|Gas setting resin systems|
Polyurethane cold box
POLITEC is a three component, polyurethane based cold box binder system for the high speed production of sand cores.
POLITEC E are a range of polyurethane cold box binders free from aromatic solvents that have been developed to meet stringent environmental and technical requirements. Odor levels and the release of aromatic compounds at the mixing and casting stage have been greatly reduced.
The POLITEC E range consists of three packages:
• POLITEC E 6010 + POLITEC E 9040 is a high-reactivity system.
• POLITEC E 6010 + POLITEC E 9050 is an improved humidity resistance system.
POLITEC XP is a range of cold box resins designed for high-speed repetition core making. All resins in the range exhibit high out of box strengths.
• XP 1000 in combination with XP 1080 offers extended bench life resulting in high productivity.
POLITEC G is a traditional range of amines varying in reactivity
The ECOLOTEC process offers a unique combination of environmental, metallurgical and productivity advantages, unmatched by any other high-production coremaking process. In the ECOLOTEC process, a water-soluble alkaline phenolic resin is mixed with sand and then hardened by gassing with carbon dioxide (CO2) thereby avoiding the problems of smell and emissions associated with systems containing amine and isocyanate. The need for amine scrubbers is avoided freeing up capital and floorspace.
ECOLOTEC binders are extremely clean, non-flammable water-based, resole-CO2 systems that require no scrubber system during coremaking or casting. Odor, fume and VOC emissions at coremaking, pouring and shakeout are significantly lower than with most other foundry resin processes. The absence of sulfur, nitrogen or phosphorous in ECOLOTEC binders ensures freedom from casting defects associated with these elements. In addition the potential for carbon pick-up is negligible. The levels of free phenol and free formaldehyde in ECOLOTEC binders are very low compared to other resin systems.
Cores bonded by way of the ECOLOTEC process demonstrate outstanding thermal properties and provide excellent casting quality on all alloys. Foundries using Foseco’s ECOLOTEC binder process will provide a cleaner, safer plant environment, while improving productivity and casting quality levels, and all at a lower overall cost.
The ECOLOTEC process is the most environmentally-friendly gas cured organic resin process available and offers significant environmental benefits compared to other cold box processes:
• very low free phenol and formaldehyde;
• no isocyanates, peroxides or heavy metals;
• no noxious fumes on mixing, coremaking or casting;
• low VOC (volatile organic compound) emissions;
• no effluent generated;
• easy to use in virtually any core or mold-making process;
• gassing times are short;
• lower applied cost;
• no gas scrubbing equipment investment or maintenance costs.
VAPOSET methyl formate set alkaline phenolic binder system
VAPOSET resin is a high performance alkaline phenolic sand binder which, when used with ester hardeners in vapor form, provides an excellent rapid cold box process suitable for both mold and core production.
VAPOSET resin is a low viscosity binder developed to give improved flowability, which leads to high strength development especially in terms of out of box strength.
VAPOSET is ideally suited to clean dry silica sand. Chromite, zircon and other sands can be used provided the different densities are allowed for.
VAPOSET has low fume evolution during mixing, casting and knockout stages. It exhibits excellent post casting breakdown and possesses superb stripping characteristics from all pattern types.
Casting surface finish is excellent on all metal types without the nitrogen, sulfur or phosphorous related defects associated with the use of other binder systems.
VAPOSET can be used in a unit reclaimed sand system or combined with reclaimed sand from cold set alkaline phenolic bonded sand.