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Solutions for Foundries
Molding Sand Additives
Services aligned to your requirementsJust give us a call and we will deliver − with wide ranging support aligned to your needs. With IMERYS, you can be sure of getting good advice from highly qualified engineers experienced in all aspects of molding material technology. We offer significant expertise acquired in many years of research and development work performed in close collaboration with the foundry industry − know-how that we will be glad to put at your disposal on the basis of a broad spectrum of services:
• Molding material analysis and assessments
• On-site casting and mold failure analysis
• Employee training courses on behalf of our customers
• Investigation-related advice in the testing of new processes and formulations
• Comprehensive Manual of Casting Defects: Incidence and avoidance of defects attributable to molding sands
• Flexible adaptation of our products to customer requirements
IMERYS – Partner to the Foundry Industry
Good ideas for perfect casting results
Our service: Individual green sand cycle analysis designed to reveal true optimization potential
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The brand IMERYS Metalcasting Solutions has emerged from the IKO brand after S&B’s strategic combination with IMERYS. We combine the strengths of IMERYS, the world leader in mineral-based specialty solutions for industry, with our deep know-how, our customized services, quality and innovation in this field.
Advantages in Abundance
IMERYS’s Molding Sand Binders – the natural solutionAs varied as the requirements on different bentonites are, all IMERYS’s molding material additives have one thing in common: They represent the current state of the art while combining ecological sense with economic benefit; because contemporary technological competence must be capable of matching cost-efficiency with environmental compatibility.
Your benefitsThere are many convincing arguments in favor of using our molding sand binders – here are the most important:
• Outstanding thermal stability leading to minimum consumption
• Improve properties
• Uniform mold compaction
• High shape and edge stability
• Minimal dust formation in return sand
• Variable lustrous carbon content and volatile matter (dependant upon selection of carbon additives).
• Rapid dispersion during mulling cycles
Our productsIMERYS has the correct molding sand binder for every foundry application:
• PREMIX - conventional molding sand binders formulated with various clay products, various organic and inorganic additives.
• IKOBOND® - newly developed clay technology designed for superior durability for high density green sand molding.
• NATIONAL® Standard Sodium Bentonite 200 Mesh is used as a binder in the preparation of green sand molding for the production of iron, steel, and non-ferrous casting.
• HYDROBOND® Bentonite is an engineered 200 mesh commercial blue Wyoming sodium bentonite that is used as a binder in foundry green sand systems.
• IKOQUICK® - the innovative solution to maximum quality with a fully modified Sodium Bentonite with the addition of organic additives.
• IMERYS Calcium Bentonite is an 150 mesh commercial calcium bentonite that is used as a binder in foundry green sand system.
IMERYS’s molding sand binders are thoroughly service-proven and reliable
Wide range of high quality
bentonite binders for all your
formative requirements.
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IMERYS – Molding Sand Binders
PREMIX
IMERYS is a pioneer in the development of the PREMIX. The premix facilities located at Cincinnati, Ohio; Waterloo, Iowa, and Birmingham, Alabama, are examples of IMERYS’s commitment to our continuing effort to the development of PREMIX ingredients, improve its production methods and provide better service for the members of the cast metals industry.
Efficiency - IMERYS’s modern blending equipment permits the necessary sand additives to be mixed according to the customer’s specific formula. The blending method provides foundrymen with the ability to adjust and control additive requirements for the entire range of cast metal production to meet the expectations of the future.
Although PREMIX varies according to the type of castings being produced, the following quality ingredients can be used (additional materials may be available upon request).
Pre-wetting - Recent foundry bag house studies revealed a large percentage of dry additives escaping through muller exhaust system. Controlled moisture additions to PREMIX
reduces these losses at the muller and reduces operation costs by eliminating the need for elaborate dust arresting equipment.
Pre-wetting assures rapid additive dispersion in the mulling cycle. Pre-wetting reduces segregation of dissimilar weight components in the PREMIX; thus stabilizing the manufactured product blended ingredients. Because of these reasons, IMERYS reserves the right to add moisture as necessary.
