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PREMIUM SAND CORE
MANUFACTURING FOR FOUNDRIES
Cold Box Sand Cores
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Ester Cured Phenolic
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Co2 cold box
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Phenolic Urethane airset
The heart of our business. Founders is a premier supplier of cold box cores. In the uncertain times of todays always changing manufacturing landscape Founders has created a seamless transition to multiple processes to ensure your foundry never deals with the raw material issue involved with core making. Founders can make a wide range of different core configurations; vertical, horizontal blown cores or hand ram in all shapes and sizes. Call us now to get a quote started.
How Cold Box Sand Cores Are Made
Cold box sand cores are made by mixing sand with a chemical binder system, blowing that sand into a core box, and then curing it with a gas catalyst so the core hardens almost immediately.
Basic process:
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Sand is mixed with binder
Clean foundry sand is mixed with a two-part resin binder, commonly a phenolic urethane system. The binder coats the sand grains but stays workable long enough to be blown into tooling. -
Sand is blown into the core box
The coated sand is shot or blown under air pressure into a metal, urethane, or printed core box. The tooling creates the final core geometry. -
Core is cured with gas
A catalyst gas, often amine gas for phenolic urethane cold box, is pushed through the sand-packed core box. The gas reacts with the binder and hardens the core without baking. -
Core is purged
Air is run through the core box to remove excess catalyst gas and fumes. -
Core is removed and finished
The hardened core is ejected, inspected, cleaned up, and any flash or seam lines are removed. -
Core may be coated
Depending on the casting requirements, the core may be dipped, sprayed, or washed with refractory coating to improve surface finish, control gas defects, and protect the core during pouring.
The major advantage is speed. Cold box cores cure fast, hold good dimensional accuracy, and are strong enough for complex core assemblies. The downside is that the process requires chemical handling, gas control, ventilation, and good binder/process discipline.
