Solutions for Foundries Molding Sand Additives 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.
IMERYS – Partner to the Foundry Industry Good ideas for perfect casting results
Services aligned to your requirements • Comprehensive Manual of Casting Defects: Incidence and Just give us a call and we will deliver − with wide ranging avoidance of defects attributable to molding sands support aligned to your needs. With IMERYS, you can be • Flexible adaptation of our products to customer requirements 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 Our service: Individual green sand cycle analysis designed to reveal true optimization potential
2 Wide range of high quality bentonite binders for all your formative requirements.
IMERYS’s molding sand binders are thoroughly service-proven and reliable Advantages in Abundance IMERYS’s Molding Sand Binders – the natural solution
As varied as the requirements on different bentonites are, Our products all IMERYS’s molding material additives have one thing in IMERYS has the correct molding sand binder for every foundry common: They represent the current state of the art while application: combining ecological sense with economic benefit; because contemporary technological competence must be capable of • PREMIX - conventional molding sand binders formulated matching cost-efficiency with environmental compatibility. with various clay products, various organic and inorganic additives. Your benefits • IKOBOND® - newly developed clay technology designed for There are many convincing arguments in favor of using our superior durability for high density green sand molding. molding sand binders – here are the most important: • NATIONAL® Standard Sodium Bentonite 200 Mesh is used as a binder in the preparation of green sand molding for the • Outstanding thermal stability leading to production of iron, steel, and non-ferrous casting. minimum consumption • HYDROBOND® Bentonite is an engineered 200 mesh • Improve properties commercial blue Wyoming sodium bentonite that is used as • Uniform mold compaction a binder in foundry green sand systems. • High shape and edge stability • IKOQUICK® - the innovative solution to maximum quality • Minimal dust formation in return sand with a fully modified Sodium Bentonite with the addition of • Variable lustrous carbon content and volatile matter organic additives. (dependant upon selection of carbon additives). • IMERYS Calcium Bentonite is an 150 mesh commercial • Rapid dispersion during mulling cycles calcium bentonite that is used as a binder in foundry green sand system.
3 IMERYS – Molding Sand Binders PREMIX
IMERYS is a pioneer in the development of the PREMIX. reduces these losses at the muller and reduces operation The premix facilities located at Cincinnati, Ohio; Waterloo, costs by eliminating the need for elaborate dust arresting Iowa, and Birmingham, Alabama, are examples of IMERYS’s equipment. commitment to our continuing effort to the development of PREMIX ingredients, improve its production methods and Pre-wetting assures rapid additive dispersion in the mulling provide better service for the members of the cast cycle. Pre-wetting reduces segregation of dissimilar weight metals industry. components in the PREMIX; thus stabilizing the manufactured product blended ingredients. Because of these reasons, Efficiency - IMERYS’s modern blending equipment permits IMERYS reserves the right to add moisture as necessary. the necessary sand additives to be mixed according to the customer’s specific formula. The blending method provides Economy of Bulk Storage - Bulk handling of IMERYS PREMIX foundrymen with the ability to adjust and control additive assures a reduction in the total labor cost of sand systems. requirements for the entire range of cast metal production to Bulk storage systems permit use of automated equipment to meet the expectations of the future. deliver sand additives directly to the muller on an accurately formulated and controlled basis. 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
Green Dry Hot Properties Squeezability/ Seacoal Wet Tensile Draw Collapsability/ Durability Compression Compression Compression Friability Flowability Reduction Strength Pockets Shakeout Evaluated Strength Strength Strength
National® Standard Less Preferred 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
NATIONAL® Additive/Clay Type IKOBOND® Calcium Bentonite Hydrobond® IKOQUICK® Standard
Seacoal Recommended Recommended Recommended Recommended Recommended 4 Causticized Lignite (KWIKFLO™) Recommended Recommended Not Recommended Recommended Recommended
Polymers (KWIKMULL®) Can Be Added Can Be Added Can Be Added Not Recommended Not Recommended
Cellulose Recommended Recommended Recommended Recommended Recommended
Cereal/Starch (Including CARBONITE® SA) Recommended Recommended Recommended Recommended Not Recommended
Carbonite® RSB Recommended Recommended Recommended Recommended Not Recommended Green Dry Hot Properties Squeezability/ Seacoal Wet Tensile Draw Collapsability/ Durability Compression Compression Compression Friability Flowability Reduction Strength Pockets Shakeout Evaluated Strength Strength Strength
