Cold Box
Product Line Overview

Tried-and-tested Technology from theInventors of the Cold Box System
The invention of the polyurethane Cold Box system

In addition we offer our customers a holistic approach(PUCB) in 1968 set a standard that still applies

that goes well beyond merely offering products. Our

to this day and led to a change in the production

application technology and technical sales specialists,

processes in foundries worldwide. With thein particular, always assess the entire production

development of this technology ASK Chemicals

process as a whole. Only this approach allows forgave the market a high-performance and highly

customer specific solutions that are precisely tailoredproductive core manufacturing method that enabled

to meet customer requirements.

high-quality mass production. Naturally, though,technologies and market requirements are changing

Finally, our specialists’ expertise is complemented

all the time – in terms of what both customers andby a broad range of services that offer our customers

suppliers want. For this reason, ASK Chemicals

real added value. In this way, for example, our designcontinues to play a leading role in innovation and isservices can be systematically deployed to optimize

always looking for new ways to enhance our offer-the process as a whole – fromings and provide our customer’s greater value.

conceptual development toactualized series production –At ASK Chemicals we provide innovation driven re-thereby offering important savings

searchand process improvement for our

throughour

product

development

approach. We focus specifically on market trends
and customer demands because of the increasingly
complex requirements our industry faces: reduced
emissions, as well as cost-efficiency. Such requirements necessitate more than just strong partnerships and outstanding technologies; rather, we believe that first-class research and developmentthat focuses on efficiency, environmentally friendly
solutions and key performance parameters is essential.

2|

customers.

Inventor of Cold Box technology
 eading research and development
L
team
Application-specific solutions
 olistic approach with value-addingH
services|3Basic Information
Major Cold Box technologies
Phenolic urethane Cold Box binders
PUCB• Invented by ASK Chemicals in 1968
• Known for high productivity and low costin useResol CO2 binders

CO2• Water-based resin• Usable with most sand types
Alkaline phenolic Cold Box binders
APCBEpoxy acrylic SO2 Cold Box binders
EASO2• Fastest curing Cold Box technology• Indefinite mixed sand life

• Predictable “first stage through cure”• Excellent release properties

Hybrid phenolic epoxy Cold Box binders
HPE• Highest dimensional accuracy• Invented by ASK Chemicals in 1990s
ASK Chemicals brands
ISOCURE PUCBISOMAX HPE

The original and universal Cold Box binder

The premium Cold Box binder possessing thewidest positive traits		4|

ECOCURE HE, SL, RS, BLUE PUCBNOVANOLThe environmentally driven phenolic urethane

Water-based, eco-friendly binding agent for

Cold Box binder

Cold Box process

ISOSET EASO2

BETASET APCB

Highest production, fastest cure and indefinite

Water-based, eco-friendly binding agent forbench time

Cold Box process

CO2

Cold Box classification
System type

Number of parts

Cold Box type

PUCB

General benefits of Cold Box• High strength and productivity• High humidity stability• Ability to create highly complex cores• No need for pre-heating core tools

Differentiating factors

Ecology

Productivity

Quality

Cost

Flexibility• Reduced odor

• Fast cycle times
from high reactivity• Less casting
defects • Reduced binder
usage• Multiple sand types• Less tooling damage• Excellent coredimensional
accuracy• High tool availability• Low BTX emissions• Minimized monomer
content• Few hazardous air
pollutants• Reduced cleaningtime• Long benchlife andhigh strengths• Exceptional
deformation
resistance• Less core scrap• Climate adaptability• Multiple metal typeusability• Less catalyst
consumption• High core stability

Custom solutions
Apart from the system solutions mentioned in this brochure, ASK Chemicals also offers you custom solutions to fit your individual
process. Please contact us to discuss your specific needs.
|53 PartPUCB

ISOCUREThe original and universal Cold Box binder system
ISOCURE binders are the industry standard for high production foundries producing sand cores andprecision sand molds. This product family can be used to make all types of cores with both highly automatedproduction equipment and manual operations. The broad range of products can be used in highly
specialised casting processes or for more standard types of applications. The use of ISOCURE binders
can be matched to a foundry whose need is to produce high quality, superior cores and molds.

