INOTEC
Product Line Overview

INOTEC technology – technological, economicand environmental benefits for foundries
The importance of the patented INOTEC technology

The development of inorganic binder technology

Our specialists’ know-how is complemented by aand thus the quantities of inorganically produced

into a binder system ready for series production

broad range of services that offers our customers

castings are rising steadily. The technology isand the market was driven to a large extent byreal added value. In this way, for example, oursuitable for aluminum and iron casting as well asASK Chemicals.

design services can be systematically deployed tonon-ferrous metal casting applications. The inorga-optimize the process as a whole – from concept

nic binder system constitutes a persuasive choice,

Embodying as it does the interaction between

development to series production – thereby offering

especially in highly productive and challenging seg-innovation-driven research and customer-driven

important savings and improvement potential forments such as the manufacture of engine blocks

development at the same time, ASK Chemicals

our customers.

and cylinder heads in permanent mold casting.

always has the requirements of the market in mind.
The economic, technological and environmental

In addition to the clear environmental benefits,requirements of our customers were always theINOTEC technology scores points in particular

focal point during development of the patented

with its technological characteristics and its

INOTEC technology. In 2014, ASK Chemicals

impressive ability to improve productivity overhas been rewarded with the BMW Supplier Inno­

conventional technologies.

vation Award in the Sustainability category for its
achievements in this respect.
ASK Chemicals offers its customers solutions that
go well beyond merely offering products. Our
application technology and technical sales specialists always keep an eye on the process as awhole and offer our customers solutions that havebeen adapted to meet the relevant conditions andare precisely tailored to meet their requirements.

Patented technology
Leading provider of inorganic bindertechnology
Technological, economic andenvironmental benefits

2||3

INOTEC binders and promoters for technological advances
Thanks to intensive research into the area of inorganic binder systems, the gap between Cold Box

New technological potential: central feeding concept

technology and the INOTEC system is being made ever smaller. Statements such as the following havebeen refuted and qualified many times: “Inorganic cores show a lower dimensional accuracy when

The absence of combustion residue offers new freedom to component developers. One impressive

casting, tend to have higher core fracture and are unstable in moisture and therefore cannot be coatedexample of this is the new central feeding concept, which is used at BMW’s Landshut plant forwith water. The waste sand cannot be regenerated, the casting surfaces show more sand accumulati-

crankcases of future engine generations. Inorganic cores are used as central feeders here, thus mini­ons, the cores have worse shake-out performance and inorganics are not suitable for iron casting” havemizing the risk of sooting ventilation ducts in the low-pressure permanent mold. This concept is notbeen refuted and qualified multiple times. By contrast, INOTEC technology offers significant technologi-

feasible with organic cores.

cal advantages for the foundry industry.
The dendrite arm spacing (DAS) of the three feeding concepts is shown in the illustration below. It isapparent that the new central feeder concept leads to DAS advantages in all component areas. TheINOTEC in iron casting
Inorganics have considerable potential in iron casting. In particular, problematic parts that require work with special sands oradditives in combination with a coating against veining are predestined for use of inorganic binders since they show a much
lower tendency towards veining – or indeed none at all – compared with organic systems.

warmest point (thermal center, binding of the feeder) and therefore the point with the highest local
DAS is in the area of the lower dead center of the piston, a point that is not subject to excessive thermalor mechanical stress. The tension rod area also solidifies very quickly and can be influenced externally
via the permanent mold. The tendency towards leaking after mechanical processing falls dramatically,
and the sealing rates are miniscule.

Technological benefits• Reduction of sand adhesion and penetration• Optimization of shake-out performance, enabling filigree water jacket cores to be

1st generation
permanent mold casting

2nd generation
permanent mold casting

3rd generation
permanent mold casting

DAS [μm]

DAS [μm]

DAS [μm]

Cylinder web

30

45

20 – 25

Bearing support

45 – 50

30

25

1st generation

2nd generation

3rd generation

removed safely from the casting• Excellent dimensional accuracy during casting due to improved thermal stability• Improved structural properties (shorter dendrite arm spacing)• The use of water-based coatings in iron casting is also possible
Reduction of sand adhesion and penetrationin aluminum casting

Improved dimensional accuracy due to higher
thermal stability

Increased thermalstability

INOTEC

4|

Source: Anorganische Innovation für die neue Diesel-Spitzenmotorisierungen im BMW M55 Oxd: Konstruktion andGießtechnik des Alu Kurbelgehäuses [Inorganic Innovation for the New Top-of-the-Range Diesel Engines inthe BMW M55 0xd: Design and Casting Technology of the Aluminum Crankcase]
Dr. E. Weissenbek, B. Zabern; Giesserei-Praxis, 5 / 2013, pp. 175 – 181

Cold Box|5INOTEC is cost-effective

INOTEC is an environmentallyfriendly productIn addition to casting-related technical benefits, INOTEC technology offers process-related advantagesThe environmental benefit of INOTEC relies on the inorganic and water-based nature of this binderover conventional processes. Particularly notable are the significant increase in productivity in the casting

technology. The lack of harmful emissions during core manufacturing, core storage and pouring

process and a drastic reduction in the consumption of resources for maintenance and servicing work.

removes the need for elaborate ventilation and air treatment systems in the process chain.