National® Standard Less Preferred 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
NATIONAL® Additive/Clay Type IKOBOND® Calcium Bentonite Hydrobond® IKOQUICK® Standard
Seacoal Recommended Recommended Recommended Recommended Recommended
Causticized Lignite (KWIKFLO™) Recommended Recommended Not Recommended Recommended Recommended
Polymers (KWIKMULL®) Can Be Added Can Be Added Can Be Added Not Recommended Not Recommended
Cellulose Recommended Recommended Recommended Recommended Recommended
Cereal/Starch (Including CARBONITE® SA) Recommended Recommended Recommended Recommended Not Recommended
Carbonite® RSB Recommended Recommended Recommended Recommended Not Recommended
IMERYS IKOBOND®, molded to perfection
IKOBOND®: Now available from the research laboratories at Wet Tensile Strength (N/cm2) IMERYS is a newly developed clay with increased durability and designed for high density molding system. This new clay Before After in mull studies has shown increased durability with respect to Green Compression Strength and Wet Tensile Strength. Test 0.30 pours of molds prepared with IKOBOND® have shown similar 0.257 0.25 0.240 results in durability providing the foundryman with increased 0.194 confidence in improved performance. 0.20 0.181
0.15 The IKOBOND®’s superior durability and quicker molding property development allows foundries to optimize their 0.10 consumption usage of bond per ton of metal poured. Molding 0.05 sand with IKOBOND® also has excellent hot compression strengths and good flowability. Conventional Clay IKOBOND®
Green Compression Strength (psi) Durability Comparison (%)
Before After Avg GCS WTS
12 94.8 11.5 11.6 100 89.6 87.8 11.0 80.0 80.8 11 80 10.3 70.4
10 60
9 40
8 20
® Conventional Clay IKOBOND Conventional Clay IKOBOND®
5 Advantages in Abundance IKOQUICK® – a product from IMERYS Research
IKOQUICK® is the innovative speciality in the world of molding Significantly improved preparation behavior sand binders – patented since 1991 (DEP No. 3704726.4/43) IKOQUICK® and IKOQUICK® PM1 and PM2 are conditioned and the subject of ongoing further development. with processed carbon in accordance with a patented technique. IKOQUICK® and IKOQUICK® PM1 and PM2 products are manufactured with the best bentonites from Outstanding properties, compelling benefits: around the world. As the graph shows, this results in a • Significantly improved bentonite dispersion significant improvement in the dispersibility of a bentonite. • Reduced dryness of the mold surface When using IKOQUICK®, the sand grains are provided with a • Increased abrasion resistance (erosion resistance) uniform layer of binder. During the preparation process, the • Outstanding sand/casting separation (avoidance of moisture is absorbed more quickly. The benefits: mold and edge cracks) • The mold strength increases more rapidly to the values • Improved, more uniform mold compaction required for an optimum molding result for a given • Increased edge stability preparation time • Higher dimensional accuracy • The improved preparation behavior of the molding material • Good green sand reclamation capabilities as results in more intensive moisture retention processed carbon-containing bentonite layers are • The moisture demand is reduced because the portion of more readily detached from the sand grains in the “free water” in the return sand decreases. The tendency recycling process for explosion penetration to occur is reduced.
6 Optimum flow properties Outstanding mold compaction and shape stability The packing density and mold strength are kept at a uniformly Resistance to erosion as a function high level when using IKOQUICK®. Even complex contours of compactibility with high mold shape factors are formed without problem. The risk of a partial occurrence of explosion penetration is reduced without processed carbon as is the tendency for gas defects to form. Mold abrasion % with processed carbon
24
22 Mold hardness for different mold
20 shape factors
18 without processed carbon 16 +GF+ units with processed carbon
14 Normal compactibility range 94 12 92
90 30 35 40 45 50 Even under maximum 88 molding difficulty, more than 80 +GF+ units are Compactibility % achieved 86 Even with a mold shape 84 factor of 3.2, the minimum requirement of 80 +GF+ units Easy-flowing molding materials are needed for today’s 82 is exceeded. advanced compaction techniques. When using IKOQUICK®, the internal friction of the grain aggregate is significantly 1 2,5 3,3 5 reduced – so the flowability of the molding material is Mold shape factor (Height/Width) 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 Avoidance of spring-back effects pattern plate. The graph shows the higher effective bottom When using IKOQUICK®, the spring-back of the mold after pressures achieved in the pattern equipment with IKOQUICK®. compaction is appreciably reduced. Mold defects resulting from spring-back effects are avoided.
