Abstract
This research is the result of 15 years of R&D at the knowledge-based company Fannavar Sanaye Pishgaman Borhan Steel, led by Dr. Borhanzadeh. For the first time worldwide, a laboratory casting mold was designed and fabricated using the novel Farbor403 composite. The main objective is the complete elimination of barium sulfate (BaSO₄) from copper casting.
Traditionally, BaSO₄ is used as a mold coating, but it causes significant challenges including recurring cost, severe environmental pollution, and contamination of casting residues, which reduces the recovery efficiency of valuable elements (Cu, Ag, Au).
The proposed mold is a multilayer system consisting of:
- Steel base,
- 99% pure copper layer,
- Heat transfer soft layer,
- Final Farbor403 composite layer.
Cooling is achieved via a combined system: bottom water circulation and top mist spraying. Experiments demonstrated that a copper block (200×200×20 mm) was separated from the mold within 5 minutes without BaSO₄, and the complete casting cycle was finished within 8 minutes.
This novel technology provides a green and sustainable solution for industrial copper casting.
Results & Discussion
Successful casting of 200×200×20 mm copper block without cracks or adhesion.
Complete elimination of BaSO₄ usage.
Enhanced recovery of valuable elements by up to 15%.
Operational cost reduction and zero hazardous residues.
Mold durability >15 cycles without degradation.
Conclusion
The Farbor403 mold represents a breakthrough in green metallurgy, enabling copper casting without barium sulfate. The developed process ensures economic savings, environmental safety, and improved casting performance, paving the way for industrial-scale application.