduces well and meets the experimental requirements. Based on the optimal moulding process conditions determined in this experiment, the total porosity, EC, and pH of the Biomass seedling pots were determined to be 67.32%, 1.63 mS/cm, and 6.7, respectively, which met the seedling requirements.

Reduction of Pressure Distribution Variation in Press Mold Based on Variable Lattice Optimization

Reduction of Pressure Distribution Variation in Press Mold Based on Variable Lattice Optimization

Microstructure and mechanical properties of freeze-casted in-situ ABOw@Al2O3/AZ91 composites

In this work, the A18B4O33w (ABOw) was in-situ generated on the surface of Al2O3 through the reaction of B2O3 and Al2O3, resulting in the thorn structure. Then, the ABOw@Al2O3/AZ91 composites were fabricated through a combination of freeze casting and pressure casting. The influence of the initial content of B2O3 on the microstructure and mechanical properties of ABOw@Al2O3/AZ91 composites was investigated. The results show that the lamellar structure of ABOw@Al2O3/AZ91 composites were weakened, which gradually changed to dendritic structure with the increasing B2O3 content. The in-situ formation of ABOw on the surface of Al2O3 was favorable to improve the compressive strength of both ABOw@Al2O3 ceramic scaffold and ABOw@Al2O3/AZ91 composites, while also reducing the anisotropy of the composites. Furthermore, the in-situ generated ABOw within the ceramic layer could effectively relieve stress concentration and delay crack initiation and propagation, which led to the enhancement of the load-bearing capacity of ABOw@Al2O3/AZ91 composites. The ABOw@Al2O3/AZ91 composite exhibited the outstanding mechanical properties with the compressive strength of ∼685 MPa, when the B2O3's content is 5 wt%.

Multiscale insights on compression cast sea sand and seawater concrete

Reinforced concrete (RC) structures in coastal and marine regions face two primary challenges, the shortage of raw materials and severe service environments. Concrete made from sea sand and seawater (SS-SW) can address the shortage of natural sand by utilizing locally available resources. Meanwhile, the newly developed compression cast technology (CCT) significantly improves the micro and macro properties of concrete, enhancing its durability in harsh environments. Therefore, the combination of SS-SW concrete and CCT to form a new compression-cast SS-SW concrete can simultaneously solve the problems of materials shortage and durability issues for coastal RC structures. However, till now, research on this type of concrete is still an open issue. This paper aims to carry out multilevel investigations on the macro and micro performance of compressed SS-SW concrete. First, 69 concrete columns were tested to understand the stress-strain behavior and associated mechanical indices. The compressive strength of compressed concrete was found to be up to 1.86 times greater than that of uncompressed concrete. Meanwhile, the porosities in both mortar and the interfacial transition zone (ITZ) of concrete under a casting pressure of 15 MPa were approximately 50 % of those in uncompressed counterpart. Existing models are inadequate for predicting the behavior of compressed SS-SW concrete, leading to the development of new and accurate models to predict its compressive strength, elastic modulus, peak strain and stress-strain curve. These findings pave the way for the design and application of this kind of concrete.

Study of mechanical properties of the YL113 die casting surface and middle layer

The YL113 die casting surface and middle layer are separated by machining and densities, porosities and mechanical properties of the YL113 die casting surface and middle layer are measured. Results show that the densities and mechanical properties of the total YL113 die casts are in between those of the YL113 die casting surface and middle layer and are identical to those of the YL113 die casting middle layer. The porosities of the die casting surface layer are smaller and fewer and its densities are bigger and mechanical properties are better than those of the middle layer. Effects of different die casting process parameters on the surface layer and the middle layer of die casting are different, of whom effects of the casting pressure and the biscuit thickness on them are most obvious. The densities and mechanical properties of the surface layers and the middle layers of die castings increase with increasing the casting pressures and the biscuit thicknesses. In addition, the effects of densities on the mechanical properties of the die casting middle layers are more obvious than those of the die casting surface layer.

