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The article aims to verify the possibility of obtaining an organic–inorganic material acting as both a binder and a lustrous carbon carrier in bentonite-bonded molding sands. Due to the wide industrial application, organoclays can be considered as innovative materials supporting the foundry technology in meeting environmental requirements. In this study, the organic modification of montmorillonite in calcium bentonite (SN) was performed by poly(acrylic acid) (PAA) and its sodium salt (PAA/Na). Additionally, for the purpose of comparison, the sodium-activated bentonite/poly(acrylic acid) (SN-Na/PAA) composites were also prepared. The collective analysis of the research results used in the assessment of the mineral/polymer interaction mechanism indicates surface adsorption combined with the intercalation of PAA monolayer into the mineral interlayer spaces. Materials were characterized by the combination of Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), Brunauer–Emmett–Teller (BET) surface area analysis and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) methods. Based on the XRD analysis, the influence of PAA/Na on the aluminosilicate layered structure was found to be destructive, which may adversely affect the binding properties of SN/PAA/Na composites considered as a potential group of new foundry binders. The SN/PAA and SN-Na/PPA composites (with appropriate polymer content) can act as a binding agent in the synthetic molding sand technology, despite coating the bentonite particles with polymer molecules. The risk of losing the mineral′s binding capacity is reduced by the good binding properties of pol(acrylic acid) itself. The article is the first stage (preceding the thermal analysis and the strength tests of molding sands with the prepared organobentonites) in determining the possibility of obtaining a new full-value foundry binder in molding sands with bentonite.

The results of thermal analysis (TG–DTG–DSC) of a foundry binder from the BioCo group in the form of a polymer composition of poly(acrylic acid)–sodium carboxymethylcellulose (PAA/CMC-Na) are presented in this article. The range of temperature of degradation has been determined. It was found that as the temperature rises, physical and chemical changes take place in the binder as a result of evaporation of solvent water, release of constitutional water, intermolecular dehydration reactions and decomposition of polymer chains with the formation of gaseous decomposition products. Pyrolysis gas chromatography mass spectrometry method (Py-GC/MS) was used to identify PAA/CMC-Na binder degradation products in a predetermined temperature range based on the previously performed thermal analysis of TG–DTG–DSC. Py-GC/MS tests were also carried out to determine the emission level of gaseous products of the polymeric binder in the context of the processes occurring in the moulding (foundry) sand, in conditions of its contact with liquid metal. In addition, Py-GC/MS tests were carried out for two commonly used foundry binders based on alkaline phenolic resin cured with esters and based on urea-formaldehyde resin with furfuryl alcohol cured with sulphonic acids. The obtained Py-GC/MS results for commercial binders were referred to the results obtained for the new PAA/CMC-Na binder. It was found that the new polymer binder is characterized by the lowest emission level of gaseous products.

A series of studies related to the production of organobentonite, i.e., bentonite-poly(acrylic acid), and its use as a matrix grain-binding material in casting moulding sand is presented. In addition, a new carbon additive in the form of shungite was introduced into the composition of the moulding sand. Selected technological and strength properties of green sand bond with the obtained organobentonite with the addition of shungite as a new lustrous carbon carrier (Rcw, Rmw, Pw, Pw, PD) were determined. The introduction of shungite as a replacement for coal dust in the hydrocarbon resin system demonstrated the achievement of an optimum moulding sand composition for practical use in casting technology. Using chromatographic techniques (Py-GC/MS, GC), the positive effect of shungite on the quantity and quality of the gaseous products generated from the moulding sand during the thermal destruction of its components was noted, thus confirming the reduced environmental footprint of the new carbon additive compared to the commonly used lustrous carbon carriers. The test casting obtained in the mould of the organobentonite moulding sand and the shungite/hydrocarbon resin mixture showed a significantly better accuracy of the stepped model shape reproduction and surface smoothness compared to the casting obtained with the model moulding sand.

This study complements the knowledge about organobentonites, which are intended to be new binders in foundry technology. In the developed materials, acrylic polymers act as mineral modifying compounds. Modification of montmorillonite in bentonite was carried out in order to obtain a composite containing a polymer as a lustrous carbon precursor. The polymer undergoes thermal degradation during the casting process, which results in the formation of this specific carbon form, ensuring the appropriate quality of the casting surface without negative environmental impact. The present paper reports the results of computational simulation studies (LAMMPS software) aimed at broadening the knowledge of interactions of organic molecules in the form of acrylic acid and acrylate anions (from sodium acrylate) near the montmorillonite surface, which is a simplified model of bentonite/acrylic polymer systems. It has been proven that the –COOH group promotes the adsorption of acrylic acid (AA) to the mineral surface, while acrylate ions tend to be unpredictably scattered, which may be related to the electrostatic repulsion between anions and negatively charged clay surfaces. The simulation results are consistent with the results of structural tests carried out for actual organobentonites. It has been proven that the polymer mainly adsorbs on the mineral surface, although it also partially intercalates into the interlayer spaces of the montmorillonite. This comprehensive research approach is innovative in the engineering of foundry materials. Computer simulation methods have not been used in the production of new binding materials in molding sand technology so far.