INORGANIC AND ORGANIC BINDERS

Dr. Kamlesh Kumar Singh

Professor
Department of Foundry Technology, National
Institute of Foundry and Forge Technology,
Hatia, Ranchi- 834 003,
 What is Binder ?

Binder is a chemical compound, which binds the sand grains each

other and impart strength, resistance to erosion, breakage and
degree of collapsibility of moulds and cores.

Classification of Binder’s
They may be classified as

•Organic,

•Inorganic
Organic binders:
Organic binders are combustible and are destroyed by heat.
Hence they contribute a degree of collapsibility to the core and
mould sand mixture. The commonly used organic binders are core
oil (0.5 to 3 %), cereal (0.5 to 2 %), resins, plastics, pitch, dextrin,
molasses, rosin, lignin, casein, gelatin, wood flour etc.

Inorganic binders:
Inorganic binders are not combustible and may have considerable
strength at high temperatures, resistance to erosion and relatively
non-collapsables depending on their nature. The commonly used
inorganic binders in core and mould making are Fire clay (< 2 %),
bentonites (0.5 to 10 %), silica flour (< 30 %), iron oxide, sodium
silicate etc.
 Reasons For Binders Requirements
•It must be readily reclaimable.

•It must be environmentally acceptable.

•It must be safe to use.

•It must have low odor at the mixing, moulding, core making and
pouring station.

•It should be no-bake, capable of providing the long work life

necessary for filling the largest mould without the loss of mould
strength.

•It must have sufficient hot strength to sufficiently pour the

castings without premature mould/core breakage.
 Reasons For Binders Requirements
•It must maintain good casting quality. The binder should not
contain significant levels of elements that are responsible for gas
defects in steel castings, such as nitrogen or that can alter the
metallurgical properties of the metal or promote other casting
defects.

•It must be cost effective. In addition to binder costs, other costs

such as labor costs, equipment cost, energy costs, core/mould
scraps, casting scraps, repairs, machining and finishing costs
must all be kept low so that a good quality casting that can be sold
at a profitable, competitive price will result.
Sodium Silicate (water glass) systems
• IS 6773-1978 covers the detail specification for sodium silicate
for use in foundries.

• Foundry sodium silicates are Meta stable solution in which SiO2

is stabilized in solution by a combination of Na2O and water.

•The partial removal of Na2O by acidic agents such as CO2 or

partial removal of water by heat generated by hot air, microwave
energy or exothermic reactions promoted by additives promotes
the precipitation of SiO2 in the form of a gel.

•The gel is capable of binding the sand grains together. The rate
of dehydration is dependent on the percentage of solids in the
binder and also on the Na2O to SiO2 ratio.
 Differences amongst various processes
using sodium silicate lie in the quality of:
• Hardener used

• Type of catalysts or other additives

• The nature of chemical reaction.

 The more commonly used silicates range from a ratio of

silica to soda of 2.0 to 3.2

 The commonly used mixtures are: a two-part system

containing a catalysts, a silicate and a three-part system
containing a catalyst, a carbohydrate polymer and a silicate.
Fig. 1: Compression strength of sand mixture containing 3.0% weight ratio sodium silicate with 0.3 % of 1.51:1
ratio triacetin to diacetin catalyst.
 CATALYST

•The catalyst systems consist primarily of Easter. An Easter is

defined as an organic compound formed as a result of a reaction
between an acid and an alcohol.

•The organic Easter will hydrolyze when reacted with a source of

hydroxyl ions. Since sodium silicate is an effective source of
hydroxyl ions, this will allows for the resulting bond in the mould
or core.
Easter commonly used in the foundry industries are:

CH3COOCH2 CH3COOCH2
 
HOCH HOCH
 
HOCH CH3COOCH2
GLYCERYL MONOACETATE GLYCERYL DIACETATE
(MONOACETIN) (DIACETIN)
CH3COOCH2 CH3COOCH2
 
CH3COOCH CH2
 
CH3COOCH2 O

GLYCERYL TRIACETATE CH2
(TRIACETIN)

CH3COOCH2 CH3COOCH2

CH3COOCH2 DIETHYLENE GLYCOL
ETHYLENE GLYCOL DIACETATE
DIACETATE
 The organic Easter will hydrolyze when reacted with a source of
hydroxyl ions.
  
