Moulding Sand Binders - S&B Industrial Minerals GmbH

IKO BOND
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MAKROBOND
Solutions for Foundries
Moulding Sand Binders

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S&B – Partner to the Foundry Industry
Good ideas for perfect moulding results
Two foundries at a given time and even in the same location may
still be worlds apart. No matter how similar they appear at first
sight, each is unique in its structure and consequently requires individual
moulding material additives that are tailored to its specific
production conditions. Taking this as its basis, S&B creates innovative
products using proven constituents and components − materials
that, when put in the service of our customers, optimise the quality
of their products and the cost-efficiency of the technology applied.
Services aligned to your requirements
Just give us a call and we will deliver − with wide ranging support aligned
to your needs. With S&B, you can be sure of getting good advice
from highly qualified engineers experienced in all aspects of moulding
material technology. We offer significant expertise acquired in many
years of research and development work performed in close collaboration
with the foundry industry − know-how that we will be glad to put
at your disposal on the basis of a broad spectrum of services:
• Moulding material analyses and assessments
• Moulding material database accessible via the Internet with
customer-related data retrieval
• On-site casting and mould failure analyses
• Performance of employee training courses on behalf of our customers
• Investigation-related advice in the testing of new processes and
formulations
• Comprehensive Manual of Casting Defects: Incidence and avoidance
of defects attributable to moulding sands
• Flexible adaptation of our products to customer requirements
Research, development and support services −
Maximising moulding material performance
Our highly qualified research, development and service staff analyse
defects in the cast product and malfunctions in the foundry production
process in relation to the very latest techniques in manufacturing and
environmental protection technology. Our scientists are never happy
with the current state of the art. They are always looking for that
“even better” solution. And in this pioneer work – the development of
concepts for the future – we rely particularly on direct communication
with our customers.
Our service: Individual green sand cycle analyses designed
to reveal true optimisation potential
You can call up and retrieve your moulding material data
at any time via the Internet
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Advantages in Abundance
S&B’s Moulding Sand Binders –
the natural solution
S&B’s moulding sand binders are
thoroughly service-proven and
reliable
As varied as the requirements on different bentonites are, all S&B’s
moulding material additives have one thing in common: They
represent the current state of the art while combining ecological
sense with economic benefit; because contemporary technological
competence must be capable of matching cost-efficiency with environmental
compatibility.
Our products
S&B has the right moulding sand binder for every application:
• IKO BOND – conventional moulding sand binders
• QUICKBOND – the innovative solution for maximum quality
• MAKROBOND – Moulding sand binder with maximum thermal
stability for minimum consumption
S&B‘s moulding sand binders can be combined in any blending ratio
with all S&B‘s lustrous carbon formers.
Your benefits
There are many convincing arguments in favour of using our moulding
sand binders – here are the most important:
• Variable montmorillonite content
• Outstanding thermal stability leading to minimum consumption
• High specific strengths
• Uniform mould compaction
• High shape and edge stability
• Minimal dust formation in return sand
We will adapt the foundry-specific properties
of our moulding sand binders to your particular
requirements.
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S&B’s Moulding Sand Binders
Versatile bentonites for wide-ranging applications
IKO BOND-D
A moulding sand binder with a high montmorillonite content, high
bonding power, high hot strength and outstanding thermal stability.
The burn-out ratio in the moulding material system is kept to a minimum
when using IKO BOND-D.
QUICKBOND-D
All basic IKO BOND bentonites are also available in a QUICKBOND
variant, for example QUICKBOND-D comprising an activated bentonite
with a high montmorillonite content manufactured according to a special,
patented process with the addition of processed carbon.
MAKROBOND ES
A moulding sand binder with a high montmorillonite content, high bonding
power, high hot strength as well as quick dispersion capability.
Properties of IKO BOND-D / QUICKBOND-D
Disintegration
properties
Thermal
stability
■ IKO BOND-D ■ QUICKBOND-D
Dispersing behaviour
Resistance to erosion
Properties of MAKROBOND ES / MAKROBOND 95
Dispersing behaviour
Specific strength
Resistance to
expansion defects
MAKROBOND 95
A moulding sand binder with a very high montmorillonite content,
excellent specific strength, very high hot strength and respectively
low burn-out ratio in the green sand cycle.
Disintegration
properties
Thermal
stability
Specific strength
Resistance to
expansion defects
■ MAKROBOND ES ■ MAKROBOND 95
Resistance to erosion
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Speciality
QUICKBOND – a product from
S&B Research
QUICKBOND is the innovative speciality in the world of moulding
sand binders – patented since 1991 (DEP No. 3704726.4/43) and
the subject of ongoing further development.
Outstanding properties, compelling benefits:
• Significantly improved bentonite dispersion
• Reduced dryness of the mould surface
• Increased abrasion resistance (erosion resistance)
• Outstanding sand/casting separation (avoidance of mould
and edge cracks)
• Improved, more uniform mould compaction
• Increased edge stability
• Higher dimensional accuracy
• Good green sand reclamation capabilities as graphite-containing
bentonite layers are more readily detached from the sand grains
in the recycling process
Significantly improved preparation behaviour
QUICKBOND is conditioned with processed carbon in accordance
with a patented technique. As the graph shows, this results in a significant
improvement in the dispersibility of a bentonite. When using
QUICKBOND, the quartz grains are provided with a uniform layer of
binder. During the preparation process, the moisture is absorbed more
quickly. The benefits:
• The mould strength increases more rapidly to the values required
for an optimum moulding result for a given preparation time
• The improved preparation behaviour of the moulding material
results in more intensive moisture retention
• The moisture demand is reduced because the portion of “free
water” in the return sand decreases. The tendency for explosion
penetration to occur is reduced.
Preparation behaviour of bentonite with and
without processed carbon
Green tensile strength N/cm 2
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0 1 3 5 7 9 11
Higher resistance to erosion
Thanks to the improved dispersibility, the moisture is more intensively
absorbed in the intermediate layers of the bentonite. The moulding
sand dries out less quickly and the improved retention of the moisture
imparts a higher level of abrasion resistance to the compacted mould.
The graph clearly shows that, particularly in the case of the compactibility
level common nowadays, the resistance to erosion is appreciably
higher when using combined bentonite/processed carbon systems.
Optimum flow properties
Resistance to erosion as a function of
compactibility
Mould abrasion %
24
22
20
18
16
14
12
Normal
compactibility range
without processed carbon
with processed carbon
13 16 19 22
Preparation time min.
without processed carbon
with processed carbon
All basic IKO-BOND binders are also available
in a corresponding QUICKBOND variant.
30 35 40 45 50
Compactibility %