Effective bottom pressure for different mold shape factors Spring-back of bentonite-bonded sand mold
without processed carbon without processed carbon Squeeze pressure (MPa) with processed carbon Spring-back in mm with processed carbon 40 2,00 35 Defect-free mold Mold stripping limit 1,80 30 stripping MSL = f (Qz/Wt) 1,60 25 Wt 2 20 1,40 Qz 15 1,20 Cods and edge disintegration Force N/cm 10 1,00
0,80 5 Qz > Wt Wt > Qz
0,60 Compaction ∆ h 50% ∆ h 40% 0,40
0,20
1,4 1,5 1,6 1,7 1,8
Green density g/cm3
7 Properties ENVIBOND®, in accordance with nature
ENVIBOND® is a bentonite-based system of molding Application sand binders. • ENVIBOND® is available as a pure inorganic binder system or as a blend in combination with the proven IMERYS The Product additives ENVIBOND® is composed of IKOQUICK® and inorganic • ENVIBOND® is added to the molding sand like a traditional additives; the IKOQUICK® part in ENVIBOND® guarantees molding sand binder uniform compression together with improved shake-out of the • ENVIBOND® is not classified as hazardous substance or molding sand. dangerous good ® Due to its special composition ENVIBOND® PM1, PM2, and • ENVIBOND has unlimited shelf life 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. Adsorption of core gases and odors This has following benefits:
• Less pollutant emissions Increased adsorption of core gases and odors released in the • Less pollution burden of the molding sand molding sand
• Less odor and reduced emissions The ENVIBOND™ bonded molding • Significantly lower consumption of molding sand binders sand emits barely any pollutants Casting and lustrous carbon formers Molding sand (Silica sand and ENVIBOND™) The additives in ENVIBOND® enable an excellent compression Core (Silica sand and organic binder system) 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.
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%
Unused filter Filter after casting Filter after in ENVIBOND® — casting in green based green sand sand based on traditional organic binder system Benefits “Smoking prohibited” in foundries
ENVIBOND® — A revolution as a result of • Fewer moisture related casting defects (for example continuous product evolution explosion penetrations) due to decrease of the moisture Foundries constantly have to produce good castings in the demand of the molding sand most efficient way while keeping the burden on environment • Environmental objectives are easier achievable and workplace at minimum levels. The know-how of the • Additional economic efficiency because less air processes taking place inside the molding sand led IMERYS to filtration is necessary innovative products. • Reduction of environmental-related investments
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 The application of ENVIBOND® in molding sand results in a significant lower content of pollutants and condensates reduction of pollutant emissions and gas formation during casting • Homogeneous compression and uniform casting surface quality due to highest possible molding sand flowability
Properties of ENVIBOND® Gas formation
Environment and workplace
Operating molding sand, prepared with Bentonite Minimum gas Recyclability and Lustrous Carbon Formers formation and of molding (4.5% loss of ignition) odor release sand Explanation of the lab trial
Operating molding sand, prepared with ENVIBOND® Gas volume (2% loss of ignition) and pollutants
Economic Casting surface Molding sand sample efficiency surrounded by Fe-metal Molding sand, prepared with (50 x 60 mm) ENVIBOND® in the laboratory (without decomposed cores) Shake-out properties
0 5 10 15 20 25 ENVIBOND® Traditional ready blend
9 IMERYS has its own bentonite mines
Quality The best bentonites from around the world
The main criterion for selecting the appropriate raw material Benefits for the environment is the subsequent application for the molding sand binder. Modern sand binders – such as IKOQUICK® – reduce the Because, although bentonite can be found all around the water requirement of the molding material. Thanks to world, high-grade, high-yield and homogeneous deposits optimum flowability and compaction properties, a uniformly are rare. IMERYS has secured its long-term access to such high mold packing density is achieved every time. deposits. Its own bentonite mines and reliable raw material suppliers guarantee the availability of bentonites of uniform The wettability of the mold surfaces by the liquid metal is quality in any quantity required. Consequently, when making reduced and the requirement for lustrous carbon formers in the raw material selection, it is always the suitability of the molding sand is decreased. The volume of volatile organic the bentonite concerned that takes priority rather than its compounds (VOC) may also be reduced. Moreover, fewer availability – because this is always guaranteed. organic crack products are formed.