 A typical reaction of an acetate Easter (triacetin) would proceed
according to this reaction.

OH

CH3COOCH2 CH3COOCH2 H 2 H H2
-
 OH    
CH3COOCH -------- CH3COOCH ----- 3 CH3COOH   C – C - C ---
-


Slow 
   
CH3COOCH2 OH  O O O
CH3COOCH2

OH
 
H2 H H2 H 2 H H2

H2O
    
3 CH3COO- + C – C – C -------- 3 CH3COOH- + C – C – C + 3 OH-
     
 As the ratio of triacetin to diacetin decreases, the rate of reaction increases.

 The preferred catalyst level is 10-12 % based on the weight of the binder
(Fig. 2).

Fig. 2: Compression strength of sand mixtures containing various percentages of a 2.58:1 ratio silicate with 1.0% of
carbohydrate polymer and various percentages of a 1.51:1 ratio of triacetin to diacetin catalyst
 Various consideration for application of self-set
silicate
1. Be certain that the selection of the catalyst has a direct relation to
the Size of the mold or core applied, the type of mixing equipment to
be used, and the distance necessary to transport the sand mixture.
2. The sand temperature should be between recommended levels of 21
to 29°C.
- Faster for cold sand, Slower for Hot sand
3. Don’t be fooled by surface skinning of the mold or core. Always
check to certain that the system has been allowed to stand for the
recommended time interval.
4. If support rods are utilized in the mold or core, be certain that they
are at room temperature.
5.Properly check the pumps for proper delivery of the materials into the
sand mass.
6. An equally important consideration is the supply of the aggregate
into the process.
7. The order of addition of the materials is absolutely essential. It is
recommended that the carbohydrate polymer be added to the
sand mixture first, then the catalyst and finally the sodium
silicate.
8. It is never recommended to mix any of the ingredients prior to
the delivery into the sand.
9. It is possible to increase the rate of reaction by placing external
conditions on the system.
10. Since the mold washes are applied to the various core binding
processes, it is essential that the system withstand the varieties
of mold washes.
11. If external heat is applied to the mold or core, be certain that it is
not exposed to prolonged heat.
CO2 Process
The most commonly used hardener in foundry industries is CO2.

The main reason for the CO2 to be the most widely used silicate
hardener is:
•Relatively easy available

•Low cost

•Almost indefinite sound working life

•Instantaneous strip after gassing

•Good surface finish and high accuracy.

However, CO2 hardened moulds and cores suffer from certain
drawbacks as:

•Non-uniform strength development in the mould/core due to

difficulty in achieving uniform gassing.

•Wastage of gas due to lack of proper control on the foundry floor.

•Over gassed moulds/cores tend to become friable on short

storage time.

•CO2 -hardened moulds/cores have a tendency to pick up

moisture under humid conditions .

•It has poor breakdown property at knock off.

Principle of hardening
•When CO2 is passed through a mass of sand bonded with
sodium silicate, both chemical and physical reactions occur.

• They may occur concurrently. Low CO2 flow rate favor the
chemical reaction whereas high flow rates favor the dehydration
reaction.

•The chemical reactions (for a 2 % weight ratio) occur as:

1.Na2O.2SiO2 (aqueous) + CO2  Na2CO3 + 2 SiO2

(aqueous)

2. Na2O.2SiO2 (aqueous) + 2CO2 + H2O  2NaHCO3 + 2 SiO2

(aqueous)
Fig. 3: Parts by weight CO2 required at 7X theoretical with various weight ratio sodium silicates.
 Testing of sand-binder mixture after gassing
•The mould/core made of sodium silicate with CO2 gassing
depends upon various factors such as the type of sand used,
silica to soda ratio of binder, additives added, mixing time,
gas flow rate, gassing time, temperature etc.

