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Resins

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Other Foundry Chemicals

Resins


	Alkaline Resol-Ester (Alphaset)
	Phenolic No-Bake Acid Cured System
	Furan No-Bake Binder System
	Polyurethane No-Bake Binder System
	Polyurethane Cold box System
	Binder System Shell moulding
	Resol – CO²

ALKALINE RESOL-ESTER (ALPHASET)

The resol-ester binder system also commonly known as AlpHaset is a two component air setting system consisting of an alkaline water based PF resin (pt1) and an ester based hardner (pt2). Over the last decade it has grown into becoming one of the most preferred system for cast iron and steel foundries across India. The product itself has improved greatly with lower viscosity, longer shelf life, better sand reclaimability, higher bond strengths and easier release over the last few years. It offers several other advantages like:

Free from sulphur, phosphorus and nitrogen.
Non-hazardous hardner (pt2)
Low Gas evolution
Offers lowest risk to defects like veining, scabs, erosion & hot tear.
Very good mould or pattern release
Increased productivity
Clean-up using water only
More environmentally friendly than other no-bakes (during mixing, moulding& pouring)
Secondary curing gives excellent hot strengths
Good Shakeout properties
Working time of 1.5 – 25 mins depending on temperature & rel. humdity

SAND MIXING
The Resol-ester system (resin (pt1) & co-reactant (pt2)) can be mixed in both batch and continuous mixers. In case of batch mixers add the co-reactant first, mix for 2 minutes followed by addition of the resin. In a continuous mixer either the resin or co-reactant can be added first.

REFRACTORY COATINGS
Water & alcohol based coatings can both be used however the system is soluble in both. Therefore it is good practice to employ good drying techniques to the core/mould surface prior to application of the coating. Alcohol based coatings must be ignited immediately after application whereas excess moisture from water based coatings must be dried off in an air circulated heating oven.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical (alkali) resistant gloves and facemasks are required while using and handling this binder system. For more information refer to MSDS.Store in shade and not under direct sunlight. Shelf life: 6 months @ 25 °C from date of manufacturing

Phenolic No-Bake Acid Cured System

The Phenolic NB system is a two part air-setting system consisting of an aqueous resole resin (pt1) and an acid based Hardner (pt2). This process is particularly suitable for production of individual heavy castings of steel, gray iron & ductile iron. Some of its features are:

Long Sand bench life
Low over-cure tendency
Improved humidity resistance
Low gas content
Low to nil nitrogen
Excellent casting finish
Reduced pollutants due to low levels of phenol & formaldehyde
Very good sand recoverability
Adjustable Bench life (2 – 15 mins) depending on temperature and Rel. Humidity

SAND MIXING
The Phenolic NB system can be mixed in both batch as well as continuous mixers. In a batch mixer however it is recommended to mix the acid co-reactant first with sand followed by resin.

REFRACTORY COATINGS
Both alcohol and water based coatings can be used. In case of alcohol-based coatings ignition immediately after application is suggested. For water-based coatings drying must be done in an air-circulating oven to remove moisture out of the system.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical (acid) resistant gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight.
Shelf life: 3 months @ 20°C from date of manufacturing

Furan No-Bake Binder System

The furan no-bake process consists of a two part air-setting system involving a Resin (pt1) and Acid hardner (pt2). This systemis developed to suit a wide variety of applications across the ferrous and non-ferrous foundries. Nitrogen content may vary depending on grade of resin. The system offers various features like

Low viscosity
Low addition rates
High hot & cold strengths
Dimensional accuracy
Rapid curing systems for shorter stripping times
High productivity
Long shelf life
Easy sand reclamation
Special Low Sulfur systems for high quality nodular iron
Nitrogen free systems for special steel applications
Adjustable Bench life (2 – 15 mins) depending on temperature &Rel Humidity.

SAND MIXING
The Furan NB system can be mixed in both batch as well as continuous mixers. In a batch mixer however it is recommended to mix the acid co-reactant first with sand followed by resin.

REFRACTORY COATINGS
Both alcohol and water based coatings can be used. In case of alcohol-based coatings ignition immediately after application is suggested. For water-based coatings drying must be done in an air-circulating oven to remove moisture out of the system.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical (acid) resistant gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight & any flames / hot surfaces The Acid hardner (part2) and resin (part1) produces a violent exothermic reaction on coming in direct contact with one another. Therefore, they must not be stored or mixed together even in small quantities. Shelf life: 6 months at 30°C from date of manufacturing

Polyurethane No-Bake Binder System

The polyurethane no-bake (PUNB) binder is a three-component system comprising of a liquid phenol-formaldehyde resin (part1), liquid polyisocyanate (part2) and a liquid catalyst (part3). The catalyst (part3) controls the curing rate of the reaction if required and in turn controls the stripping time of the core / mould. There are various features of this system, which make it an excellent choice for steel, ferrous and non-ferrous castings like:

Rapid strength development
Excellent dimensional accuracy
Very good breakdown properties
Very High productivity
Excellent hot strengths
Very good sand flow ability
High Sand reclamation
Adjustable Bench life / working time (1 – 4 mins on thermally reclaimed sand & 1 – 8 mins on fresh sand) depending on temperature

SAND MIXING
The PUNB system can be mixed in batch as well as continuous mixers but the latter is preferred due to the rapid speed of the reaction. Addition of the part 3 (catalyst) can be adjusted to get the desired stripping time. Varying the ratio of part1 and part2 does not change the speed of the reaction.

