The use of green molding materials in the production of advanced lightweighting castings

Abstract

This conference presentation shows the results achieved within NetCastPL4.0 project (Title: Networking for advancing excellence and capacity in light-weight castings for Foundry 4.0 in Poland - NetCastPL4.0; ID: 101159771; Program: Horizon Europe; Funder: Komisja Europejska (KE)). The project is being realized in cooperation between AGH Faculty of Foundry Engineering (Leader), CNR-ICMATE and Aalto University School of Engineering. This work, presented during the V International Conference of Casting and Materials Engineering ICCME 25 in Krakow, Poland on October 27-28, 2025, describes the research connected with the development of molding compounds for thin-walled castings. Two compounds with organic binders and two compounds with inorganic binders of self-curing molding sands were tested. Tests were carried out on the tensile and bending strength, permeability, and friability of the compounds. For selected molding sands, tests were carried out on their thermophysical properties (hot distortion parameter), gas emission, and thermal degradation. For castings production also molds produced using additive manufacturing (3D printing technology) were used.