Economy of Bulk Storage - Bulk handling of IMERYS PREMIX assures a reduction in the total labor cost of sand systems. Bulk storage systems permit use of automated equipment to deliver sand additives directly to the muller on an accurately formulated and controlled basis.
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Seacoal Recommended
Causticized Lignite (KWIKFLO™) Recommended
Polymers (KWIKMULL®) Can Be Added
Cellulose Recommended
Cereal/Starch (Including CARBONITE® SA) Recommended
Carbonite® RSB Recommended
Recommended
Recommended
Can Be Added
Recommended
Recommended
Recommended
Recommended
Not Recommended
Can Be Added
Recommended
Recommended
Recommended
Recommended
Recommended
Not Recommended
Recommended
Recommended
Recommended
Recommended
Recommended
Not Recommended
Recommended
Not Recommended
Not Recommended
Additive/Clay Type NATIONAL®
Standard IKOBOND® Calcium Bentonite Hydrobond® IKOQUICK®
National® Standard Less Preferred
PropertiesEvaluated
Squeezability/Flowability Durability Seacoal
ReductionWet Tensile
Strength
GreenCompression
Strength
DryCompression
Strength
HotCompression
Strength
DrawPockets Friability Collapsability/
Shakeout
Preferred Less Preferred Preferred Less Preferred Preferred Preferred Neutral Preferred Less Preferred
IKOBOND® Less Preferred Most Preferred Less Preferred Preferred Preferred Preferred Preferred Neutral Preferred Less Preferred
Calcium Bentonite Less Preferred Less Preferred Less Preferred Less Preferred Preferred Less Preferred Less Preferred Preferred Preferred Preferred
Hydrobond® Less Preferred Preferred Less Preferred Neutral Neutral Less Preferred Preferred Neutral Neutral Neutral
IKOQUICK® Preferred Preferred Preferred Preferred Preferred Neutral Neutral Preferred Preferred Preferred
IKOQUICK® PM1 Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
IKOQUICK® PM2 Preferred Neutral Preferred Neutral Preferred Neutral Neutral Preferred Less Preferred Preferred
IKOQUICK® PM3 Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
ENVIBOND® PM1 Preferred Preferred Most Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
ENVIBOND® PM2 Preferred Neutral Most Preferred Neutral Preferred Neutral Neutral Preferred Less Preferred Preferred
ENVIBOND® PM3 Preferred Preferred Most Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
IKOBOND®: Now available from the research laboratories at IMERYS is a newly developed clay with increased durability and designed for high density molding system. This new clay in mull studies has shown increased durability with respect to Green Compression Strength and Wet Tensile Strength. Test pours of molds prepared with IKOBOND® have shown similar results in durability providing the foundryman with increased confidence in improved performance.
The IKOBOND®’s superior durability and quicker molding property development allows foundries to optimize their consumption usage of bond per ton of metal poured. Molding sand with IKOBOND® also has excellent hot compression strengths and good flowability.
