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Resins / Binders




Foundry

The IVAREZ 400 R and IVAREZ 400 C System is a no-bake foundry binder system utilizing the resol phenol-formaldehyde chemistry. Providing improvements to the foundry environment, this two-part resin system allows the production of improved quality castings.

Field of Application:
Suitable for casting of iron, steel and steel alloys. It can be used in floor moulding as well as high speed loop and carousel operations.

Features:

  1. Faster rate of curing hence high productivity.
  2. Excellent BAKING STRENGTH, high resistance to metal penetration.
  3. Excellent surface finish.
  4. Excellent flow ability of sand facilitates easy production of intricate cores and moulds.
  5. Reclamation of sand is possible.
  6. Superior casting performance.
  7. Negligible NITROGEN.

Resin Name Ivarez 400
Appearance Yellow to Light brown Liquid
Viscosity (B4 Cup at 30℃) 40-45 Secs
Free Formaldehyde 0.3% Max
pH 6-6.5
Shelf Life 3 Months
Hardener Name Ivarez 400C
Resin Content 1 - 1.5 % Based on Sand
Hardener Content 30 - 50 % Based on Resin
Bench Life 3 - 10 Minutes
Stripping Time 20 - 40 Minutes

Sand Handling Comparison with other No-Bake Systems

  FURAN N-B ACID RESOL N-B ACID PHENOLIC URETHANE ALKYD ISOCYANATE Alpha set
Odor at mixing low moderate high moderate low
Pattern release good good poor /moderate excellent excellent
Effect of hot or cold sand high high moderate moderate yes
Use any sand yes yes No yes No
Core/Mold storage Long Long medium medium yes
Fast set time yes yes yes No yes
Slow set time yes yes No yes yes
Reclaimability high high moderate moderate moderate

The IVASET 226 R and IVASET 010 C System is a no-bake foundry binder system. This system consists of a phenolic resol resin of highly alkaline nature & with very low free formaldehyde & low free phenol cured by an organic ester or blend of esters. This two-part, water soluble resin system allows for the production of improved quality castings.

Field of Application:
This system can be used for all type of Metal Castings for making moulds and core. The benefits of the system are most noticeable in steel castings resulting in a significant improvement in casting quality and reduced cleaning room costs. Expansion defects, inherent to steel metallurgy, are significantly reduced due to the systems unique thermosetting characteristics. On stainless and alloyed steel, there is reduced surface carbon pickup, reducing problems in meeting surface carbon specifications.

The system also provides some specific benefits to aluminum and magnesium castings that result in improved shakeout and staining reduction or elimination. Shakeout times on cores and molds have been reduced by up to 50-90 %; the resulting savings have been instrumental in the system’s acceptance for aluminum castings.

Features:

  1. Suitable to mix with most Indian sands.
  2. Mould and cores are not affected by humidity.
  3. Hot strength is pretty good.
  4. Can be poured within 4 to 6 hours depending on size of moulds.
  5. Suitable for batch as well as continuous mixing.
  6. Environmentally clean system.
  7. Binder is water miscible i.e. contaminated parts can be easily cleaned.
  8. Negligible amount of nitrogen and no sulphur or phosphorous in the system.

Name : Ivaset 226 & Ivaset 010

Resin Specifications

Name Ivaset 226 (Grade MM3) Ivaset 226 (Grade M2)
Total Solids 47-50 % 48-52%
Viscosity (B4 Cup at 30℃) 24-26 Secs 23-25 Secs
pH 12-13 13-13.5
Free Formaldehyde 0.2% Max. 0.2% Max.

Hardener Specifications

Name Ivaset 010 (Various Grades Available)
Sp. Gravity (25℃) 1.15-1.16
R.I. 1.430 ± 0.010
Bench Life 4 - 20 Minutes (Based on Grade of Resin and Hardener)
Stripping Time 10-40 Minutes (Based on Grade of Resin and Hardener)

Sand Handling Comparison with Other No-Bake Systems

  Alpha Set FNB ACID PHENOLIC ACID PHENOLIC URETHANE ALKYD ISOCYANATE SILICATE ESTER
Odor at mixing Very low high high high moderate Very low
Pattern release excellent poor poor poor /moderate excellent good
Water cleanup Yes partly partly No No yes
Effect of hot or cold sand Moderate high high moderate moderate moderate
Use any sand Yes No No No yes No
Core/Mold storage Long Long Long medium medium short
Fast set time yes yes No yes NO NO
Slow set time Yes Yes Yes No Yes Yes
Reclaimability High/ moderate high high high high low

The Ivalinocure range is a 3 part system consisting of a resin (Part A), a catalyst (Part B) and a hardener (Part C). The Resin is a thermoplastic polyester resin made by heating standard vegetable oils with polybasic acids or their anhydrides. The catalyst is a mixture of metal octoates and the hardener is MDI.

