1. Modulated machine design
for core production with inorganic binders

2. 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

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

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

5. 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

6. Green-Line-Concept 6

7. Comparison Coldbox/HotBox/Inorganic7

8. 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

9. Technical Solutions
Ultra sonic vaporing of shooting nozzles 9

10. Technical Solutions
Ultra sonic vaporing of shooting nozzles 10

11. 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

12. Kernschießmaschinentechnik
Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit

13. Kernschießmaschinentechnik
Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit

14. Kernschießmaschinentechnik
Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit

15. 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“

16. 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

17. 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

18. 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.

19. 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.

20. 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.

21. Kernbearbeitung – Lasern/Bedrucken
Special Solutions
Kernbearbeitung – Lasern/Bedrucken

22. 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: (0) 7622 / 680 0
Fax: +49 (0) 7622 /
Laempe & Mössner GmbH
Schopfheim
Grienmatt 32
D Schopfheim 22