IMERYS
IKOBOND®, molded to perfection
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Seacoal Recommended
Causticized Lignite (KWIKFLO™) Recommended
Polymers (KWIKMULL®) Can Be Added
Cellulose Recommended
Cereal/Starch (Including CARBONITE® SA) Recommended
Carbonite® RSB Recommended
Recommended
Recommended
Can Be Added
Recommended
Recommended
Recommended
Recommended
Not Recommended
Can Be Added
Recommended
Recommended
Recommended
Recommended
Recommended
Not Recommended
Recommended
Recommended
Recommended
Recommended
Recommended
Not Recommended
Recommended
Not Recommended
Not Recommended
Additive/Clay Type NATIONAL®
Standard IKOBOND® Calcium Bentonite Hydrobond® IKOQUICK®
National® Standard Less Preferred
PropertiesEvaluated
Squeezability/Flowability Durability Seacoal
ReductionWet Tensile
Strength
GreenCompression
Strength
DryCompression
Strength
HotCompression
Strength
DrawPockets Friability Collapsability/
Shakeout
Preferred Less Preferred Preferred Less Preferred Preferred Preferred Neutral Preferred Less Preferred
IKOBOND® Less Preferred Most Preferred Less Preferred Preferred Preferred Preferred Preferred Neutral Preferred Less Preferred
Calcium Bentonite Less Preferred Less Preferred Less Preferred Less Preferred Preferred Less Preferred Less Preferred Preferred Preferred Preferred
Hydrobond® Less Preferred Preferred Less Preferred Neutral Neutral Less Preferred Preferred Neutral Neutral Neutral
IKOQUICK® Preferred Preferred Preferred Preferred Preferred Neutral Neutral Preferred Preferred Preferred
IKOQUICK® PM1 Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
IKOQUICK® PM2 Preferred Neutral Preferred Neutral Preferred Neutral Neutral Preferred Less Preferred Preferred
IKOQUICK® PM3 Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
ENVIBOND® PM1 Preferred Preferred Most Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
ENVIBOND® PM2 Preferred Neutral Most Preferred Neutral Preferred Neutral Neutral Preferred Less Preferred Preferred
ENVIBOND® PM3 Preferred Preferred Most Preferred Preferred Preferred Preferred Preferred Preferred Preferred Neutral
100
80
60
40
20
Conventional Clay IKOBOND®
GCSAvg WTS
80.0
89.6
70.4
87.894.8
80.8
Durability Comparison (%)
0.30
0.25
0.20
0.15
0.10
0.05
Conventional Clay IKOBOND®
0.240
0.194
0.257
0.181
AfterBefore
Wet Tensile Strength (N/cm2)
12
11
10
9
8
Conventional Clay IKOBOND®
11.6
11.011.5
10.3
AfterBefore
Green Compression Strength (psi)
IKOQUICK® is the innovative speciality in the world of molding sand binders – patented since 1991 (DEP No. 3704726.4/43) and the subject of ongoing further development.
Significantly improved preparation behaviorIKOQUICK® and IKOQUICK® PM1 and PM2 are conditioned with processed carbon in accordance with a patented technique. IKOQUICK® and IKOQUICK® PM1 and PM2 products are manufactured with the best bentonites from around the world. As the graph shows, this results in a significant improvement in the dispersibility of a bentonite. When using IKOQUICK®, the sand grains are provided with a uniform layer of binder. During the preparation process, the moisture is absorbed more quickly. The benefits:
• The mold strength increases more rapidly to the values required for an optimum molding result for a given preparation time
• The improved preparation behavior of the molding material results in more intensive moisture retention
• The moisture demand is reduced because the portion of “free water” in the return sand decreases. The tendency for explosion penetration to occur is reduced.
Advantages in Abundance
IKOQUICK® – a product from IMERYS Research
Outstanding properties, compelling benefits:• Significantly improved bentonite dispersion
• Reduced dryness of the mold surface
• Increased abrasion resistance (erosion resistance)
• Outstanding sand/casting separation (avoidance of mold and edge cracks)
• Improved, more uniform mold compaction
• Increased edge stability
• Higher dimensional accuracy
• Good green sand reclamation capabilities as processed carbon-containing bentonite layers are more readily detached from the sand grains in the recycling process
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Optimum flow properties
Easy-flowing molding materials are needed for today’s advanced compaction techniques. When using IKOQUICK®, the internal friction of the grain aggregate is significantly reduced – so the flowability of the molding material is appreciably increased. Your benefit: Increased effective bottom pressure due to improved transmission of the squeeze pressure applied to the mold back in the direction of the pattern plate. The graph shows the higher effective bottom pressures achieved in the pattern equipment with IKOQUICK®.
Outstanding mold compaction and shape stabilityThe packing density and mold strength are kept at a uniformly high level when using IKOQUICK®. Even complex contours with high mold shape factors are formed without problem. The risk of a partial occurrence of explosion penetration is reduced as is the tendency for gas defects to form.
Avoidance of spring-back effectsWhen using IKOQUICK®, the spring-back of the mold after compaction is appreciably reduced. Mold defects resulting from spring-back effects are avoided.