Field of Application:
This system can be used for small and large, cores and moulds of both ferrous and non-ferrous castings

Features:

  1. Can be used with all sands.
  2. Can be used with both batch and continuous mixers.
  3. Sands are very flowable.
  4. Possible to make very large cores which can take higher times to complete.
  5. Possible to have very large work times and achieve maximum strength at the end.
  6. Gives good casting finish.

Name : Ivalinocure Part A, B & C

Resin Specifications (Various Grades Available)

Viscosity (B4 cup at 30℃) 170 - 250 Secs ( Containing 0.5 to 1.75 Pb Octate)
Part A + Part B + Part C
Bench Life 4 - 30 minutes (Based on Grades of Part A, B & C)
Stripping Time 20 - 60 minutes (Based on Grades of Part A, B & C)
Shelf Life of all 3 Parts 6 months

The Phenolic Urethane Cold Box (PUCB) process utilizes an amine gas to catalyze the reaction between a phenolic resin and an isocyanate to produce a urethane bond. IVAREZ 308 is a phenolic resin that is used in conjunction with an MDI-type isocyanate, such as IVAREZ 608. Typically, both the Part 1 and Part 2 resin components are mixed with suitable sand. The resulting sand mix is then blown into a core box and is subsequently cross linked by passage of a vaporized tertiary amine catalyst to produce a urethane bond. Curing takes place at the same rate throughout.

Now, IVP also offers Di-methyl propyl amine (DMPA) as an alternative to tri-ethyl amine (TEA). DMPA is more environmental friendly; has low odour and toxicity and can be used in much smaller amounts when compared to tertiary amines, while having the same handling and operating conditions; meaning no process or machine change is required to use DMPA.

Field of Application:
The cold box process is mainly used in casting of cores for automotive castings due to its excellent dimensional accuracy. Cores for iron castings can be made. They are suited for high productivity as well as for large cores which require rapid strength increase.

Features:

  • High Productivity - Large volume high speed production
  • No tooling heat required, Cures at room temperature
  • Cost effective to run in comparison to heat cured systems
  • Low labor and energy cost
  • Good dimensional accuracy, very good flow ability of sand mix
  • Cores can be handled immediately
  • Cores can be cast as early as possible.
  • Long resin shelf life

Name : Ivarez 308 & Ivarez 608 & Ivarez 700 Catalyst

Resin Specifications

Name Ivarez 308 (Various Grades Available )
Viscosity (B4 Cup at 30℃) 40-60 Secs
Specific Gravity (30℃) 1.05 – 1.2
   

Hardener Specifications

Name Ivarez 608 (Various Grades Available )
Viscosity (B4 Cup at 30℃) 15-20 Secs
Specific Gravity (30℃) 1.1 – 1.2

Ivarez 210 Resin & Ivarez 210 Catalyst
This is a two-part system consisting of a resin in furfuryl alcohol cured by an acid catalyst. We manufacture various grades of this system.

There is even a ‘No-Nitrogen’ Grade available in this resin. The benefits of the system having NO NITROGEN are most noticeable in steel castings resulting in a significant improvement in casting quality and reduced cleaning room costs.

Field of Application:
It is recommended for production of cores & molds of iron & critical steel castings. The furan system is particularly useful when high amounts of reclaimed sand have to be used. With reclaimed sand, resin requirement is much lower.

This is a technologically cutting-edge resin.

  1. The chemistry of the system allows for the binder to absorb the initial sand expansion at pouring before final cure.
  2. It gives a faster rate of curing which leads to high productivity.
  3. It has excellent hot strength and high resistance to metal penetration
  4. It has excellent surface finish and collapsibility.
  5. It has excellent flowability of sand which facilitates easy production of intricate cores and moulds.
  6. Reclamation of sand is possible.
  7. Shelf life of binder is high.