Effect of modified investment and casting system on the recasting properties of high-gold alloy

Background/purposeHigh gold (Au) alloys have many advantages, such as good mechanical properties and stable chemical properties for dental restoration. The purpose of this investigation was to investigate the effect of zirconia (ZrO2)-magnesia (MgO)-based investment combined with an argon arc vacuum pressure (Ar-arc VP) casting process on the recasting of high Au alloys. Materials and methodsThe recasting Au alloys were compared between the control group of conventional SiO2-based investment/horizontal centrifugal (HC) casting and the experimental group of ZrO2–MgO-based investment/Ar-arc VP die casting. The first-generation castings were defined as being made from purchased Au alloys and the second-generation castings were made from 50 wt% of the original Au alloys before casting, plus the balance of the remaining 50 wt% from the previous castings. The third-generation was made from all old surplus from the previous castings. The ingots were measured for the marginal gap, surface roughness, interface oxidation, hardness, and phase identification. ResultsThe results showed that the recasting success rate reached 100%. The ZrO2–MgO-based investment/Ar-arc VP group had better edge precision, smaller oxide layer thickness, and lower hardness than the SiO2-based investment/HC group. However, surface roughness analysis indicated little difference between the two groups. Phase analysis showed that the recasting alloys of the second and third-generation groups contained higher Au contents than those of the first-generation. ConclusionOverall, the Au alloy can be better recasted and retain good mechanical properties under the clinically used 5 wt% ZrO2–MgO-based investment/Ar-arc VP casting method.

3D printed, subtractive, and conventional acrylic resins: Evaluation of monotonic versus fatigue behavior and surface characteristics

This study assessed the mechanical properties and surface characteristics of dental prosthetic acrylic resin fabricated by 3D printing, comparing it with subtractive, pressing, and molding techniques. Bar-shaped specimens (N= 90; 65 × 10 × 3.3 mm; ISO:207951) were prepared and assigned into six groups: PRINT (3D printing vis stereolithography with PriZma 3D Bio Denture, Makertech Labs); SUB (subtractive manufacturing with Vipiblock Trilux, Vipi); PRESS Base (pressing using muffle with Thermo Vipi Wave, Vipi for base); PRESS Tooth (pressing with Onda-cryl, Clássico for tooth); MOLD Base (molding using addition silicone with Vipi Flash, Vipi for base); and MOLD Tooth (molding with Dencor, Clássico for tooth). Monotonic flexural strength (FS) and elastic modulus (E) were measured using a three-point bending approach (n= 5) on a universal testing machine at a crosshead speed of 5 mm/min. Fatigue testing (n= 10) followed similar geometry and settings, with a frequency of 2 Hz, initial stress level at 20 MPa, and stress increments of 5 MPa every 2,500 cycles. Surface roughness (n= 10) was assessed through profilometry, and fractographic and topographic analyses were conducted. Statistical analyses included One-Way ANOVA for monotonic FS, roughness, and E, along with Kaplan-Meier with Mantel-Cox post-hoc and Weibull analysis for fatigue strength. PRINT showed lower monotonic FS than the SUB and PRESS Tooth but comparable fatigue strength to these groups and superior to PRESS Base and MOLD (Base and Tooth) groups. All groups had similar Weibull moduli. Surface roughness of the PRINT group was comparable to most techniques but higher than the PRESS Tooth group. Fractographic analysis revealed fractures originating from surface defects under tensile stress, with SEM showing scratch patterns in all groups except PRINT, which had a more uniform surface. Despite its lower monotonic strength, 3D printed resin demonstrated comparable fatigue strength to subtractive and pressing methods and similar surface roughness to most methods, indicating its potential as a viable option for dental prosthesis.

Abstract 6927: A refined view of pancreatic cancer genomic evolution through single-nucleus DNA sequencing