•It has been found that from the Allahabad and Rajmahal
sands, the Rajmahal sand develops higher gassed shear
strength.

• It was also observed that with higher ratio binder, 3 minutes

mulling times gives better strength compared to 5 minutes
mulling time.
•With increase in silicate content in sand mix, the as gassed
compression strength improved as shown in Fig. 4

•The hot compression strength of 3.5 % silicate mix sand for

various ratios of silica and soda is shown in Fig. 5 for a
range of temperature.

•The retained strength diminishes in a desirable fashion until

the soaking temperature reaches about 535 0C and then
they increase dramatically as shown in Fig. 6.

•The compression strength obtained for a 2.4:1 ratio silicate,

immediately and after 24 hr. in ambient temperature and
humidity condition is shown in Fig.7.
 With increase in silicate content in sand mix, the
as gassed compression strength improved(Fig.4)

Fig. 4: CO2 gassed compression strength at various contained percentage of 2.4:1 weight ratio silicate with
various gassing ratios above theoretical.
·  The hot compression strength of 3.5 % silicate mix sand for
various ratio of silica and soda (Fig. 5)

Fig. 5: Hot compression strength of 96.5 % No. 1 silica sand with various
weight ratio sodium silicate mixtures.
· The retained strength diminishes until the soaking temperature
reaches about 535 0C and then they increase dramatically (Fig. 6).

Fig. 6: Retained compression strength of 96.5 % No. 1 silica sand with 3.5 % various weight ratio of
sodium silicate mixture
 The compression strength obtained for a 2.4:1 ratio silicate,
immediately and after 24 hr. in ambient temperature and humidity
condition (Fig. 7).

Fig. 7: Compression strength of 3.25 5 2.4:1 silica mixture at various temperatures gassed at 7 
with 7 lit/min.
 Ferrosilicon process
•Exothermic reaction takes place between the sodium silicate and
ferrosilicon powder.

•The foaming action takes place and reaching the boiling condition
(at ~ 90 0C).

•The reaction takes place as:

1.Na2O.n SiO2 + H2O  2NaOH + n SiO2

2. m Si + 2 NaOH + H2O  Na2O.m SiO2 +2H2 

•For a ferrous casting and non-ferrous casting, the silica sand

used 65 mesh and 100 mesh respectively.
 Dicalcium silicate (2 CaO. SiO2) process

•Generally 2 to 3 % dicalcium silicate is used with 5-6 %

sodium silicate and foaming agent to make the mould/core.

•Mixing time is around 3 to 5 minutes. The bench life was 25

to 30 minutes.

•The mass ratio of 2.3:1 to 2.8:1 sodium silicate with sp.

gravity 1.48 to 1.5 is commonly used in this process.
Fluoride Process
• In this process the fluoride (sodium silico fluoride) powder is

used as hardener.

• For optimum properties, the hardener is used 20-25 % of

the sodium silicate (5-6 % of sand) used.

Fig 8: Effect of binder and F. hardener on Fig 9: Comparison of retained compressive strength
compressive, shear and retained strength. for various self-hardening processes.
CHAMOTTE PROCESS

• Burnt fire clay, ground to fine mesh size called chamotte can
also be an effective hardener when used with sodium silicate
process using about 2% chamotte and 4-5% sodium silicate
(2.5 mol. ratios) with high silica sand.

• This process is mainly used in steel foundry for heavy

casting. Low cost and free from defect like sand fusion, hot
tear, cold crack, scabbing are the major advantage of this
process.
CEMENT MOULDING PROCESS

•In this process, Portland cement (~ 2 %) with sodium silicate

(4-5 %) and pitch or molasses (~ 1 %) is commonly used.

•The bench life is around 15 to 20 minutes. Large size mould

can be produced for ferrous casting.

•This process has the advantage of good strength of mould

and core, better permeability and reduced ramming of sand.
 ORGANIC BINDERS

• Organic Binders are the substances which are mixed in

moulding and core making sand to obtain specific
characteristic.