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Mold shape factor (Height/Width)
94
92
90
88
86
84
82
1 53,32,5
+GF+ units
without processed carbon
with processed carbon
Even with a mold shape factor of 3.2, the minimum requirement of 80 +GF+ units is exceeded.
Even under maximum molding difficulty, more than 80 +GF+ units are achieved
Mold hardness for different mold shape factors
Compactibility %
24
30 35 40 45 50
22
20
18
16
14
12
Mold abrasion %
without processed carbon
with processed carbon
Normalcompactibility range
Resistance to erosion as a functionof compactibility
40
35
30
25
20
15
10
5
∆ h 50% ∆ h 40%
without processed carbon
with processed carbonSqueeze pressure (MPa)
Effective bottom pressure for different mold shape factors
Green density g/cm3
2,00
1,80
1,60
1,40
1,20
1,00
0,80
0,60
0,40
0,20
1,4 1,5 1,6 1,7 1,8
Spring-back in mm
without processed carbon
with processed carbon
Cods and edgedisintegration
Mold stripping limitMSL = f (Qz/Wt)
Defect-free moldstripping
Wt
Qz
Qz > Wt Wt > Qz
Compaction
Forc
e N
/cm
2
Spring-back of bentonite-bonded sand mold
Properties
ENVIBOND®, in accordance with nature
ENVIBOND® is a bentonite-based system of molding sand binders.
The ProductENVIBOND® is composed of IKOQUICK® and inorganic additives; the IKOQUICK® part in ENVIBOND® guarantees uniform compression together with improved shake-out of the molding sand.
Due to its special composition ENVIBOND® PM1, PM2, and PM3 act in the molding sand in such a way that the addition of lustrous carbon formers can be drastically reduced, without deteriorating the end casting quality.
This has following benefits:• Less pollutant emissions
• Less pollution burden of the molding sand
• Less odor and reduced emissions
• Significantly lower consumption of molding sand binders and lustrous carbon formers
The additives in ENVIBOND® enable an excellent compression of the casting form, and guarantee a lower wettability of the mold surface, and therefore a good casting surface.
The special inorganic components in ENVIBOND®, which are processed according to a patented method, increase the adsorption of core gases and odors released in the molding sand.
Application• ENVIBOND® is available as a pure inorganic binder system
or as a blend in combination with the proven IMERYS additives
• ENVIBOND® is added to the molding sand like a traditional molding sand binder
• ENVIBOND® is not classified as hazardous substance or dangerous good
• ENVIBOND® has unlimited shelf life
Filter after casting in ENVIBOND® — based green sand
Filter after casting in green sand based on
traditional organic binder system
Unused filter
Filtration measurements of operating molding sands comparing ENVIBOND® — based with traditional molding sand additives show a reduction of condensates and dust formation during casting by over 50%
Casting
Core (Silica sand and organic binder system)
Molding sand (Silica sand and ENVIBOND™)
Adsorption of core gases and odors
Increased adsorption of core gases and odors released in the molding sand
The ENVIBOND™ bonded moldingsand emits barely any pollutants
The application of ENVIBOND® in molding sand results in a significant reduction of pollutant emissions and gas formation during casting
ENVIBOND® — A revolution as a result of continuous product evolutionFoundries constantly have to produce good castings in the most efficient way while keeping the burden on environment and workplace at minimum levels. The know-how of the processes taking place inside the molding sand led IMERYS to innovative products.
