In foundry production, it is common for even a high-quality base mix to fail to provide stable performance and the predicted quality of castings. It is in such cases that the use of additional materials comes to the fore.
Basic components of the HTS
Cold-curing mixture (CCM) is a modern technology for making molds, based on the use of quartz sand, binder resins, and catalysts.
- Sand: must have high purity, controlled grain size, and stable physicochemical characteristics.
- Resins and catalysts: determine the speed and uniformity of curing.
The correct combination of these components allows you to reduce defects, but in practice there are problems: fluctuations in sand quality, humidity, uneven operation of catalysts, increased gas formation, reduced strength at high temperatures, and others.
The role of additional materials
Additional materials allow:
- reduce gas formation and improve the casting surface;
- increase the strength and heat resistance of molds;
- create a non-stick effect;
- optimize the consumption of resins and catalysts;
- stabilize hardening in different temperature conditions;
- connect or repair parts of finished forms;
- facilitate the removal of finished molds from the tooling.
This directly affects economic indicators: the number of rework decreases, the volume of scrap decreases, and the productivity of the foundry increases.
Main groups of additives
In the practice of foundry production, in addition to modifiers and regenerants, the following are used:
- non-stick coatings – minimize metal burning;
- sand additives – adjust the physical and mechanical properties of the sand mixture;
- release coatings – facilitate the production of finished tooling forms;
- adhesives, sealants and putties – used to assemble complex rods, improve or repair finished forms;
- special solvents – designed to remove residues of molding resins and mixtures from tools, equipment, etc.
- Exothermic inserts – designed to extend the metal solidification time to reduce the volume of overfill and compensate for shrinkage.
- Vents are special ventilation systems that ensure the removal of excess gases when pouring metal into a mold.
Criteria for selecting auxiliary materials
When selecting additional materials, the following must be taken into account:
- compatibility with the selected type of HTS;
- type and temperature of the alloy;
- required shape properties (strength, gas permeability, heat resistance);
- technological conditions of production (hardening time, casting complexity);
- results of previous tests in workshop conditions;
- available equipment and production volumes.
A systematic approach avoids incompatibility and ensures the stability of the technological process. The possible set of additional materials is ultimately determined by the metallurgist and production technologist.
Expert recommendations
Many years of experience show that companies that actively implement auxiliary materials receive tangible benefits:
- stable quality and reduced defect rate;
- cost optimization through sand regeneration;
- better process control even in difficult conditions;
- faster access to European standards.
It is recommended to conduct regular analysis of mixture properties, test new additives in production conditions, and seek advice from technical specialists before introducing new materials.
“UKRFAVORIT” – technological partner
The company “UKRFAVORIT” provides the supply of not only additional materials, but also ready-made technological solutions for foundry enterprises:
- supply of auxiliary materials and equipment of European quality;
- implementation of a full cycle: from molding mixtures to automated lines;
- 24/7 technical support;
- fast delivery and constant stock.
More than a hundred companies have already noted reduction in defects and cost optimization thanks to cooperation with us.
By choosing “UKRFAVORIT”, you get not just materials, but a partnership that ensures production stability and competitiveness at the international level.
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E-mail: info@ukrfavorit.com.ua
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