Quality assurance is our bond Hydrobond® We monitor all the production stages using the most advanced HYDROBOND® is an engineered 200 mesh commercial blue methods and techniques – starting with raw materials right Wyoming Sodium Bentonite that is used as a binder in foundry up to individually aligned end products – additives for the green sand systems. HYDROBOND® imparts the highest manufacture of which IMERYS always has the right bentonite degree of hydration over natural occurring Wyoming Sodium in stock. Sufficient quantities of different grades are kept Bentonites, imparts excellent green sand properties and high permanently in reserve so that we can always offer the right durability. product, prepared using special manufacturing and treatment processes for a wide range of different applications.
10 Perfect surface finish makes for a polished performance
IMERYS Seacoal
IMERYS Seacoal contains high quality bituminous coal which Typical Range of Analysis* has been produced from a natural formation of solid fuel. (Analysis on Dry Basis) Seacoal in a pulverized powder form, burns during the casting process to provide the correct mold atmosphere required for Moisture 7.0% Max. producing high quality castings. Sulfur 1.0% Max.
Two reasons why IMERYS Seacoal in your sand system Volatile Matter 34% to 43% assures better castings and lower cleaning costs: Fixed Carbon 50% to 60% HIGH VOLATILE MATTER assures better sand peel with Ash 10% Max. 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.
11 IMERYS – Partner to the Foundry Industry Good ideas for perfect molding results Carbonaceous Additives that are Clay Modifiers
IMERYS has developed a unique family of Carbonaceous Improvements which will be achieved in Additives that support molding sand by modifying the the sand system: bentonite clays (binders): • The clay water relationship will be enhanced. Foundries • KwikFlo™ will be able to add less water to achieve a given • KwikMull® compactability target. Less water means less defects associated with higher water content such as mechanical ® KwikMull is a unique blend of organic polymers that when penetration or blows. added to green sand systems enhances the performance • Because of KwikMull’s® ability to allow for superior mulling; ® of the added clay package. KwikMull has been designed to mulling efficiencies will improve. allow prepared sand to exhibit superior properties. This unique • Better sand flow due to less balling up of the sand and material actually allows for better dispersion of the clay and in decreased agglomerations. turn allows for better bonding with the sand grains. • Enhanced green and dry strengths properties. KwikMull® gives molding sand that velvety smooth feel • Better utilization of added clays. that all foundry men strive for. Although the sand compacts • Improved densities, which means less inclusions. better, the sand is not “sticky” and is still very flowable. Clays • Better collapsibility of the molding sand at shakeout. develop strengths more quickly when KwikMull® is used.
Clay Modifying Carbonaceous Additives
KwikFlo™ is a blend of organic and inorganic additives Characteristics of Sand System After Introduction used in PREMIX formulations in conjunction with Seacoal • KwikFlo™ is usually added to a PREMIX formulation at 4 to develop superior performance properties in green sand to 7% levels. Reduced later after the molding sand system molding systems! This proprietary blend of organic additives has become stabilized. is an effective replacement for causticized lignite (referred to • Green Strength will increase, providing a correct clay-water as leonardite on occasion). Causticized Lignite has become ratio is maintained because KwikFlo™ can preactivate the recognized as a proven modifier of bentonite clays. With clays in PREMIX. the addition of KwikFlo™ into a green sand formulation, a • With the addition of increased levels of Western Bentonite, reduction in the emission characteristics of molding sand the KwikFlo™ can reduce the bond usage in green sand during the pouring, cooling, and shakeout can be realized. systems over green sand systems that traditionally utilize a blend of Sodium and Calcium Bentonite. • Mold strength (as measured in mold hardness) and Benefits density (as measured in AFS sand specimen) will increase • Increases sand compaction and mold density flowability because of the addition of KwikFlo™. • Improved clay dispersion in mulling cycle • Replaces causticized lignite in green sand molding operations • Micronized particles of KwikFlo™ can diffuse rapidly into sand system • Increases 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 Double benefits: The effects of ANTRAPEX®
The doubly positive effect of ANTRAPEX® gives it a significant lead over conventional core sand additives.