Benefits• Optimized for productivity• Robust system for multiple casting types• High strength properties• Low cost in use
A premium Cold Box binder
ISOCURE Focus is the premier brand within the ISOCURE family. Known for its
exceptional performance characteristics, ISOCURE Focus is fully customizable to meetyour unique foundry process needs.
• Lowest cost in use• High strength• Improved sand flow ability

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Premium

Premium strength and speed
Excellent humidity resistance
Lowest binder consumption

Automotive
Heavy truck
Aerospace
Universal

Performance

Excellent strength and speed
Good all-around performanace
Lowest enviromental impact

Automotive
Heavy truck
Agriculture
Universal

Standard

Major

Robust performance
Good quality
Predictable curing
Cost competitive

Automotive
Heavy truck
Municipal
Universal*Tailored product recommendations available upon request.

6|

Minor

Productivity

Quality

Ecology

Quality

Flexibility

Productivity

Quality

Cost

Flexibility

3 PartPUCB

ECOCUREThe environmentally driven phenolic urethane Cold Box binder
ECOCURE phenolic urethane binders focus on providing foundries with the high-end environmental
performance without sacrificing the speed and strength of the ISOCURE family of products. This isaccomplished by not only adjusting the solvents and additives in the binder, but also changing thechemistry backbone to produce products with less environmental impact.

Benefits• Lowest environmental impact• Fast binder that runs clean• High strength properties• Low binder usage
EC 30 RS 4604 /
60 RS 4605

Smoke-reducing ECOCURE RS

Standard
systemECOCURE RS has been specially developed to reduce casting smoke emissions, as well as gas and condensate formation. In addition, ECOCURE RS
provides high thermal stability for dimensionally accurate castings. This system
is suitable for aluminum, steel and iron casting.

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Premium

Lowest environmental impact
Excellent humidity resistancePremium strength and speed
Lowest binder consumption

Automotive
Heavy truck
Aerospace
Universal

Performance

Major

Good environmental impact
Excellent strength and speed
Good all-around performance

Automotive
Heavy truck
Agriculture
Universal

Minor

Ecology

Productivity

Quality

Ecology

Quality

Flexibility

Flexibility*Tailored product recommendations available upon request.

|7

3 PartPUCB

ECOCURE HEHigh efficiency Cold Box binder
ECOCURE HE binder systems set new standards in ecology and economy. They have a lower binder
requirement without compromising the usual efficiency. As a result, several factors such as catalyst
consumption, odor, emissions, core box cleanliness, and gas formation can be positively influenced.

Benefits• Up to 40 % lower BTX emissions• Up to 25 % less amine consumption*• Up to 15 % higher core blowing cycle times• Up to 25 % lower gas and condensate formation
The high efficency principle• Increase in strength• Reduction in the amountof binder needed

Increase in reactivity• Reduction in the amountof amine needed

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *FormulierungenComparison of transversal
im Vergleich
strength
0.8 % per part, H32
Strength[N/cm²]

600
500
400
300
200
100
0

Strength
Imed. 10´´

0.5 h

1h

2h

24 h

Moisture

Sand benchlife

Water-based core
coating

24 h

3 h / imed. 3 h / 24 h

10´ / 30´ wet 10´ / 30´ wet /98 % relative humidity

8|* Tailored product recommendations available upon request.

30´ 150 °C

Standard Cold Box
ECOCURE 30 HE 2
ECOCURE 60 HE 2

3 PartPUCB

ECOCURE BLUE
Latest Cold Box platform technology
The ECOCURE BLUE platform technology is the world's first technology that has a Cold Box part 1 that is
not classified as a hazardous material* and thus helps to considerably reduce phenol emissions in theprocess. First tests also have shown a reduction of the phenol content in used sand. This leads to a positiveeffect with regard to disposal costs. Ecology and economy are not mutual exclusive, which is perfectly
shown by ASK Chemicals ECOCURE BLUE HE Systems that are in no way inferior to the currently
available best Cold Box binders on the market when looking at the reactivity, strength and casting results.

