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Inorganic Core Sand Binders

inorganic

Cylinder Head with IKO-WB Inorganic Binder: Smooth Surface

IKO-WB – Inorganic Core Sand Binder

Cores bonded with organic binders emit a range of different crack components which produce organic condensates during the casting process and subsequent pyrolization of binders. The chemical products utilized and associated with core making when using organic systems are often hazardous to health and the environment.

To eliminate the hazards associated with organic binder systems Imerys Metalcasting Solutions has developed an inorganic core binder named IKO-WB. The product is patented.

The binder is based on a modified sodium silicate, water glass system. Specific additives are utilized to enhance and promote the requisite properties of the binder. IKO-WB is individually formulated and customized for each and every application by varying the type and quantity of additive used.

R&D work was, and is focused on core making, core storage, casting surfaces, enhanced shake out, when compared to alternative inorganic binder systems, and the regeneration of spent core sand.

IKO-WB binder is suitable for application in production of brass and aluminum castings. The application for iron metallurgy remains under development with the first trials having been successfully executed.

The advantages of IKO-WB Inorganic Core Sand Binder are:

  • Emission and odor reductions in the working environment up to 95%
  • Excellent shelf life of cured cores
  • Superior flowability of prepared core sand allowing for optimum shooting/blowing and, therefore, density of the core during production
  • Excellent shake out behavior
  • Achievement of effective metallographic structures and material properties of the castings
  • Gas porosity is reduced
  • Short drying / curing times
  • Good thermal resistance
  • Reduction in the capital expenditure of environmental related investments necessary to comply with local regulatory requirements

Cores with inorganic binders compared to Cold-Box

95% Reduction in Emissions and Odor

Application:

IKO-WB utilizes a liquid activator to enhance binder contact with sand in the mixer, after dispersion the water glass binder is added followed by the additive in either liquid or powder form depending upon individual preferences. After shooting the core is cured in heated core boxes and purged with warm air to remove water present. Production time is variable and dependent upon overall dimensions of the core.