Abstract: Compositions useful for green sandcasting are discussed, as well as methods of preparing and using such compositions. Binder compositions may comprise a carbonaceous material, an inorganic binding agent, and a high aspect ratio silicate, wherein at least one of the carbonaceous material or the inorganic material in the binder composition may be oxidized. For example, the inorganic binding agent may be oxidized with a ratio of ferrous iron (Fe2+) to ferric iron (Fe3+) less than 1.2 or less than 1. Green sand prepared from such binder compositions may exhibit a reduction in emissions during sandcasting.

Abstract: Compositions useful for green sandcasting are discussed, as well as methods of preparing and using such compositions. Binder compositions may comprise a carbonaceous material, an inorganic binding agent, and a high aspect ratio silicate, wherein at least one of the carbonaceous material or the inorganic material in the binder composition may be oxidized. For example, the inorganic binding agent may be oxidized with a ratio of ferrous iron (Fe2+) to ferric iron (Fe3+) less than 1.2. or less than 1. Green sand prepared from such binder compositions may exhibit a reduction in emissions during sandcasting.

Abstract: Compositions useful for foundry processes such as green sandcasting are discussed. The compositions may comprise ball clay, bentonite, and a carbonaceous material. The ball clay may comprise leonardite and/or causticized lignite, e.g., as a portion of the natural ball clay deposit. The composition may further comprise sand, such that the resulting mixture may be formed into a green sand mold for use in casting molded articles. Incorporation of ball clay materials in the compositions may help to improve the quality of the casted article.