The positive effect of ENVIBOND® regarding emissions relies on two factors:
• Reduced down to no use of lustrous carbon formers• Adsorption of emerging casting gases that result mainly
from core binders and also from lustrous carbon formers or other gas releasing components
Your benefits• Reduction of emissions and odors up to 95% depending on
the core sand inflow
• Significantly reduced consumption of molding sand binders
• Clean air at the workplace
• Increased possibilities of molding sand recyclability due to lower content of pollutants and condensates
• Homogeneous compression and uniform casting surface quality due to highest possible molding sand flowability
• Fewer moisture related casting defects (for example explosion penetrations) due to decrease of the moisture demand of the molding sand
• Environmental objectives are easier achievable
• Additional economic efficiency because less air filtration is necessary
• Reduction of environmental-related investments
Benefits
“Smoking prohibited” in foundries
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Operating molding sand, prepared with Bentonite and Lustrous Carbon Formers (4.5% loss of ignition)
Operating molding sand, prepared with ENVIBOND® (2% loss of ignition)
Explanation of the lab trial
Molding sand, prepared with ENVIBOND® in the laboratory (without decomposed cores)
0 5 10 15 20 25
Gas volumeand pollutants
Molding sand samplesurrounded by Fe-metal(50 x 60 mm)
Gas formation
Traditional ready blendENVIBOND®
Properties of ENVIBOND®
Shake-out properties
Environment and workplace
Recyclability of molding sand
Casting surface
Economic efficiency
Minimum gasformation and
odor release
The main criterion for selecting the appropriate raw material is the subsequent application for the molding sand binder. Because, although bentonite can be found all around the world, high-grade, high-yield and homogeneous deposits are rare. IMERYS has secured its long-term access to such deposits. Its own bentonite mines and reliable raw material suppliers guarantee the availability of bentonites of uniform quality in any quantity required. Consequently, when making the raw material selection, it is always the suitability of the bentonite concerned that takes priority rather than its availability – because this is always guaranteed.
Quality assurance is our bondWe monitor all the production stages using the most advanced methods and techniques – starting with raw materials right up to individually aligned end products – additives for the manufacture of which IMERYS always has the right bentonite in stock. Sufficient quantities of different grades are kept permanently in reserve so that we can always offer the right product, prepared using special manufacturing and treatment processes for a wide range of different applications.
Benefits for the environment Modern sand binders – such as IKOQUICK® – reduce the water requirement of the molding material. Thanks to optimum flowability and compaction properties, a uniformly high mold packing density is achieved every time.
The wettability of the mold surfaces by the liquid metal is reduced and the requirement for lustrous carbon formers in the molding sand is decreased. The volume of volatile organic compounds (VOC) may also be reduced. Moreover, fewer organic crack products are formed.
Hydrobond®
HYDROBOND® is an engineered 200 mesh commercial blue Wyoming Sodium Bentonite that is used as a binder in foundry green sand systems. HYDROBOND® imparts the highest degree of hydration over natural occurring Wyoming Sodium Bentonites, imparts excellent green sand properties and high durability.
Quality
The best bentonites from around the world
IMERYS has its own bentonite mines
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IMERYS Seacoal
IMERYS Seacoal contains high quality bituminous coal which has been produced from a natural formation of solid fuel. Seacoal in a pulverized powder form, burns during the casting process to provide the correct mold atmosphere required for producing high quality castings.
Two reasons why IMERYS Seacoal in your sand system assures better castings and lower cleaning costs:
HIGH VOLATILE MATTER assures better sand peel with reduced cleaning costs; minimizes “burn-on”; provides satisfactory sand peel from casting; and inhibits pinholes.
LOW ASH CONTENT means fewer inert fines; reduces hazard of inert fines built-up in the sand system.
Seacoal is packaged in 50 lb. multi-wall paper bags, bulk bags or bulk shipped in pneumatic tank trucks.
Typical Range of Analysis* (Analysis on Dry Basis)
Moisture 7.0% Max.
Sulfur 1.0% Max.
Volatile Matter 34% to 43%
Fixed Carbon 50% to 60%
Ash 10% Max.
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Perfect surface finish makes
for a polished performance
IMERYS – Partner to the Foundry Industry
Good ideas for perfect molding results Carbonaceous Additives that are Clay ModifiersIMERYS has developed a unique family of Carbonaceous Additives that support molding sand by modifying the bentonite clays (binders):
• KwikFlo™
• KwikMull®
KwikMull® is a unique blend of organic polymers that when added to green sand systems enhances the performance of the added clay package. KwikMull® has been designed to allow prepared sand to exhibit superior properties. This unique material actually allows for better dispersion of the clay and in turn allows for better bonding with the sand grains.
