PIHBOND
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PIHBOND
“PihBond” is a single Additive solution to the Foundry Green Sand System, replacing both, the Lustrous Carbon Additive as well as the Bentonite.
“PihBond” is formulated with Highly Potent Lustrous Carbon and a judicious blend of Bentonite, ensuring an excellent “Peel Off” of sand in castings with Higher Mould Strength at considerably lowered additions. PihBond has been formulated in 2 variations – PihBond-P-009 – for Horizontally Parted Moulding Lines and PihBond –P-045 – for Vertically Parted Moulding Lines.
| Specification | PihBond-P-009 | PihBond-P-045 |
|---|---|---|
| Volatile Matter | 25+5% | 22± 5% |
| Loss on Ignition | 35+5% | 33+5% |
| MB Value | 90+6ml/gm | 92 +6ml/gm. |
| Swelling | 25+5ml | 25+5ml |
Note:
“PihBond” is not Self Igniting.
Usage:
Addition of “PihBond” is gradually reduced to nearly 70 to 60% of the Bentonite + LCA addition.
Addition of required quantity of “PihBond” is done immediately after sand is added to mixer and dry mixed as per normal practice.
Water is added in the required quantity and after adequate mixing, the mixed sand is discharged.
Our Experience
PihBond has found application in almost the entire range of casting varieties as well as various Moulding Lines:
Casting variety:
- ♦ Automotive castings
- ♦ Pump castings
- ♦ Sanitary Castings
- ♦ Others
Molding Lines:
- ♦ Jolt / Squeeze lines
- ♦ High Pressure lines & Vertical without flask and with flask.
The induction of PihBond requires the Goyal Technical Team to closely interact on the Foundry Floor with the Foundry team for closely monitoring the sand parameters. This ensures enhanced sand control, resulting in considerable improvement in Casting Finish.
Packing
25 kg / 50 kg HDPE Bags.
500 kg / 1,000 kg Jumbo Bags.
Precautions :
- ♦ Store “PihBond” In covered area away from moisture and heat.
- ♦ Ensure opened bags of “PihBond” are sealed to prevent exposure to moisture.
- ♦ Store in stacks of 2 mtrs. high maximum.
- ♦ During storage ensure that any other carbonaceous material is stacked such that at least 1 mtr. gap is maintained.
- ♦ Ensure storage of only sealed bags while stacking.
Effectiveness of PihBond
Test results as obtained in laboratory with Lab Sand Muller using New Sand + (Indian Bentonite + LCA) / PihBond + Water as per Standard. Shop floor results may vary.
- ♦ Green Compression Strength (GCS)
- ♦ 30 to 40% Product Addition Reduced.
- ♦ Dry Compression Strength (DCS)
- ♦ Moisture demand
- ♦ Wet Tensile Strength (WTS)
- ♦ New sand addition
- ♦ Sand Control
- ♦ Sand Sticking on Casting 30 to 50%
- ♦ Casting Finish – as a result of enhanced 5. Fines in the system sand control
- ♦ Fines in the system
- ♦ Foundry Cleanliness and Pollution Control
- ♦ Shot blasting time 30 to 50%
- ♦ Sand Related Rejections nearly 25%
- ♦ Weight of castings 0.5 to 2.5%
- ♦ Pollution Level
With the use of PihBond the foundries have accrued the following advantages
TANGIBLE ADVANTAGES OF PIHBOND
Reduced Addition (20 to 40%)
Increased regenerated activity ensures higher Active Clay retention on recycling,increasing GCS. To sustain this at required levels, PihBond addition needs to be reduced to optimum levels depending on various factors.
Reduction in shot blasting time
As the sand sticking to castings is reduced the shot blasting time comes down by around 30%.
Reduction of Weight - (0.5% to 2.5%)
Higher DCS achieved, results in reduced dilation of the mould during casting, resulting in better dimensional stability and reduced weight of component on account of reduced swelling. Reduction by 0.5% in Vertically parted high pressure lines and up to 2.5% in Jolt-Squeeze lines are not uncommon.
Reduced Sand Sticking (25-40%)
Highly potent Lustrous Carbon content provides an excellent barrier, reducing sand sticking. Nearly 25 to 40% reduction in sand sticking is experienced. Consequently, Shot Blasting time also reduces by at least 30%.
Reduction in Mould Breakage
In high pressure lines, specifically in KW line, mould breakage reduced by nearly 60 to 70% as compared to Pre-PihBond usage
Reduction in Sand related rejections - (30% of the Pre-PihBond)
With reduction in addition of PihBond as well as reduction of dead fines formation, the fines content of sand reduces, in turn reducing the moisture demand for maintaining similar compactability. Consequently, moisture related rejections, like Blow Holes / Pin Holes show a lowering trend.
On account of higher GCS / DCS and sustained WTS sand is anchored more firmly reducing sand erosion / sand inclusion / sand drop, etc. and also mitigating scabbing tendencies considerably.
It has been our experience that around 25% of the sand related rejections come down as compared to Pre-PihBond.