Description:
COOLTEC 4020 is single part Cold Box Foundry Binder. It consists of alkaline phenolic resin which is dissolved in water. This resin is cured by CO2 gas.
Applications:
COOLTEC 4020 system is suited for making sand cores and molds in foundries at high production rate since the shape hardens in few seconds to few minutes. In this process, sand mixed with COOLTEC 4020 is blown or hand rammed in to core / mould box followed by passage of CO2 gas to form hard core / mold. This system is usable for casting ferrous and non-ferrous metal.
Features:
- Offers instantaneous curing (Immediate strength is 80% of ultimate strength), which facilitates rapid production of core and mold making.
- No obnoxious odor and fumes produced during mixing and casting.
- Exhibits good collapsibility.
- Free from Sulfur, Nitrogen and Phosphorous. Hence, gives clean castings.
- No incidence of finning and lustrous carbon defects in castings.
- Water soluble system which makes easy cleaning of tooling and equipment.
- Nonflammable.
- Highly Environment Friendly system.
Characteristics:
| Type | Water borne Alkaline Phenol Formaldehyde Resole Resin |
| Appearance | Clear yellowish viscous liquid |
| Viscosity | 30 – 60 sec. by B4 Flow Cup @ 30°C |
| Specific Gravity | 1.290 – 1.350 @ 30°C |
| PH | >13 |
Sands:
COOLTEC 4020 is suited for Silica, Chromite and Zircon sands. However, it is not suitable for Olivine sand. It gives best results on washed & graded Silica sands of AFS 50 to 60 with round to sub angular grains and clay less than 0.3 %. Use of sands with high ADV should be avoided.
Addition Levels:
This depends upon the sand quality and geometry of core/mold. Considering application conditions, it is advisable to keep addition rate as low as possible to get optimum results. Recommended addition rate is between 2.5% and 4.5% by weight of sand.
Mixing and Mixers :
Both, Batch and Continuous mixer can be used, though Batch mixer is commonly used. COOLTEC 4020 is added to sand and mixed for around 2 to 3 minutes in batch mixing.
Molding & Blowing:
Mixed sand can be either hand rammed or blown in the boxes. Recommended blowing pressure is between 3 and 5 Bar.
Gassing:
| Gassing techniques of conventional CO2/silicate process should not be used for COOLTEC 4020. Instead, disciplined gassing should be used as under | |
| CO2 Temperature | 25 – 28°C |
| Pressure | 5 – 25 PSI |
| Flow Rate | 200 – 400 L /Hr |
| Time | 5 – 30 Seconds |
| Gas Consumption | 1 – 2 % by weight of sand |
Typical Sand Mix Properties:
| On washed and graded Silica sand (ex. Allahabad) | ||
| Addition Levels | COOLTEC 4020 | 3.5 % (Based on sand) |
| Mixing | 3 minutes | |
| RT/RH | 30°C. / 60% | |
| Gassing | 20” | |
| Comp. Strengths | ||
| Immediate | 7- 9 kg /cm2 | |
| 4 hr. | 11- 14 kg / cm2 | |
| 24 hr. | 16 – 20 kg / cm2 | |
| Bench Life | 1 – 1.5 h when mixed sand is covered with wet cloth or sealed in container | |
Coating:
Water as well as solvent based refractory washes can be used for painting cores and molds. Cores and molds can be painted immediately after their preparation. Small cores and molds can be dip coated. When water based wash is used, the paint must be dried either in circulating air oven or by torching. Use of Methanol based Coating should be avoided.
Standard Packing:
- Available in 230 kg HDPE drums.
- Small customized packing can be made available against request.
Shelf Life:
Six months from the date of manufacturing when stored in cool place and under shade.
Safety Precautions:
- COOLTEC 4020 is highly alkaline phenol Formaldehyde resin. Direct skin contact should be avoided by using necessary personal protective equipment like industrial gloves and safety goggles.
- Skin splashes should be immediately washed by sufficient water. Eye splashes should be washed by sufficient amount of water and medical consultation should be taken immediately.
- Small spillages may be removed with excess water.