Benefits• Free of hazardous ingredients**• Combines the advantages of ECOCURE HE• Can be combined with ECOCURE HE binder• Free phenol < 1 %, Free formaldehyde < 0.1 %• Savings with logistics and storage

Cold Box binders with high environmental
compatibility

Consistent development of the ECOCURE HE binders throughcombination with the ECOCURE BLUE platform
ECOCURE™

Technology platforms

Binder• 2007: ECOCURE High Efficiency• 2015: ECOCURE BLUE• 2008: ECOCURE HE 1. Generation• 2011: ECOCURE HE 2. GenerationBLUE

ECOCURE HE + ECOCURE BLUE = ECOCURE BLUE HE

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *Compared to a conventional binder system, without any harmful ingredients**
Standard Cold Box binder

Base: formophenolic / MDI
Additive with low OEL  ECOCURE BLUE

Solvents with low EHS impact

Solvents with low OEL (e.g. aromatics)

Monomers (phenol / formaldehyde)* Tailored product recommendations available upon request. ** According to the CLP regulation|9

3 PartPUCB

ECOCURE SL
Solvent-less Cold Box technology for iron and aluminum applications
ECOCURE SL completely eliminates the need for solvents in part 2 of the Cold Box formulation. It
achieves a significant reduction in emissions, saves energy and materials, and at the same time considerably improves the handling properties. ECOCURE SL is suited for both aluminum and iron casting.

Benefits• Fewer emissions due to less binder• Shorter cycle times• Less cleaning due to less binder and amine• Better shakeout• Longer cleaning intervals• Lower costs due to binder and catalyst savings

Greater added value with ECOCURE SL

4.

1.

1. SL Cold Box formulation

Greater
added value

2. Binder reduction
3. Reduced amine usage

3.

2.

4. Optimization of the entire process chain

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *Comparison of transversal strength
Standard Cold Box Formulierung

ECOCURE SL Formulierung
Solvent-free part 2:
Comparison of formulations
Typical formulation for aluminum casting:0.55 % part 1 and 0.55 % part 2
Formulation with the SL system:
0.55 % part 1 and 0.50 – 0.40 % part 2

Phenol-formaldehyde resin
Di-phenylmethane – Di-isocyanate
Additives
Cold Box
part 110 |Cold Box
part 2ECOCURE SL
part 1* Tailored product recommendations available upon request.

ECOCURE SL
part 2S olvents such as: Aromatics, polar esters,
plasticizers, fatty acids, esters, aliphatics

3 PartEASO2

ISOSET
Highest productivity, fastest cure and an indefinite benchlife
ISOSET binders were developed to solve a key problem faced by foundries; the benchlife of mixed
sand. As the sand binder mixture ages, in most binder systems it begins to advance, and at a certain
point will no longer be usable to produce quality cores and molds. This is especially costly when there ismachine down time. In most cases this sand binder mix must be discarded to avoid quality problems.
ISOSET technology solves this problem. The binder can be mixed into the sand and left indefinitely. It
will not cure until it comes in contact with the sulphur dioxide catalyst.

Benefits• Minimal core sand waste, as the sand binder
mix has an unlimited benchlife• Lower operation cost
• Can reduce need for coating
Operation cost: the benefit of foresight
At one of the leading automotive original equipment manufacturers (OEM’s) ISOSET isbeing utilised for cylinder head production. Due to “smart economics” this OEM could install
fewer machines and still produces the same number of cores /castings using ISOSET –a story about the importance of cost in use.

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

SO2

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Premium

Premium strength and speed
Highest erosion resistanceLow mixed sand waste
Lower cost to use

Automotive
Heavy truck
Aerospace
Universal

Standard

Major

Robust performance
Good quality
Cost competitive

Automotive
Heavy truck
Universal

Minor

Productivity

Quality

Ecology

Productivity

Flexibility

Cost

Flexibility*Tailored product recommendations available upon request.

| 11

3 Part
HPE

ISOMAXThe elite Cold Box binder possessing the widest positive traits
ISOMAX binders are a hybrid epoxy phenolic resin designed to produce repeatable cores at extremely fastcycle times. The dimensional stability of these cores is not surpassed by any current system. The nonferrous version also exhibits the fastest shakeout times currently seen. Coupled with the extended benchlifeof these products, ISOMAX makes for a unique technology that is capable of making worldclass castings
at a low cost to produce.

