Phenolic Urethane Cold-box Binders - A Study of Global Properties, Variables, Causes and Effects

摘要

The complexity of phenolic urethane cold-box binder materials, properties, processes and applications around the world make the development of binders to cover the expanding range of global industry requirements a challenge. The recent shifts in geographic casting production are continually raising new combinations of property requirements or more difficult combinations of conditions under which phenolic urethane cold box binders must deliver these customer requirements. A model study was undertaken to link customer requirements, from a more general or global perspective, to verifiable phenolic urethane cold-box core making product and process design characteristics. Design for Six Sigma (a registered trademark of Motorola, Inc.) techniques and tools were applied and an experimental design was developed to provide the basis for the systematic evaluation of the factors binder composition, binder level, global sand source, and global location of test piece manufacture and testing. Testing included typical core-making properties and test castings. The results were analyzed using statistical methods and effects, and the contribution of the design factors to the variation of the test results is discussed.