Abstract Numerous next-generation sequencing studies have provided an overview pancreatic ductal adenocarcinoma (PDAC)’s genomic evolution. But how its genome evolves through treatment and metastasis has not been extensively studied due to lack of samples and technical limitation of bulk sequencing on low-tumor purity samples. Herein we applied targeted single-nucleus DNA sequencing (snDNA-seq) to a cohort of 18 patients, each with >= 2 multiregional/longitudinal samples, totaling 65 samples. These included 5 early-stage resections, 11 stage IV autopsies and 2 biopsy-derived organoids taken pre- and post-treatment. We also developed a set of computational methods for this new datatype to delineate genomic evolution at high resolution. Despite higher sensitivity than bulk, snDNA-seq did not uncover significant subclonal single-nucleotide variations (SNVs) on our panel targeting 253 select genes for PDAC. But it detected a higher frequency of CDKN2A (72% against 30%) and SMAD4 (56% against 32%) alterations, mostly attributed to chromosomal deletions. Many were subclonal or only affected a few hundred base-pairs of the gene, making them elusive to bulk sequencing. Except for one case driven by BRCA2 mutations rather than the canonical KRAS oncogene, other patients had mostly linear phylogenies with more SNVs occurring before the most recent common ancestor (MRCA) of clones, for early/late-stage and longitudinal cases alike. This early fixation of drivers and rapid clonal sweep afterwards likely correlates with the particular aggressiveness of PDAC. Metastatic clones almost always fell towards the end of phylogenies and were shared among spatially separated sites, indicating late metastatic dissemination in molecular evolution time. Metastases to the liver and diaphragm appeared to be more genetically evolved than other sites, likely due to harsher selective pressure cast by the metastatic routes/distal microenvironments. 16 of 18 PDACs were observed to converge towards tumor cell-intrinsic TGF-β unresponsiveness by mutating various components of the pathway. Such convergent evolution usually happened at the primary site, indicating a strong selective advantage of the phenotype in the desmoplastic, nutrient-poor pancreas microenvironment. Continuous evolution was seen through treatment and metastasis, driven by seemingly random genome-scale copy number variations (CNVs) and focal amplification/deletions to genes such as KRAS, CDKN2A, SMAD4, MYC. These insights on PDAC’s genomic evolution inform more precision medicine efforts to come. Early fixation of driver SNVs sculpts a largely homogeneous disease that could be uniformly targeted. But special care should be taken to obviate resistance mechanisms conferred by continuously evolving CNV events- compared to SNVs, these mechanisms provide faster remodeling of the genome, and thus faster generation of new phenotypes and adaptation. Citation Format: Haochen Zhang, Palash Sashittal, Elias-Ramzey Karnoub, Akhil Jakatdar, Shigeaki Umeda, Nicolas Lecomte, Jungeui Hong, Katelyn Mullen, Akimasa Hayashi, Caitlin A. McIntyre, Benjamin J. Raphael, Christine A. Iacobuzio-Donahue. A refined view of pancreatic cancer genomic evolution through single-nucleus DNA sequencing [abstract]. In: Proceedings of the American Association for Cancer Research Annual Meeting 2024; Part 1 (Regular Abstracts); 2024 Apr 5-10; San Diego, CA. Philadelphia (PA): AACR; Cancer Res 2024;84(6_Suppl):Abstract nr 6927.

STUDY ON MECHANICAL PROPERTIES OF DEVELOPED ECO-FRIENDLY BRAKE PADS USING GRAY RELATIONAL ANALYSIS IN BOX BEHNKEN DESIGN OF EXPERIMENT

Over the years, asbestos has been a leading material for developing automobile brake pads. However, due to its hazardous nature to human health, many researchers have found that organic materials possess the potential for replacement. The organic materials used in this research were the hybrid of coconut fruit fibre CFF and oyster sea shell OSS. These materials were gathered from the river bank, dried, crushed, washed, ground, sieved, and moulded with different additives: CuO (abrasive), graphite (friction modifier or solid Lubricant), epoxy resin (binder), hardener (catalyst) by Box Behnken design BBD of L27 experiment. Therefore, an experimental test on mechanical properties was performed to check the developed brake pad's characterization. Then, grey relational analysis was used to analyze grey relational grade GRG to convert a multiple response process optimization problem into a single response optimization using maximization of maximum GRG. The optimum parameter values producing the highest value of grey relational grade were chosen as rank one, pertained to the factors setup for experiment number S3232 having moulding pressure of 11.25MPa, moulding temperature of 180oC, and heat treatment time of 180min. The optimized response values obtained from the experiment sample S3232 give the highest values on all the responses, i.e., density of 3.483g/cm3, hardness of 52.91BHN, compressive strength of 2.78MPa, ultimate tensile strength of 3.92MPa, impact energy of 17.87N, cold water absorption of 0.2863%, hot water absorption of 0.4785%, and oil absorption of 0.4402%. After that, the optimized brake pad sample (S3232) was applied to the automobile and was suitable for braking owing to its high mechanical properties.

