Physical and Chemical Fundamentals of Sodium Phosphate Use in Foundry Production

The technology of synthesis of inorganic binder material based on sodium tripolyphosphate Na5P3O10 and orthophosphoric acid has been developed. The sequence of physicochemical transformations in this system, as well as the optimal mass ratio of orthophosphoric acid and sodium tripolyphosphate are established. The research uses methods of quantitative and qualitative X-ray phase analysis, differential thermal analysis, standard methods of testing samples for compressive strength. The ratios of the atomic radii of the cation (Na) and the anion (P2O7), as well as the presence of hydrogen bonds, provide a significant increase in the binding potential compared to other sodium phosphates. It was found that the strengthening of mixtures with 2…8 mass parts including sodium pyrophosphate, the filler of which is quartz-based sand, occurs as intensely as possible when heated to 150°C. A further increase in temperature above 250 °C leads to the conversion of sodium pyrophosphate to ordinary (non-polymeric) metaphosphate NaPO3, which exists without changes in chemical structure up to 1000°C. The developed binder material, given the global trends of decarbonization and resource conservation, is a competitive alternative to widely used synthetic resins and other organic materials. It does not contain harmful substances and does not emit dangerous products when heated.