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<p>Metallic corrosion and disposal of waste foundry sand are a few of the major concerns the world is currently facing. The sand reclamation process is used widely to make waste foundry sand reusable. This process also generates micron-sized fine particles that cannot be reused again due to their low binding ability, and they have to be dumped in landfills, creating environmental and health issues. Therefore, the presented work focuses on the sustainable use of reclaimed waste foundry sand fines (r-WFS fines) of appropriate size as a reinforcement in an epoxy-based matrix. The subsequent r-WFS fines-reinforced epoxy-based polymer matrix composite was coated on a mild steel (MS) substrate to evaluate the corrosion resistance of MS using electrochemical methods. The least corrosion rate of 0.09&#xa0;mpy was observed for an MS coated with 2.5&#xa0;wt% r-WFS fines reinforced epoxy composite as compared to that of bare MS, having a corrosion rate of 44.68&#xa0;mpy, showing substantial improvement in the corrosion resistance. Plausible reasons behind the non-suitability of r-WFS fines were also explored by evaluating and comparing various properties of r-WFS fines and green sand.</p> Graphical Abstract <p></p>

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Development of corrosion-resistant epoxy-reclaimed waste foundry sand fines composite coating

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年6月12日

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  • Ishwar Sharma,
  • Kavyansh Nag,
  • Poojitha Tallapudi,
  • Aayush Sharma,
  • Bhavika Rakecha,
  • Rajendra Kumar Goyal,
  • Kunal Borse

摘要

Metallic corrosion and disposal of waste foundry sand are a few of the major concerns the world is currently facing. The sand reclamation process is used widely to make waste foundry sand reusable. This process also generates micron-sized fine particles that cannot be reused again due to their low binding ability, and they have to be dumped in landfills, creating environmental and health issues. Therefore, the presented work focuses on the sustainable use of reclaimed waste foundry sand fines (r-WFS fines) of appropriate size as a reinforcement in an epoxy-based matrix. The subsequent r-WFS fines-reinforced epoxy-based polymer matrix composite was coated on a mild steel (MS) substrate to evaluate the corrosion resistance of MS using electrochemical methods. The least corrosion rate of 0.09 mpy was observed for an MS coated with 2.5 wt% r-WFS fines reinforced epoxy composite as compared to that of bare MS, having a corrosion rate of 44.68 mpy, showing substantial improvement in the corrosion resistance. Plausible reasons behind the non-suitability of r-WFS fines were also explored by evaluating and comparing various properties of r-WFS fines and green sand.

Graphical Abstract