TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Product Features:
The IVASET 226 R and IVASET 010 C System is a no-bake foundry binder system
utilizing new, unique technology developed. Providing improvements to the foundry
environment, this two-part, water soluble resin system allows the production of improved
quality castings.
Background:
An organic foundry binder system that offered:
1. Improvements to the foundry environment (internally / externally).
2. Superior casting performance like the “silicate” binders.
3. The advantages of existing “organic” binders.
Sand Handling Characteristic:
Designed for the foundry man, system offers several advantages in the production of
molds and cores.
Low odor at mix station Use any sand
Low chemical toxicity Excellent pattern release
Water cleanup (uncured) Complete through-set
These system advantages result in an improved environment, better employee
acceptance/working condition, less pattern maintenance and increased productivity.
IVP LTD
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TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Table-I
Sand Handling Comparison with
Other No-Bake Systems
Alpha FNB PHENOLI PHENOLI ALKYD SILICAT
set ACI C C ISOCYANA E
D ACID URETHAN TE ESTER
E
Odor at Very high high high moderate Very low
mixing low
Pattern excelle poor poor poor excellent good
release nt /moderate
Watercleanu yes partl partly No No yes
p y
Effect of hot moderat high high moderate moderate moderate
or cold sand e
Use any yes No No No yes No
sand
Core/Mold Long Long Long medium medium short
storage
Fast set time yes yes No yes No No
Slow set yes yes yes No yes yes
time
Reclaimabili High/ high high high high low
ty moderat
e
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TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Casting Characteristic:
Reduced expansion defects, such as veins and scabs, are a primary benefit of the system:
The chemistry of the system allows for the binder to absorb the initial sand expansion at
pouring before final cure. Containing low nitrogen and no sulfur, related gas defects are
minimized and iron oxide addition is usually not necessary.
Steel Casting
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.
Binder related gas defects, common to steel castings, are markedly reduced or eliminated;
the system contains low nitrogen, no phosphorous and no sulfur, all of which may impart
gas defects. Most often, iron oxide addition can be eliminated.
On stainless and alloyed steel, there is reduced surface carbon pickup, reducing problems
in meeting surface carbon specifications.
IVP LTD
[Link] MARG, GHORUPDEO
MUMBAI-400 033
Telephone-(022) 64562352 – 55
TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Aluminum Casting
The system 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.
Mix Levels
The IVASET 226 R resin is used at levels on silica sand of 2-2.5 % based on sand
weight. On very fine or angular sands, higher levels may be required.
The IVASET 010 C hardener is a co-reactant, its ratio to resin should not be changed
from the recommended levels, as it can significantly alter the physical properties of cores
and casting quality of the system. It is used at levels on silica of 20-25 % based on resin.
Mixing
As with any foundry binder system, the quality of mixing of the two components is
critical to developing the optimum system performance. The IVASET 226 R resin and
IVASET 010 C hardener must have intimate contact and mixing while being coated on
the sand.
IVP LTD
[Link] MARG, GHORUPDEO
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TECHNICAL DATA
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IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
On continuous mixers, either the resin or hardener can be added first; it is, of course,
recommended that they be added as early as possible to the sand stream. On batch
(muller) mixing, add the resin first; if premixing the resin / hardener system before
addition, it should be mixed and added as rapidly as possible to avoid procure. Mixing /
mulling time should be consistent with the system “worklife” or poor composite
properties will result. Strengths obtained with batch mixers are generally much lower
than those obtained with high speed continuous mixers.
Refractory coatings
The IVASET system bond is some what soluble in the water / solvents used in wash
coatings. Proper drying techniques of the core surface before applying the coating is a
desirable practice.
Alcohol washes should be ignited immediately after coating; alight torch drying has also
been found helpful, On water based washes, external heat (torch / oven )is necessary to
vaporize the water; dry until no further steam comes off the sand but avoid excessive heat
and/or oven cure. Modest heating prior to washing has also been helpful.
Pattern Release
The IVASET SYSTEM releases extremely well, much like an alkyd and far superior to
most other no-bake systems. Pattern release agents should be minimized.
IVP LTD
[Link] MARG, GHORUPDEO
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TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Reclamation of IVASET sand
A systematic study of the different reclamation techniques and equipments on bonded
sand shows that one of the reasons for poor rebonding properties of these reclaimed
sands, seen with earlier formulations, was the presence of a thin layer of inorganic
compounds on the surface of sand grains. The study showed that removal of this layer
(e.g. by wet reclamation) leads to significant improvements in rebonding strengths. The
system sand can be reclaimed using mechanical or thermal processes. The thermal
process is preferable in that rebonding strengths can be achieved. The selection of the
reclamation process will be dictated primarily by the requirements in the foundry as is the
case with all organic binder systems.
Process control of reclaimed sand
There are three parameters that should be measured and controlled when reclaiming sand
for rebonding.
Loss on ignition
This is an important process and control test for reclaimed sand. Despite the fact that
LOI’s on phenolic ester are dramatically lower than conventional no-bakes, they must be
controlled. There are no established quantitative limits for LOI because their effect varies
from one foundry to another. Foundries must establish their own limits based on their
practices and needs.
IVP LTD
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TECHNICAL DATA
IVP LTD SHEET
AN ESTER CURED PHENOLIC NO-
IVASET 226 R AND BAKE SYSTEM
IVASET 010 C
Screen analysis
This test ensures that the screen distribution of sand remains under control. The level of
the fines in the sand must be controlled because they affect molding process in two ways;
i) they affect permeability of the sand, and ii) high level of fines significantly reduce the
rebonding strength of the reclaimed sand.
Here again, no quantitative limits are proposed; only what the foundry deems necessary
to produce castings consistently.
Strengths
The strength of the sand ensures that the cores and molds prepared have adequate
handling strength as well as the ability to withstand the pressure of molten metal in the
mold cavity. Regular measurements of strengths can be use to monitor the rebonding
properties of the reclaimed sand as well as to regulate the addition of new sand to the
system.
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SR. Description Method Limits Results Units
NO
01 Viscosity B4 cup @ 30°C 28+/-
28+/- 4 24 Secs
02 Density Wt/lit. 1.10-
1.10-1.300 1.200 Gm/cc
03 Sand (WASHED 55-
55-65 55-
55-65
,GRADED MANGLORE
SAND) AFS
04 RT/RH 30°C/72 %
05 Resin Addition 1.5-
1.5-2.5 2.0 %
06 Catalyst Addition 20 20 %
07 Mixing Muller 2+2 2+2 Minutes
minutes
08 Bench Life Sand nature 4-10 5 Minutes
minutes
09 Stripping
Stripping time Hardness 15-
15-25 15
minutes minutes
10 Compression strength
( KG/CM2)
11 After first hour 8 12,14 Kg/cm2
12 After 2nd hour 12 18,20 Kg/cm2
13 After 4th hour 22 25,26 Kg/cm2
14 After 24th hour 30 34,36 Kg/cm2
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