KwikMull® gives molding sand that velvety smooth feel that all foundry men strive for. Although the sand compacts better, the sand is not “sticky” and is still very flowable. Clays develop strengths more quickly when KwikMull® is used.
Improvements which will be achieved in the sand system:• The clay water relationship will be enhanced. Foundries
will be able to add less water to achieve a given compactability target. Less water means less defects associated with higher water content such as mechanical penetration or blows.
• Because of KwikMull’s® ability to allow for superior mulling; mulling efficiencies will improve.
• Better sand flow due to less balling up of the sand and decreased agglomerations.
• Enhanced green and dry strengths properties.
• Better utilization of added clays.
• Improved densities, which means less inclusions.
• Better collapsibility of the molding sand at shakeout.
KwikFlo™ is a blend of organic and inorganic additives used in PREMIX formulations in conjunction with Seacoal to develop superior performance properties in green sand molding systems! This proprietary blend of organic additives is an effective replacement for causticized lignite (referred to as leonardite on occasion). Causticized Lignite has become recognized as a proven modifier of bentonite clays. With the addition of KwikFlo™ into a green sand formulation, a reduction in the emission characteristics of molding sand during the pouring, cooling, and shakeout can be realized.
Characteristics of Sand System After Introduction• KwikFlo™ is usually added to a PREMIX formulation at 4
to 7% levels. Reduced later after the molding sand system has become stabilized.
• Green Strength will increase, providing a correct clay-water ratio is maintained because KwikFlo™ can preactivate the clays in PREMIX.
• With the addition of increased levels of Western Bentonite, the KwikFlo™ can reduce the bond usage in green sand systems over green sand systems that traditionally utilize a blend of Sodium and Calcium Bentonite.
• Mold strength (as measured in mold hardness) and density (as measured in AFS sand specimen) will increase flowability because of the addition of KwikFlo™.
Benefits• Increases sand compaction and mold density
• Improved clay dispersion in mulling cycle
• Replaces causticized lignite in green sand molding operations
• Micronized particles of KwikFlo™ can diffuse rapidly into sand system
• I ncreases flowability and squeezability of molding sand
• More accurate casting dimensions
• Reduced emission characteristics in green sand
• Compatible with most PREMIX formulations
• Smooth, silky feel to system sand
• Improves clay efficiency
• Product must be included in a PREMIX formulation
Clay Modifying Carbonaceous Additives
ANTRAPEX® is a service-proven core sand additive that positively influences both the core and the bentonite-bonded molding material. The additive is mixed with core sand and thus contributes to reducing expansion and penetration defects. After core breakdown, ANTRAPEX® passes into the molding material where it has a positive effect on the casting surface and sand stability. The amount of adhering molding sand is also minimized.
The ProductANTRAPEX® is a blend of organic and inorganic components. The core sand additive has been developed by IMERYS especially for the PUR Cold Box process.
PropertiesANTRAPEX® offers the following outstanding technological properties and benefits:
• Following casting production, compressive stresses in the core are reduced. As a result, expansion defects such as finning (veining) are reduced or completely avoided.
• The organic components improve the finish of the casting.
• The need for coating is reduced and may even be eliminated.
• ANTRAPEX® has no negative influence on the flowability of the core sand.
Your benefitsANTRAPEX® facilitates the production of high-quality castings:
• Casting surfaces of near-perfect finish
• Significantly reduced expense in terms of core coating operations
• Following core breakdown, the residues develop lustrous carbon
• Good recyclability.
• Reduced gas formation in the core
Minimal Gas FormationCompared with other organic additives, the proportion of volatile components in ANTRAPEX® is minimal. The degree of gas formation is lower - with maximum gas release postponed to a later point in the process. Gas defects in the core are thus reduced.
Casting without ANTRAPEX® can cause finning and veining.
The use of ANTRAPEX® in the core send reliably eliminates the likelihood of finning and veining!
