APPENDIX II Detailed Lists of Potential Contaminants at Foundry Sites
APPENDIX II Detailed Lists of Potential Contaminants at Foundry Sites
APPENDIX II Detailed Lists of Potential Contaminants at Foundry Sites
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Appendix <strong>II</strong><br />
3(a) Mould & Coremaking Resins, Hardeners & C<strong>at</strong>alysts<br />
BINDER<br />
SYSTEM<br />
FIRST<br />
USE<br />
SETTING<br />
METHODS<br />
RESIN CONSTITUENTS<br />
HARDENER/CATALYST<br />
CONSTITUENTS<br />
Alkaline<br />
phenolic *<br />
1984/5<br />
Self-set,<br />
gassed<br />
Aqueous alkaline K or Na-based<br />
phenol formaldehyde resin; can<br />
contain methanol<br />
Self-set: organic esters<br />
Gassed: methyl form<strong>at</strong>e or CO 2<br />
Alkyd<br />
urethane<br />
1960’s Self-set<br />
Part 1: drying oil modified alkyd<br />
(polyester)<br />
Part 2: polyisocyan<strong>at</strong>e<br />
Cobalt naphthen<strong>at</strong>e (commonly<br />
incorpor<strong>at</strong>ed in Part 1)<br />
Ecolotec 1990’s Gassed Alkaline phenolic resin CO 2<br />
SO 2 cured<br />
epoxy resin<br />
1983 Gassed<br />
Modified epoxy resin mixed with<br />
an organic hydroperoxide; a<br />
furan version (from 1975) is also<br />
available<br />
Sulphur dioxide gas<br />
Free radical 1990’s Gassed<br />
Furan * 1958 Self-set<br />
Uns<strong>at</strong>ur<strong>at</strong>ed urethane oligomers<br />
& acrylic monomers, with an<br />
organic peroxide<br />
Urea formaldehyde (UF), phenol<br />
formaldehyde (PF) & furfuryl<br />
alcohol (FA) resin mixtures<br />
Sulphur dioxide gas<br />
Para-toluene, xylene or benzene<br />
sulphonic acids, sulphuric acids &<br />
phosphoric acid, or mixtures.<br />
Hotbox 1960 He<strong>at</strong><br />
Methylal<br />
cured<br />
phenolic resin<br />
mid-<br />
1980’s<br />
Gassed<br />
Phenolic (PF) and urea furan (UF)<br />
resins<br />
Phenolic resin<br />
No-bake oils 1950’s Self-set Esterfied or alkyd oil<br />
Oil sand **<br />
Phenolic<br />
urethane *<br />
Pre-<br />
1900<br />
1968-<br />
70<br />
Polidox 1980’s<br />
He<strong>at</strong><br />
Self-set,<br />
gassed<br />
Self-set,<br />
gassed<br />
Resin shell * 1950 He<strong>at</strong><br />
Ammonium chloride, urea & acid<br />
salts<br />
Methylal vapour with a toluene<br />
sulphonic acid c<strong>at</strong>alyst<br />
Sodium perbor<strong>at</strong>e or polymeric<br />
isocyan<strong>at</strong>e<br />
Modified vegetable oils & dextrin emulsions<br />
Part 1: phenol formaldehyde<br />
resin in ester/arom<strong>at</strong>ic<br />
hydrocarbon solvents<br />
Part 2: Isocyan<strong>at</strong>e, e.g., MDI<br />
Self-set: liquid tertiary amine,<br />
e.g., phenylpropylpyridine<br />
Gassed: dimethylethylamine or<br />
triethylamine<br />
Sodium polyacryl<strong>at</strong>e Alkaline powder & CO 2<br />
Mostly supplied as dry co<strong>at</strong>ed<br />
sand, but phenol novolak resin<br />
liquid in methanol, shellacs,<br />
waxes (if sand co<strong>at</strong>ed <strong>at</strong> foundry)<br />
hexamine<br />
Silic<strong>at</strong>e * 1952<br />
Self-set,<br />
gassed<br />
Sodium silic<strong>at</strong>e solutions<br />
containing SiO 2 and Na 2 O in<br />
varying proportions<br />
Self-set: organic esters<br />
Gassed: CO 2<br />
Warm box 1978 He<strong>at</strong> Furan resins<br />
Copper salts or inorganic salts <strong>of</strong><br />
sulphonic acid<br />
* most common current systems ** commonly used historically for core making<br />
Note: The term “self-set” is used to describe systems th<strong>at</strong> cure <strong>at</strong> room temper<strong>at</strong>ure after the resin<br />
and liquid hardener are mixed together with the sand.<br />
Page <strong>II</strong>-v
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