Optimization Techniques in Compression Moulding: A Comprehensive Review

Quality and productivity have been used as terms to control process parameters and lower process defects. Several defects emerge when products are manufactured using the compression moulding process.Since the second-largest industrial process used to produce plastic goods and also the most popular method of producing thermoset and thermoplastic polymer composites is compression moulding.By this method control of temperature and pressure gives the desired shape of product. This method can be applied to both thermoset and thermoplastic materials. Due to the low flow index of thermoset plastics, considerable pressure is needed, which can only be achieved by the compression moulding method.The components, functionality, equipment, and tooling behaviour of the compression moulding process are covered in this study of paper. The advantages, drawbacks, and equipment used, as well as the material processing parameters, part design, tooling, and cost of compression moulding process parts are also discussed.In this work, many process variables—including moulding temperature, pressure, preheat time, and material weight are taken into account for the response research of the mechanical properties and internal defects created by the compression moulding process.

Significant Difference in the Properties of Porcelain Insulator Produced through Slip and Press Cast Forming Techniques

Significant Difference in the Properties of Porcelain Insulator Produced through Slip and Press Cast Forming Techniques

Methodology to Investigate Effect of Prosthetic Interface Design on Residual Limb Soft Tissue Deformation.

Residual limb discomfort and injury is a common experience for people living with lower limb amputation. Frequently, inadequate load distribution between the prosthetic device and the residual limb is the root cause of this issue. To advance our understanding of prosthetic interface fit, tools are needed to evaluate the mechanical interaction at the prosthetic interface, allowing interface designs to be evaluated and optimised. Present a methodology report designed to facilitate comprehension of the mechanical interaction between the prosthetic interface and the residual limb. As a pilot study, this methodology is used to compare a hands-on and hands-off interface for a single transtibial prosthesis user using secondary Magnetic Resonance Imaging (MRI) data. MRI data of the residual limb while wearing a prosthetic interface is segmented into a hard tissue and a skin surface model. These models are exported as stereolithography (STL) files. Two methods are used to analyse the interface designs. Firstly, CloudCompare software is used to compute the nearest vertex on the skin surface for every vertex on the compiled internal bony surface for both interface types. Secondly, CloudCompare software is used to compare registered skin surfaces of the residual limb while wearing the hands-on and hands-off interfaces. The maximum and minimum nearest distances between the internal bony surface and skin surface were similar between interface types. However, the distribution of nearest distances was different. When comparing the skin surface while wearing both interfaces, where the fit is more compressive can be visualized. For the dataset used in this study, the classic features of a hands-on Patella Tendon Bearing interface and hands-off pressure cast interface could be identified. The methodology presented in this report may give researchers a further tool to better understand how interface designs affect the soft tissues of the residual limb.

The development of glutin-based biocomposite materials with advanced hydrophobicity

Biocomposite materials, which contain components of natural origin, have low resistance to water absorbtion due to high lyophilicity of components. It leads to quick destruction of biocomposite products under the conditions of high humidity exploitation that defines the necessity and importance of conducting scientific research in this sphere. The aim of the article is to research the hydrophobic additives influence on the compressive strength and hygroscopicity of biocomposite materials consisting of glutin matrix (100 parts by weight) and wood flour (100 parts by weight). The technology of forming biocomposite materials includes a step-by-step pressing the composition at a pressure of 10-15 MPa and a heat treatment of the product in a press mold at a temperature of 140°C. Experimental methods of investigating the biocomposite materials compressive strength and hygroscopicity were used in the work. It was experimentally determined that the modifying additive (paraffin) optimal content is 4 parts by weight per 100 parts by weight of biopolymer matrix. At this content, there is an increase compressive strength by 2.8-4.6 times of the biocomposite materials compared to biocomposites with different paraffin content. As a result of the state analysis of biocomposite samples which were destroyed under the static loading influence, the features of the cracks occurrence and propagation in biocomposites depending on different modifying additive content, the conduct of the composition preliminary processing or biocomposites additional processing in a thermal field were determined. The use of protective hydrophobic coatings on the biocomposite samples surface provided an increase in the biocomposites resistance to the moisture negative influence. The most effective were coatings based on a paraffin solution, which provided a reduction in water absorption by 45-50% compared to biocomposites coated with wax, drying oil Oksol, and sunflower oil. The complex use of hydrophobic substances as modifying additives and protective coatings has practical significance, as they positively affect the processes of forming the structure, increasing the strength and hydrophobicity of biocomposite materials used in a humid environment

