System Description:
This is a three part Gas Set System comprising of:
- COOLBOX 2018 – Which is Part 1 and works as a sand Binder. It is a benzylic ether type Phenol Formaldehyde resin in organic solvents.
- COOLBOX 2020 – Which is Part 2 and works as a Hardener (co-binder). It is Polyisocyanate in organic solvents.
- COOLBOX 700 – Which is Part 3 and works as a Catalyst for the reaction between Part 1 and Part 2.It is a Tertiary Amine.
Applications:
COOLBOX system is used for making sand cores in iron foundries at high productivity Cold Box process. In this process, sand mixed with Part 1 and Part 2 is blown in to the core box followed by passing of Amine gas to form hard core. COOLBOX system is highlighted by very low odor level, long bench life of mixed sand, very low sticking tendency and low moisture sensitivity.
Features:
- Offers instantaneous curing, hence high rate of productivity for core making.
- Offers long bench life of mixed sand, thus reducing core scrap.
- Shows low sticking tendency resulting in easy core release.
- Shows lesser resin wipe-off and so lesser build-up on core boxes.
- Exhibits excellent collapsibility , thus reducing fettling times.
Properties of COOLSET 3010 / COOLSET 3020:
| Appearance | Clear Yellowish Liquid |
| Viscosity | 25 – 65 sec. by B4 Flow Cup @ 30°C |
| Specific Gravity | 1.05 – 1.15 @ 30°C |
| Free Formaldehyde | < 0.5 % |
Properties of COOLBOX 2020:
| Appearance | Clear Dark Brown Liquid |
| Viscosity | 15 – 25 sec. by B4 Flow Cup @ 30°C |
| Specific Gravity | 1.10 – 1.15 @ 30°C |
Properties of COOLBOX 700:
| Appearance | Clear Colorless Liquid |
| Specific Gravity | 0.70 – 0.75 |
Sands:
COOLBOX system gives best results on washed & graded Silica sands of AFS 50 to 60 with round to sub angular grains and having clay less than 0.3 %. ADV of the sand should be low to avoid shortening of bench life and consequential core friability.
Addition Levels:
This depends upon properties required and sand quality used. Usual addition level of Part 1 is 0.8 to 1.2 % by wt. of sand and that of Part 2 is also in the same range. Ratio of Part 1 and Part 2 addition is usually 50:50 (w / w) but offset ratio like 55/ 45 can also be used to favour economics.
Mixing and Mixers:
It is common to use COOLBOX system on batch mixers manually. COOLBOX 2018 is first added to sand and mixed for around 2 minutes followed by addition of COOLBOX 2020 and further mixing for 2 minutes. Mixing can also be done on automatic high speed batch mixers with programmed arrangement for pre-weighing, sequential adding and mixing of Part 1 and Part 2 with sand.
Coatings:
Water as well as solvent based refractory washes can be used for painting COOLBOX bonded cores. Cores can be painted immediately after ejection. Dipping is the most recommended and used application method to facilitate high production rates. When water based wash is used, the paint must be dried in an oven with good air circulation.
Typical Sand Mix Properties:
| On washed and graded Silica sand (ex Mangalore) | ||
| Addition Levels | COOLBOX 2018 | 0.8% to 1.0 % (Based on sand) |
| COOLBOX 2020 | 0.8% to 1.0 % (Based on sand) | |
| Mixing | 2 minutes x 2 minutes (Part 1 followed by Part 2) | |
| RT/RH | 300C. / 60 % | |
| Gassing / Purging | COOLBOX 700 (TEA) / Dry Air | |
| Tensile Strengths | ||
| Immediate | 80 – 110 psi | |
| 4 hr. | 120 – 140 psi | |
| 24 hr. | 160 – 200 psi | |
Standard Packing:
| COOLBOX 2018 | 200 kg Yellow MS drum |
| COOLBOX 2020 | 200 kg Black MS drum |
| COOLBOX 700 | 10 kg Blue MS tin |
| Customized small packing can be made available on request. | |
Shelf Life:
Six months for all 3 Parts from the date of manufacturing when stored in cool and dry place away from rain water and direct sunlight.
Safety Precautions:
- Like other synthetic resins, this Binder can cause skin irritation. Therefore, operators should always use industrial gloves, safety goggles & nose masks.
- Hardener contains Polyisocyanate and care should be taken to protect eyes against splashing. In case of accidental contact, the affected parts should be immediately flushed with plenty of water and an eye specialist should be consulted with.
- Catalyst is a tertiary amine liquid. Eyes should be protected against splashing. In case of accidental contact, the affected parts should be immediately flushed with plenty of water.