Modulated machine design for core production with inorganic binders

Inorganic binders Main Advantages Emission and odor free for humanity and environment, Compliance with future environmental laws, Reduction of casting failures caused by core gas, Condensate deposit on the mould drop or rather decrease significantly, thereby increase in productivity and cost reduction in the maintenance, Decoring ability due to adjustable water soluability, Reduction of disposal costs of the used sand, Cost savings in the field of exhaust technique and scrubbers Higher uptimes of core boxes based on lower cleaning time Etc. 2

Inorganic binders are inert Organic binders burn Inorganic binders are inert 3

Inorganic binder Organic binders burn, condensates contaminates the mold With inorganic binders the mold is clean 4

Basic Facts Characteristics of inorganic binders Hardening physically and chemically Mostly physical instead of chemical reaction Characteristics in machine engineering Opportunity to heat toolings Opportunity for hot air flushing 5

Green-Line-Concept 6

Comparison Coldbox/HotBox/Inorganic 7

Challenges and Solutions Avoid dry and hardening of core sand in the shooting nozzles due to dry and hot ambient atmosphere. ↓ Solutions: Cooling of the shoot plate and the nozzles as know from hotbox system or shell core. Problem: In difference to hotbox systems wherein hardening starts by temperature only, inorganic system will dry out at the nozzles‘ tip even when cooling the nozzle. Moisturing of the ambient area around these shooting nozzles by water spray. Water droplets will condensate at the cool nozzles, water droplets wash away binder skin from the sand grains and cause defects in the core surface and body. Water not to be sprayed in as droplets but as cold vapor. The evaporation of the water will be done by ultra sonic generator (system patended by Laempe). 8

Technical Solutions Ultra sonic vaporing of shooting nozzles 9

Technical Solutions Ultra sonic vaporing of shooting nozzles 10

Challenges and Solutions Avoid dry and hardening of core sand in the sand hopper above the machine and in the shooting unit after the shot. ↓ Solutions: Moisturing of the air above the sand level by water spray and covering of the hopper top. Problem: Water droplets will condensate at the cool nozzles, water droplets wash away binder skin from the sand grains and cause defects in the core surface and body. Water not to be sprayed in as droplets but as cold vapor. The evaporation of the water will be done by ultra sonic generator (system patended by Laempe). 11

Kernschießmaschinentechnik Solution Kernschießmaschinentechnik Ultra sonic vaporing of shooting unit

Kernschießmaschinentechnik Solution Kernschießmaschinentechnik Ultra sonic vaporing of shooting unit

Kernschießmaschinentechnik Solution Kernschießmaschinentechnik Ultra sonic vaporing of shooting unit

Kernschießmaschinentechnik Challenges and Solutions Kernschießmaschinentechnik Challenge: Due to the lower floability of certain binders and depending to the design of the shoot plate, sand channels may be formed in the shooting system. ↓ Solutions: Using of a „bridge breaker“(system patended by Laempe). Side effect: Using the bridge breaker will also deliver informations about the sand level in the shooting unit and so optimize sand dosing – even under such conditions where conventional optical systems will not work. Forming of „sand channels“

Kernschießmaschinentechnik Challenges and Solutions Kernschießmaschinentechnik Challenge: (Most) Inorganic binders require warm or hot coreboxes. Coreboxes need to be heated up to 200°C (392°F) Heating methods Advantages Disadvantages electrical heating by conventional resistance heaters known technology from hotbox technology easy to operate accurate temperature control easy tool designing, especially if separate heater plates are used Only middle-rate heat transfer heater cardrigdes reduce freedom of tool design; efficiency of the heat transfer is depending to tool accuracy for big toolings energy transfer requires big cables Thermo transfer oil good heat transfer known technology from high pressure casting process tool design unusual for coreboxes due to liquid channels complex piping system required Steam exellent heat transfer Reduced piping system required compared to oil heating High energy density mostly unknown technology to pattern makers and operators hot steam under high pressure

Kernschießmaschinentechnik Challenges and Solutions Kernschießmaschinentechnik Test equipment: Specially adapted coreshooter type LBB10 10 l shooting volume Equipped to operated all known binder processes Mixer directly installed above sand shutter Ultra sonic moisturing system for shooting system and shoot plate

Kernschießmaschinentechnik Challenges and Solutions Kernschießmaschinentechnik Heating equipment: Oil temperature unit make ROBOMAT and steam generator make CERTUSS. Both systems with heating capacity of 30 kW.

Kernschießmaschinentechnik Challenges and Solutions Kernschießmaschinentechnik Comparisson of piping system: Oil pipes with supply line and back line for each circuit. Steam system with supply line for each circuit and common back line.

Not only for inorganic bonded cores… Special Solutions Not only for inorganic bonded cores… Challenge: Identification of castings in relation to core production data, like shift, binder or sand batch, etc. even after batch-independent core storage. ↓ Solutions: Marking the cores by an ink printer directly after production and engraving a code by laser into the sand core.

Kernbearbeitung – Lasern/Bedrucken Special Solutions Kernbearbeitung – Lasern/Bedrucken

Contact Thank you for your attention! Laempe & Mössner GmbH Let‘s work together to keep our world for the next generations. Laempe & Mössner GmbH Tel: + 49 (0) 7622 / 680 0 Fax: +49 (0) 7622 / 680 391 Email: info@laempe.com Laempe & Mössner GmbH Schopfheim Grienmatt 32 D - 79650 Schopfheim 22