DOI: 10.18503/1995-2732-2025-23-3-69-78
Abstract
Problem statement (relevance). Foundry production is characterized by significant consumption of resources. The use of expensive materials for its needs, mainly imported, significantly increases the cost of castings. At the same time, industrial waste is still in little demand in foundry technologies, the compositions of which allow them to act as an inexpensive alternative to widely used ones. A significant amount of work on this topic does not affect the development of a generalized procedure for working with waste for the needs of foundry. Objectives are creating scien-tific principles for the use of industrial waste in foundry technologies and their practical implementation for a number of examples. Methods Applied. In the course of the work, methods of general scientific knowledge (observation, comparison, experiment, analysis, synthesis, generalization, formalization, analogy, modeling, hypothesis), mathematical operations on sets, methods for determining the properties of waste and products obtained from them were used. Result. For the first time, a scientific approach to the use of industrial waste in foundry technologies based on system analysis has been developed. Practical Relevance. A database with examples of the use of industrial waste in foundry technologies and computer programs (Selection of methods for determining the properties of waste for use in foundry technologies, Selection of directions for application of waste in foundry technologies) were developed. The developed scientific approach was tested using examples of use in foundry technologies: aluminum slag, sludge from the production of polyvinyl chloride, abrasive dust, breakage of ceramic casings of steel casting by molten models, sludge from salt quenching baths, sludge from nitrate baths, sludge from quenching tanks, intermediate product for processing sludge from nitrate baths.
Keywords
industrial waste, scientific approach, recycling, casting technologies, industrial waste – casting technologies system, graphic model, computer programs, implementation examples
For citation
Grachev A.N., Leushin I.O., Mantserov S.A. On the Development and Practical Implementation of a Scientific Ap-proach to the Use of Industrial Waste in Foundry Technologies. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2025, vol. 23, no. 3, pp. 69-78. https://doi.org/10.18503/1995-2732-2025-23-3-69-78
1. Gilmanshina T.R., Illarionov I.E., Hudonogov S.A., Kovaleva A.A., Budnik E.V. Studying the possibility of using graphite-containing slags in the compositions of non-stick coatings. Liteyshchik Rossii [Russian Foundrymen], 2022;(5):28-30. (In Russ.)
2. Kidalov N.A., Grigoreva N.V. The effect of waste from contact oil purification on the film structure of aqueous sodium silicate on the surface of refractory chromite filler. Izvestiya Volgogradskogo gosudarstvennogo tekhnicheskogo universiteta [Proceedings of the Volgograd State Technical University], 2021;(6(253)):83-87. (In Russ.)
3. Kidalov N.A., Belova N.V., Belov A.A., Surikov D.S., Polyak S.R. Investigation of the effect of waste from the production of compound feeds from grain crops on the technological properties of sand-liquid-glass mixtures. Izvestiya VolgGTU. Ser. Metallurgiya [Proceedings of VolgSTU. Metallurgy series], 2024;(7(290)):51-55. (In Russ.)
4. Kidalov N.A., Belov A.A., Belova N.V., Polyak S.R., Dibrov A.I. Investigation of the effect of used coffee grounds on the formation of the properties of sand-liquid glass mixtures. Liteynoe proizvodstvo [Foundry], 2024;(8):15-19. (In Russ.)
5. Feoktistov N.A., Pivovarova K.G., Ponamareva T.B., Chernov V.P., Kulakov B.A., Dubrovin V.K. Optimization of the composition of self-drying non-stick paint based on used alumochrome catalyst. Teoriya i tekhnologiya metallurgicheskogo proizvodstva [Theory and technology of metallurgical production], 2023;(3(46)):25-29. (In Russ.)
6. Kidalov N.A., Grebnev D.Yu., Gabelchenko N.I., Grebnev Yu.V. Development of a process for modifying foundry steels with finely dispersed mechanical engineering waste. Zagotovitelnye proizvodstva v mashinostroenii [Procurement production in mechanical engineering], 2024;22(2):56-58. (In Russ.)
7. Safronov N.N., Kharisov L.R., Aflyatonov D.R. Technology and hardware design of remelting of cast iron chips by electroslag process. Chernye metally [Ferrous metals], 2023;(1):32-37. (In Russ.)
8. Ryazanov S.A., Nikitin K.V., Sokolov A.V. About complex processing of aluminum salt slags. Metallurgiya mashinostroeniya [Metallurgy of mechanical engineering], 2013;(5):48-52. (In Russ.)
9. Pude G.C., Naik G.R., Naik P.G. Application Of Process Activity Mapping For Waste Reduction A Case Study In Foundry Industry. International Journal of Modern Engineering Research (IJMER). 2012;2(5):3482-3496.
10. Mounika M.P., Pardhiv G. Total industrial waste management by advanced tequniques. International Research Journal of Engineering and Technology (IRJET). 2017;4(10):205-213.
11. Trombly J. Recasting a dirty industry. The U.S. foundry industry is about to be rein vented to maximize pollution prevention. Environ. Sci. Technol. 1995;29(2):76A-78A.
12. Spirin N.A., Shvydkiy V.S., Lobanov V.I., Lavrov V.V. Vvedenie v sistemnyj analiz teplofizicheskih processov v metallurgii: Uchebnoe posobie dlya vuzov [Introduction to the system analysis of thermophysical processes in metallurgy: a textbook for universities]. Yekaterinburg: UGTU, 1999, 205 p. (In Russ.)
13. Grachev A.N., Leushin I.O., Korovin V.A., Leushina L.I. The use of industrial waste in foundry and metallurgical technologies. Experience of the Department of Metallurgical Technologies and Equipment. Chernye metally [Ferrous metals], 2024;(1):73-78. (In Russ.)
14. Grachev A.N., Leushin I.O., Deev V.B., Koshelev O.S. Processing of aluminum melts using mesh filters impregnated with sludge from salt hardening baths. Tsvetnye metally [Non-ferrous metals], 2018;(8):85-90. (In Russ.)
15. Grachev A.N., Leushin I.O., Leushina L.I. Development of compositions of exothermic mixtures for steel and cast iron casting using thermal production waste. Chernye metally [Ferrous metals], 2018;(2):39-43. (In Russ.)
16. Grachev A.N., Leushin I.O., Maslov K.A., Leushina L.I. The use of sludge from salt hardening baths for aluminum alloys refining. Tsvetnye metally [Non-ferrous metals], 2015;(11):76-79. (In Russ.)