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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 the characteristics, key challenges, and critical control measures associated with alkaline phenolic resins in production. He also shared practical application examples that highlighted the benefits of using these resins, offering real-world solutions for industrial use.
In the early 2000s, alkaline phenolic resins were first introduced in domestic joint ventures and foreign-funded foundries. Many new steel casting plants or facilities using water glass sand were renovated during this period, primarily for applications in cast steel, cast iron, and non-ferrous alloys.
The alkali phenol resin process offers several notable advantages:
1. The resin is free from nitrogen, and the curing agent does not contain sulfur or phosphorus, which helps avoid defects such as surface degradation, thermal cracking, and nitrogen porosity.
2. It features a thermoplastic and secondary hardening process at high temperatures, significantly reducing thermal cracking and burr defects in steel and ductile iron castings.
3. The process does not emit harmful or irritating gases during sand mixing, molding, core making, or casting, greatly improving working conditions.
4. It has excellent collapsibility, which reduces sand cleaning time and increases labor efficiency.
5. It is compatible with various types of raw sand, showing strong adaptability to different sand sources.
6. The amount of resin required is relatively high.
7. Its sand regeneration performance is not as good as that of furan resins.
Considering these characteristics, there are several issues that need attention during actual production. First, it's essential 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, thereby lowering resin and coating consumption. Second, proper classification and management of core sand are crucial—this ensures optimal utilization and minimizes waste while reducing regeneration pressure and promoting a sustainable cycle. Third, sand regeneration remains a challenge due to the tough film formed by alkali phenolic resin, which is harder to regenerate compared to furan resin. To address this, companies should implement measures such as ensuring high-quality original sand, selecting advanced regeneration equipment, minimizing resin usage, reducing the sand-to-iron ratio, and maintaining regeneration systems properly.
Additionally, companies should focus on material consumption management to cut costs and reduce waste. They should also invest in appropriate equipment and methods, such as using a curing speed automatic regulator that adjusts the curing agent based on resin addition, and remotely monitoring equipment performance for better efficiency.
With its unique advantages, the alkali phenolic resin self-hardening sand process is expanding rapidly in its application range. However, it's important to be aware of certain challenges, including sand regeneration, core sand classification, and material management. By addressing these issues through targeted measures, the full potential of the process can be realized.