Casting
Reduction in expansion and penetration defects in the core
Highly effective lustrous carbon former in the molding sand
Advantages in Abundance ANTRAPEX®, with double benefits – in the core and in the molding material
ANTRAPEX® is a service-proven core sand additive that Your benefits positively influences both the core and the bentonite-bonded ANTRAPEX® facilitates the production of high-quality castings: molding material. The additive is mixed with core sand and • Casting surfaces of near-perfect finish thus contributes to reducing expansion and penetration • Significantly reduced expense in terms of core ® defects. After core breakdown, ANTRAPEX passes into the coating operations molding material where it has a positive effect on the casting • Following core breakdown, the residues develop lustrous surface and sand stability. The amount of adhering molding carbon sand is also minimized. • Good recyclability. The Product • Reduced gas formation in the core
® ANTRAPEX is a blend of organic and inorganic components. Minimal Gas Formation The core sand additive has been developed by IMERYS Compared with other organic additives, the proportion of especially for the PUR Cold Box process. volatile components in ANTRAPEX® is minimal. The degree of Properties gas formation is lower - with maximum gas release postponed to a later point in the process. Gas defects in the core are ANTRAPEX® offers the following outstanding technological thus reduced. 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. Casting without ANTRAPEX® The use of ANTRAPEX® in • ANTRAPEX® has no negative influence on the flowability of can cause finning and veining. the core send reliably eliminates the core sand. the likelihood of finning and veining!
14 IMERYS – Molding Sand Blasters Auxiliary Products for PREMIX
Although PREMIX varies according to the type of castings Economy of Bulk Storage - Bulk handling of IMERYS PREMIX being produced, the following quality ingredients can be used assures a reduction in the total labor cast of sand systems. (additional materials may be available upon request). Bulk storage systems permit use of automated equipment to deliver sand additives directly to the muller on an accurately Special Organic Additives formulated and controlled basis. • 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.
15 IMERYS – Partner to the Foundry Industry Good ideas for perfect molding results CARBONITE® Additives
Our Products CARBONITE® RSB is a white, free-flowing powder for use Carbonites® have been developed by IMERYS as a unique with natural and synthetic sands. CARBONITE® RSB controls family of Carbonaceous Additives that support molding sand expansion stresses in green molding sand. Formulated for (some of these include): gray iron, ductile iron, malleable iron, aluminum, brass and • Carbonite® SA bronze castings. • Carbonite® RSB • Eliminates rat-tails, buckles and expansion scabs • And others • Stabilizes green sand CARBONITE® SA is a unique starch additive. It is a cold • Reduces thermal expansion water-soluble material that is blended into either a PREMIX or • Improves flowability bentonite clay. As an additive it can: • Eliminates skin drying • Provide sharp edges and detail to clay bonded sand • Does not alter other sand properties • 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
16 IMERYS – Partner to the Foundry Industry Additional Auxiliary Products
The Cellulose family of additives have been utilized in the Soda Ash is our inorganic additive that can be used to foundry industry for years. Cellulose is a fibrous substance of minimize sand encapsulations. approximately 100 mesh. Cellulose effectively compensates for sand expansion during Cereal is a product that has been around the foundry industry the casting cycle providing control over the occurrence for many years. It can be used in all metal casting foundries of rat-tails, buckles and expansion scabs. Cellulose is the (Steel, Iron, Aluminum, and Brass/Bronze). It is an all purpose replacement for this family of materials! binder.