REFRACTORY COATINGS
Both alcohol and water based coatings can be used. In case of alcohol-based coatings ignition immediately after application is suggested. For water-based coatings drying must be done in an air-circulating oven to remove moisture out of the system.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical resistant gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight & any flames / hot surfaces Shelf life: 6 months at 30°C from date of manufacturing The polyisocyanate (part2) reacts violently with water or alcohol and releases CO². Hence care must be taken for them to not come in contact with eachother.

Polyurethane Cold box System

The Polyurethane Coldbox binder is a 3-component system comprising a liquid PF resin (part1), a liquid polyisocyanate (part2) and a liquid catalyst (part3). The liquid amine catalyst is vaporized and used to crosslink a sand mix containing part1 and part2. In recent times the Coldbox system has grown into becoming one of the most preferred systems for the foundries worldwide making automotive components. It offers various benefits like:

Very high productivity
High tensile strengths
Excellent dimensional accuracy
Superior release
Good humidity resistance
Extended Bench life up to 60 mins
Fast curing speeds
Quick curing products for Core Centers

SAND MIXING
The PUNB system can be mixed in batch mixers only and the mixed sand can be stored up to 1 hr (bench life) depending on temperature & rel. humidity without a significant drop in performance. The mixed sand must be transferred and used in a core shooter within this period. The catalyst (part3) must be vaporized and passed through the corebox to cure the sand mix.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical resistant gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight & any flames / hot surfaces Shelf life: 6 months at 30°C from date of manufacturing The polyisocyanate (part2) reacts violently with water or alcohol and releases CO². Hence care must be taken for them to not come in contact with eachother.

Binder System Shell moulding

The shell mouldingbinder is a 2-component system comprising of a liquid novolac type PF resin and a powder based hardner (part2). Also referred to as the Croning process it has been applied to foundries across the globe for over 60 years. Even though in recent years its use has been replaced with newer / more productive binder systems it still offers excellent reliability & various advantages like:

Very high bending & tensile strengths
Excellent humidity resistance
No peel-back
High temperature resistance & stability
Superior veining resistance
Good shakeout
Excellent for critical applications like water jackets

SAND MIXING
The shell resin binder system must be mixed in a batch mixer using the warm coating process. Addition levels and Coating cycles may vary from one customer to another depending on requirements.

REFRACTORY COATINGS
Both alcohol and water based coatings can be used. In case of alcohol-based coatings ignition immediately after application is suggested. For water-based coatings drying must be done in an air-circulating oven to remove moisture out of the system.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical resistant gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight & any flames / hot surfaces
Shelf life: 6 months at 30°C from date of manufacturing

Resol – CO²

The Resol – CO² binder is a highly alkaline single component liquid resin that cures in the presence of CO² gas. It offers various advantages for use in steel, ferrous and non-ferrous castings like:

Superior veining resistance
No lustrous carbon defects
No phosphorus, sulphur or nitrogen
Low odor during moulding, pouring and shakeout
Excellent breakdown properties leading to easy shakeout
Non-flammable & low BTX emissions
Easy cleaning of mixer & other equipment

SAND MIXING
Sand mixing must be done in a batch mixer for 3 minutes for good mixing. Once mixed, the sand must be kept covered with wet cloth to avoid minimum contact with air. Gassing time of CO² depends on core dimension.

REFRACTORY COATINGS
Use of alcohol based coatings is recommended but in special cases water based coatings maybe used. In case of alcohol-based coatings ignition immediately after application is suggested. For water-based coatings drying must be done in an air-circulating oven to remove moisture out of the system. It is a good practice to apply coating 30 minutes after gassing the core.

SAFETY PRECAUTIONS, STORAGE & HANDLING
Use of protective clothing, chemical resistant (alkali) gloves & facemasks are to worn while using and handling this binder system. For more information please refer to MSDS. Store in shade away from direct sunlight & any flames / hot surfaces
Shelf life: 3 months at 30°C from date of manufacturing

PHENOLIC HOT BOX

RESITAL 6861
Resital 6861 is a pure phenolic hot box resin modified with urea for use in warm and hot countries. The Nitrogen level is very low as a result the through cure is slightly slower than that of urea based phenolic hot box resin with higher nitrogen level. On the other hand there is the advantage that it is possible to work without using iron oxide. This resin is used in grey cast iron foundry and can be used on all types of core shooters.

Catalyst 6593
This is an aqueous solution of ammonium salts combined with a number of additives which ensure a long bench life. This is only reactive at elevated temperatures & initiates rapid cross linking.

Konserver
This is a bench life extender & composed of polymerized additives and aromatic solvents. This also improves the flowability and releasing properties of the Sand Mix.

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