Economic benefits

Environmental benefits

mold temperatures and thus shorter cycle times• Shorter solidification times owing to lower permanent
Keine Geruchsbelastung derMitarbeiterof permanent molds• No buildup of condensate and therefore increased availability• Much less cleaning required• No need for air treatment• Improved cast part qualities• No environmentally harmful emissions• No buildup of condensate• No unpleasant odors affecting employees• Environmental friendliness confirmed by com-A cost-effective alternative

INOTEC comparedDue to the absence of organic components, the use of the INOTEC
system does not result in the buildup of condensate, which in turn reduces
the amount of cleaning involved. Investment in air treatment measures isalso saved, making INOTEC a cost-effective alternative.

A comparative environmental lifecycle assessment between the INOTEC system and a Cold Box system showed the best possible
result for the INOTEC technology. INOTEC is more environmentally friendly than Cold Box technology. An environmental lifecycle
assessment involves examining the potential environmental effects from the cradle to the grave, i.e., from the production of raw
materials to the production and utilization of the product, right up to waste management or recycling (DIN EN ISO 14040: 2009). Inthe foundry, the utilization phase is divided into the following steps: Core production, casting, core removal and sand reclamation.

Cold BoxINOTEC

Cold BoxINOTEC

Solidification time in minutes

65.5

Casts without cleaning / availability of permanent molds

15257

Cleaning time required within 24 hours in minutes

320

20

Cast part output in units/hour

7.8

10.8

parative environmental lifecycle assessment

Eutrophication potential
Primary energy demand
Abiotic depletion potential
Photochemical oxidant formation potential
Ozone depletion potential
Acidification potentialSource: Anorganisches Bindersystem im Sandwich zwischen “Technology Push” und “Market Pull” [InorganicBinder System Sandwiched Between “Technology Push” and “Market Pull”] from Giesserei 99 (2012),
Issue 2, pages 52 et seq.

6|

Global warming potential

39 %Cold BoxINOTECINOTEC is better than the Cold Box system
in all impact categories.

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Product portfolio
The INOTEC technology comprises a two component binder system of INOTEC (liquid binder) andThe INOTEC tooling kit approach allows easy and tailor-made adjustments by applying mixtures ofINOTEC promotor (solid additive component). Depending on the requirements, INOTEC is available inINOTEC (e.g. INOTEC HS 1000 and INOTEC HC 2000, 1:1) and INOTEC promotors (e.g. INOTEC“High Solid” (HS) and “High Compaction” (HC) versions as well as in the form of intermediate solutions

promotor TC 4500 and INOTEC promotor WJ 4500, 1:1). This tooling kit approach enables the regula-made from both binders.

tion of specific core properties with on-site available binder materials. A specific example for thisapproach is given below for the manufacturing of aluminum cylinder heads.

BinderProperties

INOTEC HS 1000

Good strength levels; very low gas potential;
no emissions; no buildup of condensate;
typical application at 160 – 200 °C core box tooling temperature

INOTEC HC 2000

Very strong flow properties, Good compaction
Core removal possible via mechanical and wet methods
Very low gas potential, no emissions, no buildup of condensate
Typical application at 160 – 200 °C core box tooling temperature

INOTEC HS 3000

Improved moisture resistance; good strength levels;
Very low gas potential; no emissions; no buildup of condensateTypical application at 160 – 200 °C core box tooling temperature

INOTECHS 1000 + HC 2000 (1:1)

HS 1000 + HC 2000 (1:1)

HS 1000 + HC 2000 (1:1)

INOTEC promotor
TC 4500

WJ 4500

WJ 4500 + TC 4500 (1:1)

Application

Properties

Top cores

Reduces penetration and sand adhesion; high degree ofcompaction;
100 % inorganic

Water jacket cores

Especially suitable for filigree / thin geometries;
reduces penetration and sand adhesion; high dimensional
accuracy during casting; good core removal capability;
100 % inorganic

Port cores

Especially suitable for filigree / thin geometries; reduces
penetration and sand adhesion; high dimensional accuracy
during casting; good core removal capability;
100 % inorganic

The choice of the solid additive component, known as the INOTEC promotor, is determined by the metalbeing poured and the application. Depending on the core requirements, INOTEC promotors are available

INOTEC modular system for variable core geometries and complex casting part series

for specific core geometries (e.g. top cores, water jacket cores) or for universal applications.

