Siberian Federal University, Krasnoyarsk, Russia
T. R. Gilmanshina, Cand. Eng., Associate Prof., e-mail: gtr1977@mail.ru
T. A. Bogdanova, Cand. Eng., Associate Prof.
I. V. Dubova, Cand. Eng., Associate Prof.

Casting and mechanical plant "SKAD", Divnogorsk, Russia

D. I. Yagodin, Executive Director

The paper shows the possibility of using red slag as a filler of separation coatings for metal molds and can be used as a textural one. The red sludge of JSC RUSAL Ural – a branch of RUSAL Kamensk-Uralsky, which is a material with a particle size of 4–100 microns, was used in the work. The mate-rial is represented by hematite, cancrinite and kaolenite. Iron, the content of which in the studied material is about 30%, by weight, is mainly bound to hematite. With a content from 1 to 10%, by weight. the metals aluminum, calcium, sodium, titanium are represented, from nonmetals carbon and silicon are included in this range. Aluminum is represented in cancrinite, kaolinite and katoite. Titanium is in the phases of anatase, rutile and perovskite. The composition also contains a number of amorphous phases that are not determined by XRF. The paper studies and proves the possibility of using red sludge in coating compositions. The physicochemical and technological properties of water coatings with different red sludge content have been investigated. It is determined that coatings containing 8–13 wt. % red sludge, have a good covering ability, forming an even thin layer without visible defects. Coatings containing 13–20 wt. % of red sludge, have an unsatisfactory covering ability, since their application is associated with a number of difficulties: the coating quickly settles and therefore lies unevenly. When the content in the coatings is less than 8 wt. % of red sludge does not make it possible to form a layer of sufficient thickness on the surface of metal molds.
The work was carried out at the Center for Collective Use “Knowledge-intensive methods of research and analysis of new materials, nanomaterials and mineral raw materials” of the Federal State Autonomous Educational Institution of Higher Education “Siberian Federal University”.

1. Znamensky L. G., Ivochkina O. V., Zakharov N. A., Starshinov V. Refractory coatings for special casting methods. Tekhnologii metallurgii, mashinostroeniya i materialoobrabotki. 2020. No. 19. pp. 170–178.
2. Klimosh Yu. A., Barantseva S. E., Kurilo I. I. et al. Igneous rocks of Belarus – a refractory filler for release coatings for chill casting of aluminum alloys. Trudy BGTU. Seriya 2: Khimicheskie tekhnologii, biotekhnologiya, geoekologiya. 2019. No. 2 (223). pp. 23–29.
3. Pivovarchik A. A., Slepneva L. M., Rozum V. A. Development of release coatings based on organosilicon materials for injection molds. Liteyshchik Rossii. 2007. No. 1. pp. 36–40.
4. Voevodina M. A., Kurasov A. A. Calculation model for selection of refractory coating characteristics. Technological cooperation between science and production: new ideas and development prospects: collection of articles of the International scientific and practical conference. Chelyabinsk, 2018. 2018. pp. 19–22.
5. Khakimova V. A. Analysis of the possibility to control the temperature of the chill mold during its operation. Mavlyutov readings: proceedings. Ufa : Ufa State Aviation Technical University, 2021. 2021. pp. 315–323.
6. Sergeev N. N., Sergeev A. N., Kutepov S. N. et al. The use of protective wear-resistant coat-ings to increase the durability of casting molds. Izvestiya Yugo-Zapadnogo gosudarstvennogo universiteta. Seriya: Tekhnika i tekhnologii. 2022. Vol. 12. No. 2. pp. 8–25.
7. Gavariev R. V., Savin I. A., Leushin I. O. Impact of the functional coating on service durability of injection molds for the zinc alloys pressure casting. Tsvetnye Metally. 2016. No. 1. pp. 66–70.
8. Roorda S. Influence of mold coating wear on heat transfer coefficient in aluminum permanent molds. Worcester Polytechnic Institute, 2021. 67 p.
9. Campbell J. Complete casting handbook: metal casting processes, techniques and design. Butterworth Heinemann, 2011. 1220 р.
10. Gilmanshina T. R., Kosovich A. A. et al. Release coatings for low pressure casting : monograph. Krasnoyarsk : Siberian Federal University, 2019. 160 p.
11. Gavariev R. V., Savin I. A., Soldatkina E. N. Choice of protective coating of metal molds for casting non-ferrous alloys. Solid State Phenomena. 2020. Vol. 299. pp. 867–871.
12. Klimosh Yu. A., Kurilo I. I., Kharitonov D. S., Barantseva S. E. Influence of the filler behavior on corrosion properties of release coatings. Modern electrochemical technologies and equipment – 2019: proceedings of the International Scientific and Technical Conference. Minsk : Belarusian State Technological University, 2019. 2019. pp. 193, 194.
13. Mu K. et al. Effect of powder mold release agent on aluminum alloy melt under gravity casting conditions. International Journal of Automation Technology. 2022. Vol. 16, Iss. 6. pp. 888–896.
14. Leushin I. O., Makarov V. S., Leushina L. I., Geiko M. A. Possibilities of using car enamel waste in the production of iron casting. Chernye Metally. 2020. No. 12. pp. 22–26.
15. Pyagai I. N. Experience of red mud processing with obtaining a number of valuable elements (Sc, Zr, Y) and iron-containing raw materials for the steel industry. Chernye Metally. 2019. No. 1. pp. 49–54.
16. Zinoveev D. V. et al. Review of world practice of red mud processing. Part 1. Pyrometallurgical methods. Izvestiya vuzov. Chernaya metallurgiya. 2018. Vol. 61. No. 11. pp. 843–858.
17. Vasyunina N. V., Dubova I. V., Gilmanshina T. R. et al. Methods for extracting valuable elements (Fe, Al, Na, Ti) from red mud. Ekologiya i promyshlennost Rossii. 2020. Vol. 24. No. 9. pp. 32–38.
18. Xiao Liu, Yuexin Han, Fayu He et al. Characteristic, hazard and iron recovery technology of red mud – A critical review. Journal of Hazardous Materials. 2001. Vol. 420. 126542.
19. Samal S. Utilization of red mud as a source for metal ions: review. Materials. 2021. Vol. 14, Iss. 9. 2211. DOI: 10.3390/ma14092211
20. Antunes M. L. P. et al. Use of industrial waste to produce ceramic coatings on metal. European Journal of Sustainable Development. 2019. Vol. 8, Iss. 5. 9.
21. Singh S., Aswath M. U., Ranganath R. V. Effect of mechanical activation of red mud on the strength of geopolymer binder. Construction and building materials. 2018. Vol. 177. pp. 91–101.
22. Bao Li., Ting-an Zhang, Zhi-he Dou, Guo-zhi Lue et al. Kinetics of AlOOH dissolving in caustic solution studied by high-pressure DSC. Transactions of nonferrous metals society of China. 2011. Vol. 21, Iss. 1. pp. 173–178. DOI: 10.1016/S1003-6326(11)60695-X
23. GOST 10772–78. Water foundry coatings for mould paints. General specifications. Introduced: 01.01.1979.
24. GOST 8420–74. Paint and lacquer materials. Method for determination of relative viscosity. Introduced: 01.01.1975.
25. Svarika A. A. Coatings of foundry molds. Moscow : Mashinostroenie, 1977. 216 p.