Advantages in Abundance
ANTRAPEX®, with double benefits – in the core and in the molding material
Reduction in expansion and penetration defects in the core
Highly effective lustrouscarbon former in the molding sand
Double benefits: The effects of ANTRAPEX®
The doubly positive effect of ANTRAPEX® gives it a significant lead over conventional core sand additives.
Casting
14
IMERYS – Molding Sand Blasters
Auxiliary Products for PREMIX
Although PREMIX varies according to the type of castings being produced, the following quality ingredients can be used (additional materials may be available upon request).
Special Organic Additives• Cereal
• CARBONITE® SA
• CARBONITE® RSB
• Cellulose
As a compliment to the Primary Ingredients found in PREMIX the addition of special Organic and Inorganic Additives (referenced to as Auxiliary Products and others) can be added to most formulated mixtures. These additives can be requested by foundrymen or suggested by representatives of IMERYS as technical advice related to visits and/or suggested improvements to a foundry molding sand. Because of these reasons; IMERYS reserves the right to add materials as necessary.
Economy of Bulk Storage - Bulk handling of IMERYS PREMIX assures a reduction in the total labor cast of sand systems. Bulk storage systems permit use of automated equipment to deliver sand additives directly to the muller on an accurately formulated and controlled basis.
15
IMERYS – Partner to the Foundry Industry
Good ideas for perfect molding results CARBONITE® AdditivesOur ProductsCarbonites® have been developed by IMERYS as a unique family of Carbonaceous Additives that support molding sand (some of these include):
• Carbonite® SA
• Carbonite® RSB
• And others
CARBONITE® SA is a unique starch additive. It is a cold water-soluble material that is blended into either a PREMIX or bentonite clay. As an additive it can:
• Provide sharp edges and detail to clay bonded sand
• Replaces cereal by a ratio of 3 to 1 or 2 to 1
• Minimizes spring back in high pressure molding
• Increases dry strength
• Improves flowability compared to cereal formulations
• Increases wet tensile
• Reduces friable edges
CARBONITE® RSB is a white, free-flowing powder for use with natural and synthetic sands. CARBONITE® RSB controls expansion stresses in green molding sand. Formulated for gray iron, ductile iron, malleable iron, aluminum, brass and bronze castings.
• Eliminates rat-tails, buckles and expansion scabs
• Stabilizes green sand
• Reduces thermal expansion
• Improves flowability
• Eliminates skin drying
• Does not alter other sand properties
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IMERYS – Partner to the Foundry Industry
Additional Auxiliary Products
The Cellulose family of additives have been utilized in the foundry industry for years. Cellulose is a fibrous substance of approximately 100 mesh. Cellulose effectively compensates for sand expansion during the casting cycle providing control over the occurrence of rat-tails, buckles and expansion scabs. Cellulose is the replacement for this family of materials!
• Improves shakeout by reducing retained strengths
• Promotes thermal stability
• Develops flowability
• Provides cushioning effect between expanding sand grains
Cellulose becomes an intricate part of the sand-clay matrix. This characteristic assures complete distribution during the mulling cycle. The high fiber content of Cellulose converts readily to activated carbons promoting complete dispersion of clays.
Soda Ash is our inorganic additive that can be used to minimize sand encapsulations.
Cereal is a product that has been around the foundry industry for many years. It can be used in all metal casting foundries (Steel, Iron, Aluminum, and Brass/Bronze). It is an all purpose binder.
• Develops high green strength
• Promotes high scratch hardness
• Limited effect on flowability of molding sand
IMERYS has many additional auxiliary materials that are available to the foundry industry and is made available to PREMIX formulations!
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Advantages in Abundance
RIKO® – Reduce Waste, Improve Quality
RIKO® is the innovative solution in the world of molding sand binders and molding sand (patented process). RIKO® technology generates totally hydrated bentonite and coal from foundry waste streams. This results in better performing bentonite and reduction of disposal costs.