Optimisation of mechanical behaviour of Calotropis gigantea and Prosopis juliflora natural fibre-based hybrid composites by using Taguchi-Grey relational analysis

The properties of organic fibre-based hybrid materials are influenced by a variety of factors and even minor changes in these variables can outcome in substantial discrepancies in strength. In this regard, the current study aims to optimise various influencing parameters such as weight percentage, alkaline treatment concentration, and fabrication parameters (compression moulding pressure, and temperature), with the goal of enhancing the overall strength of the composite. Calotropis gigantea-stem and Prosopis juliflora-bark fibres were used in varying weight percentages to create epoxy-based hybrid composites. After fabrication the mechanical characterisation like tensile, flexural, and impact properties of the composites were tested. Taguchi experimental design was applied, and the results were analysed using a hybrid Taguchi-grey relational investigation method. It was observed that a combination of 20 wt.% Calotropis gigantea/20 wt.% Prosopis juliflora/6 % NaOH pretreatment/100 °C temperature with 14 MPa pressure and had the most desirable mechanical properties in the fabricated composites. Calotropis gigantea ranks first in enhancing the composite strength, followed by Prosopis Juliflora, NaOH pretreatment%, compression moulding temperature and pressure. This work highlights the significant role of Calotropis gigantea and Prosopis Juliflora fibres in enhancing composite strength and provides valuable insights for future research in the field of hybrid composite development.

Examination of a Hot-Work Tool Steel Treated with Different Nitriding Processes after Cyclic Heating

This research examines the effect of salt bath, and nitriding processes on hot forming tool steel. The chosen steel is BÖHLER W350 ISOBLOCK hot forming tool steel, which is widely used in the industry for pressure casting. After surface treatment, some samples were exposed to cyclic heat and corrosion effects in a molten aluminium medium, thus simulating the conditions experienced during pressure casting. Microhardness measurements were performed on the samples treated with different procedures. The results were compared using a scanning electron microscope and energy-dispersive X-ray spectrometry.

Experimental Study on Compression Moulding of Carya cathayensis Husks at Room Temperature

Abstract Using crushed hickory husks as raw materials, a single factor test was carried out on a hydraulic-plunger forming machine with different moisture contents and length–diameter ratios (LDRs) of forming mould in order to obtain biomass moulding fuel (BMF) briquettes. The moulding pressure in the forming mould was measured by the sensor, and the microstructures of the BMF briquettes were observed via stereomicroscope. Results showed that hickory husks could be compressed and formed into BMF briquettes at room temperature. When the moisture content of the raw materials was 14 percent and LDR of the forming mould was 4.5, the quality of BMF was best, and relaxation density of the BMF briquette was 0.98 g/cm3. When the moisture content stayed same, the forming pressure increased correspondingly with the increase of the LDR of the forming mould. When the LDR of the forming mould stayed the same, the moulding pressure increased first and then decreased with increase of moisture content. This study is of great significance because it demonstrates improvement in the utilization range of hickory husks, with the potential for reducing environmental pollution and increasing farmers’ income.

Effect of process parameters on characteristics and pore structure of foam ceramics prepared from granite sawing dust

Foam ceramics made from solid waste have recently attracted considerable interest because of their environmentally friendly and sustainable properties. This study examines the manufacturing of foam ceramics through the direct sintering of granite sawing dust. An orthogonal experimental design was employed to explore the impact of the foaming-agent content, sintering temperature, holding time, and moulding pressure on the characteristics of foam ceramics. The experimental and analytical results show that under the given conditions involving a foaming agent content of 0.8 wt%, a sintering temperature of 1200 °C, a holding time of 30 min and a moulding pressure of 5 MPa, the produced foam ceramics have excellent properties. These included a bulk density of 0.892 g/cm³, water absorption of 0.130 %, porosity of 59.67 %, high compressive strength of 10.721 MPa, and thermal conductivity of 0.247 W/(m·K). Analysis of the pore structure revealed that the samples had an evenly distributed and sealed pore structure, which effectively increased the porosity and bulk density. This study effectively demonstrates the viability of producing porous ceramics from granite sawing dust, presenting a green and economically sustainable method for waste management and the creation of high-functioning materials. These findings offer promising prospects for the greater implementation of granite waste in the construction sector.