Benefits• Fast cycle times• Excellent shakeout• Extended life of mixed sand
• Dimensional stability
A productivity boost in brake disc production
ASK Chemicals ISOMAX binder system is utilised in the production of one of the largest original
equipment manufacturers (OEM’s) in the world. Here ISOMAX pumps out millions of disc brakerotors in just one location using two production lines.

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

700 Series

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Premium

Major
Excellent dimension stability
Fastest cycle times
Extended life of mixed sandExcellent shakeout

Brake disc
Manifolds*Tailored product recommendations available upon request.

12 |Quality

Minor

Flexibility

Productivity

Cost

2 PartAPCBNOVANOL
Water-based binding agent for Cold Box process
NOVANOL is a water-based, alkaline phenolic binder with excellent heat resistance that has been speciallydeveloped for steel applications, although this binder is equally suited to iron and non-ferrous applications.
NOVANOL is an alternative to BETASET if CO2 is to be used instead of methyl formate. The application of
NOVANOL is recommended for all types of castings. Since they are water-based binding systems, this binder
is a good solution for foundries that are seeking to improve their environmental performance.

Benefits• Perfect for steel casting• Clean process• Easy stripping

NOVANOL – the versatile system for steel castings
This universal binder systems provides excellent castings surfaces even without coating
application. It provides good strength values. The NOVANOL system is largely solventfree; there are only very low emissions during manufacturing and storage of the cores.
The installation of a gas scrubber is not required.

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

CO2

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Performance

Major
Water-based binder
Perfectly suited to steel castings
Low odor emissions during coreand mold making
Excellent final strength

Hydraulic parts
General industrial
Automotive

Quality

Minor

Flexibility

Ecology*Tailored product recommendations available upon request.

| 13

2 TeileAPCB

BETASET
Water-based and eco-friendly binding agents for the Cold Box process
BETASET are water-based, alkaline phenolic binders with excellent heat resistance that have been
specially developed for steel casting application, although they are equally suited for iron and nonferrous casting.

Benefits• Perfect for steel casting• Easy stripping• Suited for water-based coatings

Excellent casting surfaces
BETASET is specially well adapted for the production of middle and small series of heavy coresfor steel and iron applications, and especially for the customers who are looking for a very good
casting surface without nitrogen contamination.

Recommendations
Catalyst

Coatings

Additives

Auxiliaries

Methylformate

MIRATEC *VEINO *ECOPART *Attributes

Application

Quick reference

Performance

Major
Water-based binder
Perfectly suited to steel castings
Low odor emissions during coreand mold making
Excellent final strength

Hydraulic parts
General industrial
Automotive*Tailored product recommendations available upon request.

14 |Quality

Minor

Flexibility

EcologyOur

Auxiliaries Portfolio

Release Agents
ASK Chemicals’ highly engineered release agents come in a variety of formulations toaccommodate various applications.

patterncore material

protecting surfaceof pattern
avoiding defect• ZIP SLIP are release agents for all gas-curing, cold-curing and hot-curing core and moldmaking processes as well as green sand applications.
• BENTOGLISS solvent-free release agents are highly recommended for bentorite-bonded
molds from the pattern.

release agent• ECOPART are eco-friendly and efficient release agents for all gas-curing, cold-curing as well as
hot-curing core and mold making processes.

Metal Cleaners
highly effecitve

ZIP CLEAN metal cleaners are highly efficient and thus reduce time and money.

cleanerprotecting surfaceof patternpattern• Metal cleaners free of NMP available• Low odor

Adhesives
ASK Chemicals’ adhesive solutions – suitable for automatic metering devices – encouragehigh production profitability, reducing your handling and cycle time. ASK Chemicals’ adhesives
are suitable for air-drying, oven-drying and microwave drying.
• Water-based• 2 component glues• Hot melt glues• Quick glue

adhesive

Core Putty Fillers
With ASK Chemicals’ ASKOPASTE core putty fillers you can reduce your scrappedcores by simply repairing them.

core putty filler

fast drying
suitable for many
core materials• Ideal for the repair and reworking of minor core defects and damaged contours• Optimized packaging for efficient transport and application

Cope Seals

flexible gap sealing

ASK Chemicals’ ASKOROPE cope seals are ideal for when you need to prevent leakage
from the mold through the mold joint, particularly in the in-gate area.

reliable sealingcope sealCore Box Vents
ISOVENTS shorten gassing times, minimize cleaning and extend the service life of the vents,
thereby increasing foundry productivity.
• Available in multiple sizes| 15

Added Value for our Customers
Technical service and sales – for complete process transparency
Technical servic and sales at ASK Chemicals offer our customers comprehensive expertise in all areas offoundry technology and metallurgy. We offer a comprehensive service that focuses on the production
process as a whole and helps customers not only to cut costs but also to enhance their processes.
ASK Chemicals also conducts casting defect analyses and offers its customers the opportunity to havetailored training sessions on the customer’s own premises.