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Easy-flowing moulding materials are needed for today’s advanced
compaction techniques. When using QUICKBOND, the internal friction
of the grain aggregate is significantly reduced – so the flowability
of the moulding material is appreciably increased. Your benefit:
Increased effective bottom pressure due to improved transmission of
the squeeze pressure applied to the mould back in the direction of the
pattern plate. The graph shows the higher effective bottom pressures
achieved in the pattern equipment with QUICKBOND.
Effective bottom pressure for
different mould shape factors
Squeeze pressure (MPa)
40
35
30
25
20
15
10
5
∆ h 50 % ∆ h 40 %
without processed carbon
with processed carbon
Outstanding mould compaction and shape stability
The packing density and mould strength are kept at a uniformly high
level when using QUICKBOND. Even complex contours with high
mould shape factors are formed without problem. The risk of a partial
occurrence of explosion penetration is reduced as is the tendency for
gas defects to form.
Mould hardness for different mould shape factors
+GF+ units
94
92
90
88
86
84
82
Even with a mould shape factor of
3.2, the minimum requirement
of 80 +GF+ units is exceeded.
without processed carbon
with processed carbon
Even under maximum moulding
difficulty, more than 80
+GF+ units are achieved
Avoidance of spring-back effects
When using QUICKBOND, the spring-back of the mould after compaction
is appreciably reduced. Mould defects resulting from spring-back
effects are avoided.
Spring-back of
bentonite-bonded sand mould
Spring-back in mm
2,00
Defect-free mould
1,80
stripping
1,60
1,40
1,20
1,00
0,80
0,60
0,40
0,20
Force N/cm 2
Q z > Wt
Compaction
Mould stripping limit
MSL = f (Q z/Wt)
Wt > Q z
Wt
Q z
Cods and edge
disintegration
without processed carbon
with processed carbon
1,4 1,5 1,6 1,7 1,8
Green density g/cm 3
Improved dimensional accuracy of the castings
Scientific investigations prove that QUICKBOND improves the compaction
properties of moulding sand and reduces mould cavity springback.
The benefit: Higher and more uniform mould strength resulting
in increased dimensional accuracy of the castings.
Dimensional accuracy in complicated
casting geometries
20,0
19,5
19,0 Theoretical casting weight 90
18,5
Compaction 40 %
Activated clay content 7.5 %
without processed carbon
Optimised flowability and compaction
properties plus improved preparation
behaviour of the moulding sand increases
the dimensional accuracy of the castings!
Weight savings
3.5%
Casting weight scatter in g
Weight of the casting in kg
Weight scatter
–33%
with processed carbon
130
110
70
1 2,5 3,3 5
Mould shape factor (Height/Width)

