Sintered ceramic sand for foundry with cold core box

Short Description:

The cold box method refers to a resin sand forming process that is catalyzed/hardened by blowing in gas or aerosol, and formed instantaneously at room temperature. The common method is the triethylamine method, which uses phenolic-urethane resin and is hardened by blowing triethylamine gas. The characteristics of this process are: the core sand can be used for a long time, the mold-drawing time is short, the production efficiency is high, and the energy consumption is low.


Product Detail

Product Tags

The cold box method refers to a resin sand forming process that is catalyzed/hardened by blowing in gas or aerosol, and formed instantaneously at room temperature. The common method is the triethylamine method, which uses phenolic-urethane resin and is hardened by blowing triethylamine gas. The characteristics of this process are: the core sand can be used for a long time, the mold-drawing time is short, the production efficiency is high, and the energy consumption is low.

Diesel engine castings, such as cylinder blocks, cylinder heads, intake and exhaust pipes, etc., some have complex core shapes and small partial cross-sectional areas, which are prone to false shots, fractures, etc., or veins appear in the castings due to the large expansion of silica sand. The probability of defects such as sticky sand and pores is also relatively high.

Sintered-ceramic-sand-for-foundry-with-cold-core-box-(4)
Sintered-ceramic-sand-for-foundry-with-cold-core-box-(5)

Using ceramic sand or mixing ceramic sand and silica sand in proportion, the amount of resin added is reduced by 20-30%, and the above defects have been significantly improved. At the same time, the sand core has good collapsibility, which reduces the workload of casting cleaning. As a result, more and more diesel engine casting foundries have adopted ceramic sand cold core box technology.

Ceramic Sand Property

Main Chemical Component Al₂O₃≥53%, Fe₂O₃<4%, TiO₂<3%, SiO₂≤37%
Grain Shape Spherical
Angular Coefficient ≤1.1
Partical Size 45μm -2000μm
Refractoriness ≥1800℃
Bulk Density 1.5-1.6 g/cm3
Thermal Expansion(RT-1200℃) 4.5-6.5x10-6/k
Color Sand
PH 6.6-7.3
Mineralogical Composition Mullite + Corundum
Acid Cost <1 ml/50g
L.O.I. <0.1%

Compare with other raw sand test result of Cold box process

Raw Sand Resin Add. 2h Tensile Strength Gas Evolution
Sintered Ceramic Sand 1.5% 2.098 MPa 10.34 ml/g
Scrubbed Sand 1.5% 1.105MPa 13.4 ml/g
Baked Sand 1.5% 1.088 MPa 12.9 ml/g
Sintered Ceramic Sand+ Scrubbed Sand 1.5% 1.815 MPa 12.5 ml/g
Sintered Ceramic Sand+ Baked Sand 1.5% 1.851 MPa 12.35 ml/g
Chromite Sand+ Scrubbed Sand 1.5% 0.801 MPa 10.85 ml/g
Chromite Sand+ Baked Sand 1.5% 0.821 MPa 10.74 ml/g

Compare with Castings defects rate of Cold box process

Raw Sand Veins Core Broken Sinter Choke Total
Sintered Ceramic Sand 0% 2% 0% 0 2%
Scrubbed Sand 28% 12% 4% 3% 47%
Baked Sand 24% 10% 3% 2% 39%
Sintered Ceramic Sand+ Scrubbed Sand 12% 4% 1% 2% 19%
Sintered Ceramic Sand+ Baked Sand 7% 3% 2% 2% 14%
Chromite Sand+ Scrubbed Sand 13% 6% 5% 4% 28%
Chromite Sand+ Baked Sand 12% 4% 2% 2% 20%

Parts of Particle size Distribution

The particle size distribution can be customized according your requirement.

Mesh

20 30 40 50 70 100 140 200 270 Pan AFS

μm

850 600 425 300 212 150 106 75 53 Pan  
Code 40/70   ≤5 20-30 40-50 15-25 ≤8 ≤1       43±3
70/40   ≤5 15-25 40-50 20-30 ≤10 ≤2       46±3
50/100     ≤5 25-35 35-50 15-25 ≤6 ≤1     50±3
100/50     ≤5 15-25 35-50 25-35 ≤10 ≤1     55±3
70/140       ≤5 25-35 35-50 8-15 ≤5 ≤1   65±4
140/70       ≤5 15-35 35-50 20-25 ≤8 ≤2   70±5
100/200         ≤10 20-35 35-50 15-20 ≤10 ≤2 110±5

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