Benefits• Improved decision-making thanks to greatertransparency• Reliable recommendations• Quick response• Customized solution development

Our pilot foundry – more than juststate-of-the-art
ASK Chemicals offers fully equipped test foundries at its sites in
Hilden and Dublin (Ohio). Modern core shooting machines allow
to replicate the customer's processes at the pilot foundry and to
perform troubleshooting and systematically advance technologies
and products in collaboration with our R&D department.
Highlights• Ultramodern core shooting machine on an industrial scale
for all common processes available on the market.
• Advanced core shooting machine on a laboratory scale
for quality assurance and process control• Mold production, including all inorganic processes• Melting of flake graphite and nodular graphite cast iron up
to 100 kg (220.46 lb)• Melting of aluminum up to 160 kg (352.74 lb)• Metallurgical studies, e.g. spectral analyses of iron andaluminum structures

16 |• Cost-in-use reporting (i.e. savings)• Casting defect analyses• On-site training sessions

Design Services – for perfect casting results
Our Design Services team monitors the entire process from the development of the designconcept and validation right up to the production of the cast part prototype. Our Design Services team has the right combination of design, production and simulation expertise, co-operates with external companies and service providers, and enjoys extensive industry experience.
ASK Chemicals' simulation service offers wide-ranging technical knowledge and understanding
combined with state-of-the-art simulation programs (MAGMA, Novacast, FLOW-3D and ArenaFlow).

Benefits• Higher productivity and optimized
catalyst consumption• Optimized design and manufacture ofmodel plates, core boxes and molds• Manufacturing process design,• Less casting defects• Shorter product launch times• Quicker time to market

including inorganic technology• Calculation of optimal feed

Simulation services
The simulation of casting processes provides foundries with invaluable casting mold information. Specifically,
this benefit allows for the optimization of gating and feeding systems, overflows, venting design and risers.
Moreover, it provides critical insight into the influences and effects directly related to casting integrity, such as
cooling and heating measurements, filling and solidification times.

From the idea to the prototype
ASK Chemicals supports your entire process from the concept to prototype production.

Simulation

Cores /
Molds

Prototypes| 17

Research and development – for innovation near you
Our Research and Development department performs both innovation-driven groundwork as well as
market and customer-driven development. Interaction between these three areas is of fundamental
importance in terms of offering our customers technologically sophisticated products and efficiencyenhancing solutions at all times. Through close cooperation and the constant exchange of ideas with
our application technology and technical sales specialists, research and development at ASK Chemicals
is always in tune with the market and also maintains a presence on the customer’s own premises.

Benefits• Many years of experience• Global presence and availability• Comprehensive knowledge of the regional• Short response times for our customers• First-class equipment

sand types and technological requirements

Comprehensive research and development services
Pilot foundry

Product development and technical support• Fully equipped research foundry• Casting defect analysis• Mold production, mold / core package assemblyand casting• Full spectrum of chemical and polymer analysis• "Real world" foundry process representation
Metallurgical investigations• Comprehensive examination of the graphite structure
and metallic matrix: graphite size, number of nodules,
degree of dispersion, nodularity, ferrite / pearlite ratio• Preparation of metallurgical reports
Sand laboratory• Examination of high-temperature materials• Testing of tensile strength, compression andtransverse loading• Sand characterization and analysis

18 |• Product, process and test method development

www.ask-chemicals.com/locations

This information is based on our current state of knowledge and does not represent assurance of the properties of the products described. We are only liable for
product-related advice and information within the scope of duties of disclosure included in collateral contractualagreements unless expressly agreed otherwise. (03/ 24)

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Please contact ASK for any questions concerning the usage of these marks.