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Give full play to the advantages of the alkaline phenolic resin process
Zhang Kefeng, the deputy general manager of Jinan Shengquan Group Co., Ltd. (referred to as Zhang Zong), provided a comprehensive overview of alkaline phenolic resin, highlighting its unique characteristics, key production considerations, and practical application examples. He emphasized how the use of basic phenolic resins offers an effective and reliable solution for modern foundry operations.
In the early 2000s, alkaline phenolic resins began to be used in domestic joint ventures and foreign-owned foundries. Many new steel casting plants or facilities using water glass sand were renovated, with the resin primarily applied in cast steel, cast iron, and non-ferrous alloys.
The alkali phenol resin process has several notable features:
1. The resin is free from nitrogen, and the curing agent contains no sulfur or phosphorus, which helps avoid defects such as surface degradation, thermal cracking, and nitrogen porosity caused by sulfur accumulation on the casting surface.
2. It employs a thermoplastic and secondary hardening system at high temperatures, significantly reducing issues like thermal cracking and burr formation in steel and ductile iron castings.
3. The process does not emit harmful or irritating gases during sand mixing, molding, core making, or casting, leading to improved working conditions and a safer environment.
4. It exhibits excellent collapsibility, which reduces the time required for sand removal and enhances labor efficiency.
5. The process is compatible with various types of raw sand, offering strong adaptability to different sand sources.
6. A relatively high amount of resin is typically added, which can affect cost efficiency.
7. Sand regeneration performance is not as good as that of furan resin, requiring additional attention in this area.
Considering these characteristics, there are several challenges that need to be addressed in real-world applications. First, it's crucial to emphasize the importance of vibration and compaction during molding and core making. Higher compaction not only improves core strength and surface quality but also reduces sticking and porosity, ultimately lowering resin and coating consumption.
Second, proper classification and management of core sand is essential. This ensures optimal resource utilization, minimizes waste, and eases the burden on sand regeneration systems, promoting a sustainable cycle.
Third, sand regeneration remains a critical issue. Alkali phenolic resins have a tough film structure, making regeneration more difficult compared to furan resins. To address this, companies should implement measures such as maintaining high-quality original sand, investing in advanced regeneration equipment, reducing resin addition levels, optimizing the sand-to-iron ratio, and ensuring regular maintenance of regeneration systems.
Additionally, enterprises should focus on material consumption control to cut costs and minimize waste. They should also invest in suitable equipment and technologies, such as a curing speed automatic regulator, which can adjust the amount of curing agent based on resin usage and monitor equipment performance remotely.
The alkali phenolic resin self-hardening sand process is gaining popularity due to its distinct advantages. However, it’s important to remain vigilant about challenges such as sand regeneration, core sand management, and material efficiency. By addressing these issues proactively, companies can fully leverage the benefits of this process and enhance overall production performance.