The INOTEC system is suited for the adjustment of sand core characteristics depending on the type and geometry of thecore. For this purpose, different INOTEC binder system components with specific characteristics are used in a defined
mixing ratio in order to meet the specific demands of the respective sand cores with a moderate material consumption.

Promotor
INOTEC promotor TC 4500

INOTEC promotor WJ 4500

INOTEC promotor TC 4000

INOTEC promotor TC 5000

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Application
Top cores

Water jacket cores

Universal

Universal

Metal

Properties

Aluminum

Reduces penetration and sand adhesion
High degree of compaction
100 % inorganic

Aluminum

Especially suitable for filigree / thin geometries
Reduces penetration and sand adhesion
High dimensional accuracy during casting
Good core removal capability
100 % inorganic

Aluminum

Reduces penetration and sand adhesion
High degree of compaction
High dimensional accuracy during casting
100 % inorganic

Aluminum

Especially suitable for filigree / thin geometries
Improved core removal
Reduces penetration and sand adhesion
High degree of compaction
High dimensional accuracy during casting
Improved moisture stability
100 % inorganic

Binder 1
INOTEC HS 1000
or INOTEC HS 3000

Binder 2
INOTEC HC 2000

Strength /Moisture stability

Promotor 1
TC 4500

Promotor 2
WJ 4500

Flowability

Exemplary blends:

Binder 1

Binder 2

Promotor 1

Promotor 2

Binder 2

Promotor 2

Water jacket cores

Binder 1

Promotor 1

Top cores

Port cores|9Added Value for our Customers
Technical service and sales – for complete process transparency

Design Services – for perfect casting results

Research and development – for innovation near you

Technical service and sales at ASK Chemicals offer our customers comprehensive expertise in all areas

Our Design Services team monitors the entire process from the development of the design concept andOur Research and Development department performs both innovation-driven groundwork asof foundry technology and metallurgy. We offer a comprehensive service that focuses on the production

validation right up to the production of the cast part prototype. Our engineers have a wide range ofwell as market and customer-driven development. Interaction between these three areas isprocess as a whole and helps customers not only to cut costs but also to enhance their processes.

experience and a clear understanding of all aspects of foundry technology and metallurgy. Our Designof fundamental importance in terms of offering our customers technologically sophisticated

ASK Chemicals also conducts casting defect analyses and offers its customers the opportunity to have

Services team has the right combination of design, production and simulation expertise, co-operates

products and efficiency-enhancing solutions at all times. Through close cooperation and thetailored training sessions on the customer’s own premises.

with external companies and service providers, and enjoys extensive industry experience. ASK Chemicals'

constant exchange of ideas with our application technology and technical sales specialists,simulation service offers wide-ranging technical knowledge and understanding combined with state-of-research and development at ASK Chemicals is always in tune with the market and also

the-art simulation programs (MAGMA, Novacast, FLOW-3D and Arena-Flow ).

maintains a presence on the customer’s own premises.

Benefits

Benefits®

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
ASK Chemicals to replicate the process on the customer’s own
premises, perform troubleshooting and systematically advancetechnologies and products in collaboration with our R&D
department.
Highlights• Ultramodern core shooting machine on an industrial scale
for all current processes• Cost-in-use reporting (i.e. savings)• Casting defect analyses• On-site training sessions• Higher productivity and optimized
catalyst consumption• Optimized design and manufacture of• Many years of experience• Global presence and availability• Comprehensive knowledge of the regionalmodel plates, core boxes and molds• Manufacturing process design,• Less scrap• Shorter product launch times• Quicker time to market

including inorganic technology• Calculation of optimal feedsand types and technological requirements

Simulation services

Comprehensive research and development 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.

Pilot foundry

Product development and technical support• Fully equipped research foundry• Casting defect analysis• Mold production, mold / core package assemblyand casting• Full spectrum chemical and polymer analysis

From the idea to the prototype

Metallurgical investigations

ASK Chemicals supports your entire process from the concept to prototype production. Your benefit:
you enjoy wide-ranging expertise from a single source.

• 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• Mold production, including all inorganic processes

Sand laboratory
Simulation

Cores /Molds• Examination of high-temperature materials

Prototypes• Testing of tensile strength, compression andtransverse loading• Melting of aluminum up to 160 kg (352.74 lb)• Sand characterization and analysis• Metallurgical studies, e.g. spectral analyses of iron andaluminum structures

10 |• Product, process and test method development• "Real world" foundry process representation• Advanced core shooting machine on a laboratory scale
for quality assurance and process control• Melting of flake graphite and nodular graphite cast iron up
to 100 kg (220.46 lb)• Short response times for our customers• First-class equipment| 11| 12

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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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