Improved molding sand behaviorRIKO® bond slurry when added to molding sand results in an improvement in molding sand properties because of the improved dispersion of the bentonite and carbons. When using RIKO® the molding sand grains are provided with a uniform layer of binder and organics that result in an improved casting surface. During the preparation of molding sand RIKO® bond slurry rapidly disperses into the molding sand. This dispersion results in improved mold compaction and shape stability of the prepared molds. The packing density and mold strength are kept at a uniformly high level when using RIKO®
bond slurry. Even complex contours with high mold shape can be improved!
RIKO® Process ProductsThe RIKO® process develops two components from foundry waste streams:
• Slurry which contains both bentonites and carbon additives.
• Sand to be introduced into molding sand
The RIKO® bond slurry contains both bentonites and carbons replacing a portion of the PREMIX that is added to green sand at the muller or in a foundry’s sand cooler. This addition can be substituted for any desired amount of PREMIX depending upon the mass balance of bond to molding sand. The RIKO® bond slurry reduces the quantity of bond that is required to generate molding sand strength properties. RIKO® bond slurry is an ideal dispersion providing fully hydrated bentonite particles significantly improving the molding sand characteristics .
The RIKO® sand is designed to be used in molding sand application as “make-up” sand. The RIKO® sand is finer by the fact that it is generated in dust collection systems. With the shortage of fine sand because of the use of traditional foundry sand in other industrial applications the RIKO® sand has become a valuable addition to the raw materials available to the foundry industry.
RIKO® bond slurry can also be made available to PREMIX formulations manufactured at IMERYS facilities as an ingredient.
The RIKO® process utilizes foundry dust as a source of materials for green sand molding operations to create a high value product in a sustainable way. The advantages that the RIKO® product brings to foundries include:
• Enhanced molding sand properties
• Reduction in casting defects
• Improved molding sand performance
• Reduced bond consumption
• Reduction of waste disposal costs
RIKO® Slurry
RIKO® process
Foundry waste system
Reclaimed sand
Advantages in Abundance
SlagBuster® – A Slag Coagulant for Immediate Reaction Slagbuster® is made out of granular, non-metallic material specifically designed to remove slag in molten metal applications. Any slag present on the molten metal will adhere to Slagbuster® and continue to float. The combined slag/ Slagbuster® can then be removed from the molten metal in large pieces, resulting in clean molten metal for the casting process.
All Slagbuster® C, M, F grades can be used in multiple foundry applications: steel; grey, malleable and ductile iron; bronze and brass; etc.
Production selection depends on many considerations, including metal charge cleanliness, furnace or ladle dimensions, metal cleanliness objectives targeted by the industry, etc.
ApplicationAll Slagbuster® C, M, F can be used in either furnace or ladle. However, for best results, it is suggested to use Slagbuster® C, M in furnace and Slagbuster® F in ladle.
All Slagbuster® C, M, F should be generously distributed on top of the molten metal of a full ladle or furnace. Slagbuster® will expand very rapidly in contact with molten metal and it will change color, turning into a white color. At this point, the material and slag should be removed from the metal.
Slagbuster® should only be used once the pouring ladle or the furnace is full.
PackagingSlagbuster® can be packaged in Super Sacks, 55 gallon drums or paper bags.
CautionSlagbuster® should always be stored in a dry environment.
Slagbuster® is available in three different sizes:• Slagbuster® C (Coarse)
• Slagbuster® M (Medium)
• Slagbuster® F (Fine)
Advantages• Slagbuster® reacts immediately with the slag when
it is added onto the melt.
• Forms a solid mass with the slag making it easy to remove from the melt.
• Prevents slag buildup on furnace refractory, ladle walls and pouring tips.
• Prevents slag inclusions such as magnesium sulfides in the finished products.
• Contribute to reduce the overall scrap rate and increase profitability.
• Can be also used as insulating cover.
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Our history We have a long tradition as a supplier of foundry-grade bentonites, originally using our world renowned reserves on the Greek island of Milos. With the acquisition of IKOErbsloeh in 2001, we moved closer to foundry customers in Europe supplying them with bentonite, coal and application technology. We expanded first into the Americas and then to China and India by incorporating the expertise, technology and assets of local foundry suppliers.
For more information visit us at www.imerys.com
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