• These may also help in improving high temperature plasticity

and hot strength, produce anti metal penetration properties and
impart good surface finish to the castings.
Commonly used Organic Binders:
•Coal dust

•Linseed oil
•Dextrin
•Molasses

•Phenol formaldehyde
•Urea formaldehyde
 Coal Dust

• Coal dust is a fine powdered form of coal, which is created by the

crushing, grinding, or pulverizing of coal

• Because of the brittle nature of coal, coal dust can be created

during mining, transportation, or by mechanically handling coal

• Use of coal dust increases both green and dry strength, reduces
expansion and metal penetration.

• It however tends to decrease the permeability of the sand.

 Linseed Oil

• It is used either with cereal binders like dextrin or with dextrin

and bentonite.

• The high linolenic acid content of linseed makes the oil an

excellent drying agent for example in foundry, wood treatments,
linoleum.
 Dextrin

• Dextrins are a group of low-molecular-weight carbohydrates

produced by the hydrolysis of starch or glycogen.

• Dextrins are mixtures of polymers of D-glucose units linked

by α-(1→4) or α-(1→6) glycosidic bonds.

• Dextrins can be produced from starch using enzymes like

amylases, as during digestion in the human body and during
malting and mashing, or by applying dry heat under acidic
conditions (pyrolysis or roasting)
 Molasses

• It is used as binder in both moulding and core making for iron

casting.

• It enhances the bench life of the sands and imparts high strength
and collapsibility .

• Its decomposition at high temperature generates CO2, which set

up a set up a hardening action of mould and increases hot
compressive strength.

• Molasses is a viscous by-product of the processing of sugar cane,

grapes or sugar beets into sugar.
  Phenol Formaldehyde

• Phenol formaldehyde resins (PF) include synthetic thermosetting

resins such as obtained by the reaction of phenols with
formaldehyde.

• Sometimes the precursors include other aldehydes or other

phenol.

• Phenolic resins are mainly used in the production of circuit

boards
  Phenol Formaldehyde
• In the form of Bakelite, they are the earliest commercial
synthetic resin.

Fig:-Phenol Formaldehyde
  Phenol Formaldehyde
Formation and structure

•Phenol-formaldehyde resins, as a group, are formed by a step-growth

polymerization reaction that can be either acid- or base-catalysed.

•Since formaldehyde exists predominantly in solution as a dynamic

equilibrium of methylene glycol oligomers.

•The initial reaction in all cases involves the formation of a

hydroxymethyl phenol:

HOC6H5 + CH2O → HOC6H4CH2OH

  Phenol Formaldehyde

• The first reaction gives a methylene bridge, and the second

forms an ether bridge:
HOC6H4CH2OH + HOC6H5 → (HOC6H4)2CH2 + H2O

• The diphenol (HOC6H4)2CH2 (sometimes called a "dimer") is

called bisphenol F, which is itself an important monomer in the
production of epoxy resins.

• Bisphenol-F can further link generating tri- and tetra-and

higher phenol oligomers.
2HOC6H4CH2OH → (HOCH4CH2)2O + H2O (Phenol
Formaldehyde)
 Urea Formaldehyde

• Urea-formaldehyde, also known as urea-methanal, overall

structure is a non-transparent thermosetting resin or plastic.

• Made from urea and formaldehyde heated in the presence of a

mild base such as ammonia or pyridine
 Urea Formaldehyde

Properties

•Urea-formaldehyde resin's attributes include high tensile strength,

flexural modulus, and heat distortion temperature, low water
absorption, mould shrinkage, high surface hardness, elongation at
break, and volume resistance
 Urea Formaldehyde

Chemical structure

•The chemical structure of UF resins can be described as that of

polymethylene .

• This description leaves the details of the structure

undetermined, which can vary linearly and branched.