Resin Specifications

Name Ivarez 210
Appearance Brownish coloured liquid
Density at 30℃ 1.160 ± 0.05
Shelf Life 6 months - 1 Year
Resin Content 0.9 - 1.5 % Based on Sand
Hardener Content 30 - 40 % Based on Resin
Bench Life 7-20 Minutes
Stripping Time 15-50 Minutes

Note: Please do not add furan resin with catalyst without sand.

Sand Handling Comparison with other No-Bake Systems

  FURAN N-B ACID PHENOLIC N-B ACID PHENOLIC URETHANE ALKYD ISOCYANATE
Odor at mixing low high high moderate
Pattern release good poor poor /moderate excellent
Effect of hot or cold sand high high moderate moderate
Use any sand yes No No yes
Core/Mold storage Long Long medium medium
Fast set time yes No yes NO
Slow set time Yes Yes No Yes
Reclaimability high high moderate moderate

The PEP-Set system is a 3 part system, consiting of Ivarez 1505 resin, Ivarez 3505 catalyst and Ivarez 2590 hardener. It is a rapid through curing Phenolic Urethane System ideal for making medium and large cores and moulds of repetitive nature. PEPSET System is the fastest among all the other Nobake system.

Field of Application:
This system is suitable for ferrous and non-ferrous casting production.

Features:

  1. Very high productivity is obtained which eliminates bottlenecks in production.
  2. This system could contribute greatly to an overall Energy Saving.
  3. The Gas Evolution is very low.
  4. Due to high tensile system and erosion resistance to metal, precise dimensions of castings are maintained resulting in sound castings.
  5. Being an organic binder, gives excellent surface finish to the casting.
  6. It has very good collapsability.
  7. Stripping time can be adjusted by varying percentage addition of catalyst.
  8. Sand mix has good flow ability and compatability until just before the stripping time.
  9. Sand can be reclaimed.

Name : PEP-Set System: Ivarez 1505 Resin, Ivarez 2590 Binder & Ivarez 3505 Catalyst
Resin pH 4 to 5
Resin Density 1± 0.1
Resin Viscosity (B4 Cup at 30℃) 27 - 34 secs (Various Grades Available)
Bench life 6-6.5
Shelf Life 2 to 7 minutes (Various Grades Available)
Stripping time 3 to 12 minutes (Various Grades Available)
Shelf Life of all 3 Parts 6 months

The Ivarez 501 resin and Ivarez 501 catalyst system is a shell foundry binder system, commonly known as novalac resin, a thermoplastic phenol formaldehyde type resin.

The IVAREZ 501 ( EPR 50 ) is specially designed shell resin with epoxy compound to give better cold strength (Transverse & Tensile ) to resin coated sand .This thermo plastic phenol formaldehyde resin is highly suitable for thin section shell core particularly water jackets.

Field of Application:
The binder system is used to make resin coated sand which is in turn used in foundry to make cores and moulds. Resin coated sand can be used to make castings of high precise dimensions and smooth surface. It can be used in production of cores and moulds in ferrous and non-ferrous metal casting for automobile foundries, pump and motor casting foundries, engine block foundries and other general engineering industries.

Features:

  1. Improved cure depth and uniformity of cure at identical pattern temp. and cycle times offers potential for reducing cycle time.
  2. Excellent sand flow ability with high resistance to peel back.
  3. Increased transverse strength due to improved through cure.
  4. Increased build up with improved through cure.
  5. Low dilation of molds and cores.

Product Name : Ivarez 501

Resin Specifications

Name Ivarez 501 (Grade : SUPER ) Ivarez 501 (Grade : EPR 50)
Total Solids (1gm at 150℃ for 1 hr) 70-72 % 71-73%
Viscosity (B-6 Cup @ 30℃) 90 - 100 Secs 100-120 Secs

Hardener Specifications

Name Ivarez 501 Catalyst
Ash Content @ 1000℃ for 1 Hour 2.2 - 3 %
Hexamine Content 69-75 %
Fineness through 200 mesh 99 % minimum

Specifications

Name Ivarez 501 (Grade : SUPER ) Ivarez 501 (Grade : EPR 50)
Build Up % 48 - 56 % 52 - 58 %
Peel Back % 1 % Max 1 % Max
Stick Point ℃ 98-100 98-100