Proven future technology
The Cold-Box process has the leading core production process for series casting for 50 years. Syncing with the further advances in castings for highly developed consumer markets, the HA Group, as one of the leading foundry chemical supplier, has continuously optimized its binder systems ever since. A comprehensive product range is now available especially for the Cold-Box process, so that foundries can always find the optimum binder solution depending on the area of application and customized products.
HA Group`s Cold-Box binder systems strike the perfect balance: lower emissions and uncompromising performance.
The Strengths of Cold-Box Technology
The Cold-Box system owes it position as the leading core production process to its wide range of applications, efficiency and cost-effectiveness. Excellent strength properties and very good dimensional accuracy mean that Cold-Box cores meet the growing demands placed on modern castings. Special technical criteria, such as elasticity, thermal stability and low gas generation, have also been continuously optimised.
Innovative Cold-Box binder systems from HA Group enable:
- the highest levels of casting quality
- highly complex casting structures
- minimal wall thicknesses
- highly automated production
- casting of various alloys
- High Mechanical Solution Approaches
- Quick curing products for Core centers
- Superior release from die
- Good Humidity resistance
Production-related advantages from the foundries point of view:
- No heated core box required
- Flexibility when selecting the tooling material (plastic, wood, metal)
- Proven, robust process
- Fastest possible cycle times
- Optimal decomposition properties
- Good reclaimability of core sand
- Excellent shelf life of cores
- Lowest binder addition
Technological Milestones of the Cold-Box Process
Curing Technology
Developing and improving curing technology
Core Package Application
Very effective way to produce high quality products
Application of Water Coatings
Improved water and moisture resistance of the cores
Focus of Development: Improved Environmental Properties
An increasing challenge for foundries, however, is meeting ever stricter environmental requirements. Since emissions in the Cold-Box process are inherent to the system, efforts to further develop Cold-Box binders have focused not only on technological optimisation but also on improving environmental properties. For more than three decades, the research department of the HA Group has been dedicated to reducing the environmental impact and emissions from its products. Our research and development aim to reduce emissions step by step through the reduction of organic components.
Solution Approaches
- Performance improvement to allow for reduced quantities of additives
- Replacing aromatic solvents
- Substitution of aromatic solvents and other harmful ingredients
- Use of inorganic elements in organic binders
- Use of additives that „capture and neutralise“ contaminants
The HA Group has successfully pursued all these paths in product development over recent years and decades, resulting in our four product types: Sigmacure, Biocure, Silcure and Sipurid.
Sustainability Milestones of the Cold-Box process
Reclaiming
Developing binder systems suitable for different sand qualities
Amine Recycling
Reduction of emissions saves crucial resources
Reduction of Aromatic Solvents
Use of renewable resources
Improved Workplace Conditions
Reduction of free monomeres and harmful ingredients
Reduction of Organics
Significant savings through Silicatic CB Systems, inorganic additives
Innovative Cold-Box solutions
Biocure: Over 20 Years of Experience with Plant-Based Solvents
In 1996, HA was the first supplier in the world to launch a patented, more evironmentally friendly Cold-Box alternative, which enabled both a reduction in odour emissions during core production and a significant reduction in BTX values (benzene, toluene, xylene) after casting. HA has replaced the aromatic solvents in Biocure products, for example, by using methyl esters that are obtained from plant-based, renewable raw materials such as rapeseed. Since the chained (aliphatic) molecules contain more hydrogen and less carbon, CO2 emissions are also reduced.
- HA is the only manufacturer with more than 20 years of experience with plant-based CB
- Use of renewable raw materials
- Reduced BTX, BTEX und CO2 emissions
- Reduced odour during core production
- Reduced catalyst consumption
- Superior seperation of core and tool
- Elemination of casting defects such as erosion and scabbing due to high heat resistance
- Excellent dimensional accuracy
- Particulary suitable for casting in bentonite-bonded moulding material.
Sigmacure: A Robust Classic
Sigmacure is the robust classic product: a Cold-Box binder system in which the two components, phenolic resin and polyisocyanate solvents. This system provides foundries with a product line whose efficiency is based on decades of experience.
- High productivity, fast cycle times
- Good process ability, good sand durability even with moderate sand quality
- Moisture resistant even under highly humid condition
- Many customized variants for special requirements
- Suitable for any existing equipment
- High process safety
Silcure: Inorganic Elements in Solvent
In 1999, HA introduced Cold-Box systems with shares of silicate-containing solvents to the foundry industry. These solvents contain Si compounds in the molecule instead of hydrocarbons. A lower carbon content results in reduced BTX, BTEX and CO2 emissions.
- High thermal stability
- Very low condensate formation, thus less cleaning efforts
- Low gas formation, thus fewer casting defects (scabbing, gas defects, pinholes)
- Suitable for die casting
Additives
Additives are required to both reduce casting defects and achieve specific properties. They are organic, inorganic or mixed.
Inorganic additives can make a major contribution to reducing foundry emissions (CO2, pollutants, odour and smoke).
Strengths of new generation additives
- Small amounts needed
- High strength
- Excellent anti-veining effect
- Minimal gas formation
- Low erosion tendency
- Allows uncoated casting in many cases
Theory and Practice
As demand for highly complex castings with ever more stringent quality requirements increases, it has become ever more urgent to solve the pressing issues of resource conservation and sustainability. But achieving the highest levels of quality and environmental compatibility do not have to be mutually exclusive. Gargi Hüttenes-Albertus supplies proven and continuously refined Cold-Box quality. Read more about how our products help foundries save resources and the success of our tailor-made solutions.
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