•These are grouped by their average molar mass and the content
of different functional groups.
Urea Formaldehyde
 Alpha set Process
• The alpha set process lies under the category of cold set process.
• The phenolic resole resin binder contains no furfuryl alcohol or
nitrogen and does not require a sulphur containing catalyst to
harden it.
• The two part binder consists of the water soluble, alkaline
phenolic resin and between 15 and 30% of the liquid ester co-
reactants.
• A blend of esters is chosen to provide the required setting time
but cause only partial cross linking of the phenolic resin.
• In process, known as the Alpha Set process, the alkaline phenol-
formaldehyde resin, resol type, containing below 1% of hydrous
phenol and below 0.2 % of free formaldehyde is applied
• As hardeners esters are used.
Furfuryl alcohol
 SO2 Process
• The S02 process is lies under the category of cold box process.

• The system is based on the use of a furan resin, with furfuryl

alchoal. Formaldeyde giving the best results.

• The sand is mixed with a peroxide for example methyl ethyl

ketone peroxide (MEKP) added at between 20 and 50% of the
resin weight , an adhesion promoter and silane.

• Following compaction , sulphur dioxide gas is passed through

the mixture and is oxidesed by the peroxide to produce sulphur
trioxide.

• The sulphur trioxide dissolves in the water association with the

resin to produce sulphuric acid high polymerases the resin.
 The Epoxy S02 Process

• Introduced commercially in 1983 and known also under the

trade name Ruutapox.

• A two-part binder system is used with Part A comprising a

combination of a modified epoxy resin with an aromatic
peroxide and Part B consisting of an epoxy resin with
acrylic modifiers to improve reactivity and the cure speed.

• Polymerisiation of the resin is achieved by the passage of

S02 through the compacted sand
 The Free-Radical Cure Process
• Introduced during 1982 and known as the FRC process, this
process uses a three component binder addition. The
components are:

• A vinyl unsaturated urethane oligomer that contains reactive

carbon-carbon bonds

• An organic peroxide and

• A vinyl silane adhesion promoter, to increase strength and

improve storage life.
 Furan Process

• Furan is a heterocyclic organic compound, consisting of a

five-membered aromatic ring with four carbon atoms and one
oxygen.

• The classes of compounds containing such rings are also

referred to as furans

• Today furfuryl alcohol is used in binders for hot-box, warm

box and gas hardened processes as well as in the traditional
Furan-No-Bake system.
 Furan NO-Bake (FNB)

• It is suitable for making all types of metal castings in all

sizes, and particularly used for the production of molds
and larger cores.

• This acid catalyzed cold setting binder consists of

hardening catalysts such as sulfuric acids, sulfonic acids
and phosphoric acids and of a reactive furan-type resin.

• FNB is known for its superior shakeout characteristics

and the sand can be reused by thermal and/or
mechanical reclamation.
 Furan Hot Box Process
• Furan Hot Box process uses furan resins in combination with
latent acid catalysts, e.g. ammonium salts.

• The Warm Box process is operated at lower temperatures and

was developed by the Quaker Oats Company for the rapid
production of cores in existing hot box equipment.

• This type of furan binder contains more furfuryl alcohol than

in hot box furan binders.

• A latent copper salt catalyst is used to cure the binder very

rapidly upon heating.
 Furan SO2 process

• Furan S02 process is a gas cured binder system for the rapid
production of small moulds and cores.

• Curing of the furanic resin occurs right away, when the sand
mix is exposed to SO2 gas at room temperature.

• Furan resin self-hardening sand named from furan no-bake

process, it takes furan resin as adhesion agent and mixes with
catalyzer to produce sand molds, the sand moulds can concrete
under room temperature.
 Furan SO2 process

Advantages
•The sizes of metals castings are accurate, the outline of the
metal castings is clear, the surface of the metal castings is
smooth; the appearance quality is good and the micro-
structure is compact.

•The sand moulds do not need to be oven dry, so it shortens

the period of production and save energy.

•Because there is no oven dry, so the sand moulds are

compact, and reduce the intensity of labour.
 Furan SO2 process

Disadvantages

High requirement for the quality of the raw materials.

•There is stimulating gas during moulding and pouring.

•The cost of resin sand is high, and should be considered

comprehensively.
THANKS