• Improves shakeout by reducing retained strengths • Develops high green strength • Promotes thermal stability • Promotes high scratch hardness • Develops flowability • Limited effect on flowability of molding sand • Provides cushioning effect between expanding sand grains IMERYS has many additional auxiliary materials that are Cellulose becomes an intricate part of the sand-clay matrix. available to the foundry industry and is made available to This characteristic assures complete distribution during the PREMIX formulations! mulling cycle. The high fiber content of Cellulose converts readily to activated carbons promoting complete dispersion of clays.
17 Advantages in Abundance RIKO® – Reduce Waste, Improve Quality
RIKO® is the innovative solution in the world of molding bond slurry. Even complex contours with high mold shape can sand binders and molding sand (patented process). RIKO® be improved! technology generates totally hydrated bentonite and coal ® from foundry waste streams. This results in better performing RIKO Process Products bentonite and reduction of disposal costs. The RIKO® process develops two components from foundry waste streams: • Slurry which contains both bentonites and carbon additives. The RIKO® process utilizes foundry dust as a source • Sand to be introduced into molding sand of materials for green sand molding operations to ® create a high value product in a sustainable way. The RIKO bond slurry contains both bentonites and carbons The advantages that the RIKO® product brings to replacing a portion of the PREMIX that is added to green foundries include: sand at the muller or in a foundry’s sand cooler. This addition • Enhanced molding sand properties can be substituted for any desired amount of PREMIX depending upon the mass balance of bond to molding sand. • Reduction in casting defects The RIKO® bond slurry reduces the quantity of bond that is • Improved molding sand performance required to generate molding sand strength properties. RIKO® • Reduced bond consumption bond slurry is an ideal dispersion providing fully hydrated • Reduction of waste disposal costs bentonite particles significantly improving the molding sand characteristics .
® Improved molding sand behavior The RIKO sand is designed to be used in molding sand application as “make-up” sand. The RIKO® sand is finer by RIKO® bond slurry when added to molding sand results in the fact that it is generated in dust collection systems. With an improvement in molding sand properties because of the the shortage of fine sand because of the use of traditional improved dispersion of the bentonite and carbons. When foundry sand in other industrial applications the RIKO® sand using RIKO® the molding sand grains are provided with a has become a valuable addition to the raw materials available uniform layer of binder and organics that result in an improved to the foundry industry. casting surface. During the preparation of molding sand RIKO® bond slurry rapidly disperses into the molding sand. This RIKO® bond slurry can also be made available to PREMIX dispersion results in improved mold compaction and shape formulations manufactured at IMERYS facilities as an stability of the prepared molds. The packing density and mold ingredient. strength are kept at a uniformly high level when using RIKO®
Reclaimed sand
RIKO® Foundry RIKO® Slurry waste system process Advantages in Abundance SlagBuster® – A Slag Coagulant for Immediate Reaction
Slagbuster® is made out of granular, non-metallic material Application specifically designed to remove slag in molten metal All Slagbuster® C, M, F can be used in either furnace or ladle. applications. Any slag present on the molten metal will adhere However, for best results, it is suggested to use Slagbuster® to Slagbuster® and continue to float. The combined slag/ C, M in furnace and Slagbuster® F in ladle. Slagbuster® can then be removed from the molten metal in large pieces, resulting in clean molten metal for the All Slagbuster® C, M, F should be generously distributed on casting process. top of the molten metal of a full ladle or furnace. Slagbuster® will expand very rapidly in contact with molten metal and it All Slagbuster® C, M, F grades can be used in multiple foundry will change color, turning into a white color. At this point, the applications: steel; grey, malleable and ductile iron; bronze and material and slag should be removed from the metal. brass; etc. Slagbuster® should only be used once the pouring ladle or the furnace is full. Slagbuster® is available in three different sizes: Packaging ® • Slagbuster® C (Coarse) Slagbuster can be packaged in Super Sacks, 55 gallon drums • Slagbuster® M (Medium) or paper bags. • Slagbuster® F (Fine) Caution Slagbuster® should always be stored in a dry environment.
Production selection depends on many considerations, including metal charge cleanliness, furnace or ladle dimensions, metal cleanliness objectives targeted by the industry, etc.
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.
19 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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