( Phenolic Urethane Amine Cold Box Process )


CERACOLD R 500 series is a highly reactive process for making sand cores in foundry by cold box process. This process does not require heat to cure & form a sand bond. The curing mechanism is instantaneous, core get cured within few seconds. The basic of process of bonding is poly – urethane technology, hence it is very much sensitive with contamination of moisture by any means. The success of process depends on quality of sand, dryness of air & tooling.

This binder system is consists of three constituents

CERACOLD R – 501 Phenolic Resin dissolved in solvent
CERACOLD H – 510 Isocyanate, acts as a hardener.
CERACOLD C – 520 Amine catalyst

CERACOLD R – 501 & CERACOLD H – 510 are mixed with dry silica sand & mixed sand is cured within seconds, when CERACOLD C – 520 is passed in gaseous form through sand mixture.

Typical Properties of CERACOLD

COLOUR Reddish brown Reddish brown Colourless to yellow
APPEARANCE Clear Liquid liquid Liquid
SPECIFIC GRAVITY @30°C 1.05 – 1.10 1.16 - 1.20 0.71 – 0.73
VISCOSITY BY B4 CUP @30°C 30 – 50 seconds 14 – 19 seconds  N.A

Material Safety Data Sheet (MSDS) is Available on Request

Typical Sand Mix

Dry silica sand ( AFS No 50 – 60 )
(Free from carbonate & chlorides)
100 parts
CERACOLD R – 501 0.8 – 1.0 % BOS mix for 1-1½ minutes.
CERACOLD H – 510 0.8 – 1.0 % BOS mix for 1-1½ minutes.
CERACOLD C – 520 0.1 – 0.3 % BOS in gaseous form.
( CERACOLD C – 520 requirement varies with quality of sand & tools )
Sand can be prepared by using both continuous & batch type mixer.
Bench life of prepared sand 40-60 minutes (Keep under dry cover).

Typical Tensile Strength & other Properties

Immediate 6 – 8 kg/cm2
4 hours 10 – 12 kg/cm2
24 hours 12 – 16 kg /cm2
Gas evolution 14 cc/gm max.

These properties may vary with quality of sand & ambient conditions.

Core Making Process

CERACOLD process requires special core shooter with amine gas generator for making cores. Apart from core shooter, special precaution should be taken for dryness & cleanliness of air, which is used for blowing sand & for gas generator. The desired dew point of air is -40° C.

The prepared sand mixture is blown in the core box & gaseous CERACOLD C - 520 is passed through blown sand mass under controlled pressure & temperature. The excess

CERACOLD C – 520 is removed from core by purging dry & warm air. The core is stripped from core box immediately. The typical cycle time for core making is less than a minute.

The contamination of moisture from any source will detoriate the core quality.

Silent features of CERACOLD process

  • Highest productivity than any other core making process.
  • No heat is required for curing, so tooling may be in wooden, plastic, aluminium is possible.
  • Excellent dimensional accuracy, since almost 100 % curing of core takes place in the core box.
  • Cores are ready for assembly or usage immediately after stripping.
  • Excellent surface finish of castings
  • Excellent shake out properties.
  • Low gas evolution, hence, less gas related defects in castings.
  • Good resistance to casting defects like scab, veining or erosion.
  • Suitable for all types of metal.

Mould & Core Paints

  • Water base paints are suitable, but air dry type solvent base paints can be used.

Shelf Life

  • Six month from the date of manufacture for all three resin components.

Standard Packing

  • CERACOLD R – 501 : 50 / 200 kg Yellow Coloured MS Barrel
  • CERACOLD H – 510 : 50 / 200 kg Black Coloured MS Barrel
  • CERACOLD C – 520 : 10 kg Blue Coloured MS Drum

Storage & Handling

Store under roof away from heat & moisture. Direct flame contact should be avoided.

While handling , prescribed safety measures should be used.

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