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Specialized Binder Systems and Additives for
Complex Foundry Applications
2nd South African Metal Casting Conference P. GröningWFO Technical Forum 2017
Agenda
Introduction
Modern Cold-Box Systems
Special Properties – Elasticity / Deformation
Emissions – Gas / Smell / Fume
Additives
Conclusion
2
General Requirements – Foundry Industry
Technical Growing complexity, increased
core intensity Reduction of casting weight Casting walls becoming thinner Low dimensional tolerances
3
Political / Developments Environmental legislation Decreasing acceptance of
residents Printing cores and metal! E-Mobility
Application Requirements
4
Advanced Cold-Box binder
Inorganic core sand additive
Thin coating layer
Source : Eisenwerk Brühl Germany
Modern Cold-Box Systems - Profile
Standard Properties
High strength level
High productivity
5
Special Needs Low gas evolution
Low Emissions
Elasticity
High thermal stability
Problem of modern Binder & Production Technology
Source : Eisenwerk Brühl Germany
Common assembly technologies Screwing Glueing Staple Gun (Tacker)
6
Elasticity Cold-Box Generations
7
Gen 1 Gen 2 Gen 3 Gen 4
Aliphatic SolventsSilicatic Solvents
Matrix Elasticity / Flexibility
8
Very strong but not flexible
Very strong and flexible
Not flexible and not strong
Flexible but not strong
Force
Way
Source : Jung Instruments
Comparison Cold-Box Binder Type
9
0
20
40
60
80
100
120
140
160
0 0,2 0,4 0,6 0,8 1 1,2
Forc
e in
N
Way in mm
Bio 0,8/0,8
Bio 0,8/0,8
Silikat 0,8/0,8
Silikat 0,8/0,8
Elasticity Aliphatic
Aliphatic
Silicatic
Silicatic
Elasticity Modification Cold-Box System
10
0
20
40
60
80
100
120
140
160
0 0,2 0,4 0,6 0,8 1
Forc
e in
N
Way in mm
1 WM 10 / 2WM 10
1 WM 10 / 2WM 10
1 WM 12/ 2WM 12
1 WM 12/ 2WM 12modified
unmodified
modified
unmodified
unmodified
Cold-Box Process - Sipurid
New generation Cold Box - Properties1. OH groups reduced
> Viscosity of the base resin is reduced> Less solvent required – 50%
2. Increased molecular mass> Amount of isocyanate can be reduced
3. Silicate embedded in resin matrix – chemical bond> Improved thermal stability> Less organic in the resin / system> Less emission (gas, odour, condensates)
11
Sipurid – CB System
12
0%10%20%30%40%50%60%70%80%90%
100%
Cold-Box Standard P 1 Cold-Box Standard P 2 Cold-Box Sipurid P 1 Cold-Box Sipuriud P 2
Base Base + TEOS Solvents aromatic/aliphatic Solvents TEOS Additives
Examination Thermal Deformation
13
Measuring device outside heating oven
Source : IFG Düsseldorf
Thermal Deformation – Results
14
0,00000
0,00010
0,00020
0,00030
0,00040
0,00050
0,00060
0,00070
0,00080
0,00090
0,00
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
0 100 200 300 400 500
Eong
atio
n[%
]
Tens
ile S
tress
[N/m
m²]
Temperature [°C]
CB Standard System
Tensile stress Elongation
0
0,0001
0,0002
0,0003
0,0004
0,0005
0,0006
0,0007
0,0008
0,0009
0,00
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
0 100 200 300 400 500
Elon
gatio
n [%
]
Tens
ileSt
ress
[N/m
m²]
Temperatur [°C]
CB deformation reduced System
Tensile Stress Elongation
Casting Examination – Deformation Behaviour
15
Very important property for fragile and complex cores
Standard Cold-Box System Special Cold-Box System
Casting trialAlloy: AluminiumCasting temperature: 750 °CCasting weight: 8 kgCore: Cold-BoxCore dimension: 5,5 mm
Gas Evolution – Binder Systems
16
Gas evolution @ 720°C Gas evolution @ 900°CStandard CB System 183 280gas reduced CB System 1 149 164gas reduced CB System 2 144 124
0
50
100
150
200
250
300m
l
Gas Evolution100 % Silica Sand0,7 % Part 1 0,7 % Part 2
BTX Emissions
17
BTX 900°C aliphatic System 334silicatic System 275silicatic Sipurid System 216
0
50
100
150
200
250
300
350
400m
g/kg
BTX Emissions 100 % Silica Sand0,7 % Part 1 0,7 % Part 2
100 % Silica Sand0,9 % Part 1 Sipurid0,5 % Part 2 Sipurid
Smell and Fume
18
Engine V8 Cold-Box Silicatic-Process
Measuring HoodCasting
Core package
Additives
19
Additives
Organic
Sealed wood or plant based
Carbon basis
Starch - based
Hybrid forms Inorganic
Minerals with a low melting point
Substances with high thermal conduction
Substances with a low expansion
behaviour
Additives
20
Properties inorganic additives No additional gas evolution
No additional pollutant emissions
Controlled sintering behaviour
Uncoated application possible
Addition rate 2-5%
Conclusion
For the succesfull production of complex castings the used binder systemsand additives have to be chosen accordingly
Modern binder systems with low gas evolution and small emission footprint
Additives with controlled sintering properties and low gas evolution
21
Thank You !