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Our moulding sand binders ensure
good results even in the case of
complicated casting contours
IKO BOND-E
A moulding sand binder with a medium montmorillonite content,
medium bonding power, low hot strength and medium thermal stability.
IKO BOND-E quickly disperses in the muller.
IKO BOND-BF
A moulding sand binder with a high montmorillonite content, high
bonding power, medium hot strength and medium thermal stability.
IKO BOND-BF offers particular benefits in cases of short sand preparation
periods.
Properties of IKO BOND-E / IKO BOND-BF
Disintegration
properties
Thermal
stability
Dispersing behaviour
Resistance to erosion
Specific strength
Resistance to
expansion defects
■ IKO BOND-E ■ IKO BOND-BF
IKO BOND-T
A moulding sand binder with a low montmorillonite content, medium
bonding power, low hot strength and low thermal stability. IKO BOND-T
is readily dispersible and is quickly distributed in the muller.
IKO BOND-HF
A moulding sand binder with a medium montmorillonite content, high
bonding power and low hot strength. The disintegration properties of
moulding sands bonded with IKO BOND-HF are outstanding.
Properties of IKO BOND-T / IKO BOND-HF
Disintegration
properties
Thermal
stability
Dispersing behaviour
Specific strength
Resistance to
expansion defects
Resistance to erosion
■ IKO BOND-T ■ IKO BOND-HF
IKO BOND-W
A natural sodium bentonite with a very high level of thermal stability
and outstanding bonding power. Owing to its exceptional hot strength,
sand disintegration is less than in the case of other IKO BOND
moulding sand binders.
IKO BOND-G
A moulding sand binder with a high montmorillonite content, high
bonding power, high hot strength and high thermal stability. Thanks
to its outstanding dispersibility, it offers high compressive strength,
particularly in cases involving significant replenishment.
Properties of IKO BOND-W / IKO BOND-G
■ IKO BOND-W ■ IKO BOND-G
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Disintegration
properties
Thermal
stability
Dispersing behaviour
Resistance to erosion
Specific strength
Resistance to
expansion defects
For details, see flap

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Quality
The best bentonites from around the world
S&B has its own bentonite mines
The main criterion for selecting the appropriate raw material is the
subsequent application for the moulding sand binder. Because, although
bentonite can be found all around the world, high-grade,
high-yield and homogeneous deposits are rare. S&B has secured
its long-term access to such deposits. Its own bentonite mines and
reliable raw material suppliers guarantee the availability of bentonites
of uniform quality in any quantity required. Consequently,
when making the raw material selection, it is always the suitability
of the bentonite concerned that takes priority rather than its availability
– because this is always guaranteed.
Quality assurance is our bond
We monitor all the production stages using the most advanced
methods and techniques – starting with raw materials right up to
individually aligned end products – additives for the manufacture of
which S&B always has the right bentonite in stock. Sufficient quantities
of different grades are kept permanently in reserve so that we can
always offer the right product, prepared using special manufacturing
and treatment processes for a wide range of different applications.
The production process:
1. Exploration of the deposits and quality-dependent statistical
simulation of our inventories
2. Grading of the bentonites immediately following extraction from
the deposit
3. Homogenisation of the raw material prior to soda activation
4. Precise metering of the soda addition and subsequent homogenisation
5. Gentle drying with repeated homogenisation/pulverisation
6. Weather-protected storage
7. Preparation and treatment in our production facilities
8. Despatch as bulk material, in Big Bags, in sacks or in containers.
Transport by truck, rail or ship
9. Comprehensive quality control of all process stages (DIN EN ISO 9001)
Benefits for the environment
Modern sand binders – such as QUICKBOND – reduce the water
requirement of the moulding material. Thanks to optimum flowability
and compaction properties, a uniformly high mould packing
density is achieved every time.
The wettability of the mould surfaces by the liquid metal is
reduced and the requirement for lustrous carbon formers in
the moulding sand is decreased. The volume of volatile organic
compounds (VOC) may also be reduced. Moreover, fewer organic
crack products are formed.
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Any questions
The specialists at S&B will be glad to provide you with any further
information and advice you require – including on matters relating to
our lustrous carbon formers and core sand additives. Give us a call,
send us a fax or write to us.
• • • • • • • • • • • • • • • • • • • • Phone: +49 (0) 23 65 - 804-0
• • • • • • • • • • • • • • • • • • • • Fax: +49 (0) 23 65 - 804-211
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info@ikominerals.com
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S&B – moulding its service to your need …
… for the problem-free manufacture of even the most critical
castings. Our sand binders guarantee maximum stability and contour
integrity – while maintaining outstanding sand plasticity.
S&B Industrial Minerals GmbH
Schmielenfeldstr. 78
45772 Marl, Germany
Tel: +49 (0) 23 65-8 04-0
Fax: +49 (0) 23 65-8 04-211
Internet: www.ikominerals.com
E-mail: info@ikominerals.com
© 2007 S&B, Marl
S&B Industrial Minerals SARL
Rue du doris
44350 Montoir-de-Bretagne, France
Tel: +33 (0) 240 458 900
Fax: +33 (0) 240 458 700
Internet: www.ikominerals.fr
E-mail: contact@ikominerals.fr