ASK Chemicals GmbH

ASK Chemicals presents its binder technologies for additive manufacturing processes

Hilden, June 10, 2019 - ASK Chemicals presents its solutions for 3D sand printing at GIFA 2019 from 25 to 29 June 2019. The Hilden-based company's 3D binder technology combines print head compatibility, dimensional accuracy and productivity.

3D sand printing itself is not a novelty for foundries; though for a long time it has only been used for the production of prototypes and small series. Dr. Jens Muller, Global Head of R&D and Innovation at ASK Chemicals explains, “With the development of ever faster printers, especially in recent years, 3D sand printing offers foundries completely new possibilities and opportunities. Of course, binder technology has to be developed further, especially for these new productive systems. I am therefore very pleased that we will be able to present new solutions for both inorganic and organic sand core production at GIFA 2019.”

A new requirement profile
With 3D sand printing using the powder binder jetting process, production of sand cores using contour-forming models and core tools is eliminated. The geometry of the sand cores is initially developed digitally based on CAD models. Next, the recoater applies a layer of a few hundred micrometers of quartz sand fully automatically. Then the binder liquid is selectively applied to the sand bed via the print head. The process of layered sand application by means of the recoater and selective binder input via the print head is repeated according to the specifications of the digital CAD model. Finally, the binder-free support sand is removed, and the printed component may be taken to a post-curing process.

The compatibility and durability of the print head components along with the chemical components of the binder fluid are as critical to achieving success as the application and dripping behavior of the fluid. This is collectively referred to as “print head compatibility”. The physical and chemical properties of the binder fluid play a crucial role in this process. The physical effects during selective binder input onto the sand bed, such as the migration of the fluid into the unprinted areas of the support sand, must be understood and controlled in order to ensure a high dimensional stability and low finishing cost of the sand cores produced. “Of course, 3D binders still also have to meet high thermal stability requirements to withstand the stresses during the casting process,” explains Dr. Müller.

New solutions for new requirements
The development of NOVASET 3D, a phenolic resin binder for cold curing, has reduced the laborintensive finishing effort and drastically improved the process efficiency over standard binders. NOVASET 3D has a low veining tendency and guarantees clean casting surfaces for all types of casting.

The inorganic two-component system INOTEC 3D, consisting of an INOTEC 3D printing fluid and an INOTEC 3D promoter, is applicable for hot-curing additive manufacturing processes. “As a productive inorganic binder system, INOTEC 3D stands for zero emissions during core productionand core storage and when using the sand cores in the casting process”, emphasizes Dr. Christian Appelt, Global Business Manager Inorganic Binder Systems at ASK Chemicals. Further advantages are the low finishing effort of the sand cores produced, which lead to castings of high dimensional accuracy and surface quality due to the high thermal stability. Above all, INOTEC 3D supports current trends in the engine casting segment of the light metal casting industry.

A special highlight at this year's booth will be the live demonstration of the inorganic binder INOTEC 3D inorganic binder on the new voxeljet VX1000-S printer.

•  ASK Chemicals Website

GIFA 2019: More efficiency in the process chain gives an edge over the competition

Hilden, June 3,2019 – Efficiency and quality are key competitive advantages. If you want to reduce costs, increase productivity and at the same time offer a high-quality product, you have to keep an eye on the entire value chain. Potential levers can be found in many places here, for example in the selection of suitable raw and auxiliary materials, but also by taking appropriate measures to reduce emissions. At GIFA 2019 from June 25 to 29, ASK Chemicals will present solutions that make a valuable contribution to increasing efficiency (Hall 12, Stand A22).

Foundry processes are complex. Sands and binders, release agents and coatings, feeders and filters, rejects and post-processing, input quantities and much more – there are numerous levers with which costs can be saved and productivity increased. "With our efficient solutions, we support our customers in optimizing their total cost of ownership, i.e. the cost-effectiveness along their entire process chain," explains Dr. Volker Böhm, Chief Business Development Officer at ASK Chemicals. "This is how we help them to maintain and increase their competitiveness in a sustainable way."

The total cost of ownership is the sum of all costs associated with an asset, including ongoing indirect or direct expenses. The calculation quickly shows the advantages of the efficient use of raw materials along the entire value chain.

In addition to the key aspect of efficiency, other aspects are relevant for a sustainable future, explains Dr. Böhm: "Our products ensure that our customers are also on the safe side when it comes to new requirements for occupational safety and environmental protection.

Replace process steps or raw materials
One example is the hybrid additives offered by the Hilden-based company with its VEINO ULTRA product family. At GIFA 2019, ASK Chemicals will be presenting the new VEINO ULTRA 4874, the latest addition to the range, which makes it possible to dispense with coating.

Hybrid additives offer numerous advantages depending on the field of application. For example, they increase material efficiency – less material is needed to achieve the same performance. They also help prevent veining and other casting defects, reducing post-processing and scrap costs. In addition, hybrid additives reduce material input elsewhere by making the use of expensive special sands partially or completely unnecessary.

Increase efficiency
One approach that the Hilden-based company has been successfully pursuing for many years is to optimize the efficiency of its products to such an extent that two effects are achieved: Not only do customers need less product to achieve the desired performance but what's more, fewer emissions are released. An example of this are the emission-reduced ECOCURE BLUE binders. Foundries can work with less resources or materials without having to make concessions with regard to strength, reactivity or casting results. On the contrary, the formulation of the product even reduces emissions – especially VOC, BTX, phenol and formaldehyde.

Reducing reworking
An important lever for increasing efficiency in engine casting is the avoidance of coating residues in the casting, as the requirements for residual dirt content in engines are constantly on the rise. The removal of coating residues is time-consuming and cost-intensive, but with MIRATEC TS this additional processing is no longer necessary. This innovative coating offers excellent protection against veining and penetration defects and also contains special peel-off additives. Thanks to this formulation, the coating is almost automatically detached from the component after casting, solidification and cooling. This enables OEMs to meet their high requirements without additional investment in equipment or loss of productivity.

Reduce cleaning intervals and increase productivity
The use of release agents is already standard practice today. They help to ensure that the sand core can be easily removed from the core tool. Of course, this also affects the tool: Increased efficiency of the release agent translates into lower contamination and wear of the core tool. Here, the formulation of the release agent is of critical importance. Modern ECOPART release agents are environmentally friendly and label-free, reduce application cycles and thus have a positive influence on downstream cleaning intervals — while even protecting the tool.

ASK Chemicals is presenting this and other efficiency enhancing solutions at the GIFA in Düsseldorf from June 25-29, 2019 in Hall 12, booth A22.

Further information about GIFA is available at www.gifa.ask-chemicals.com.

•  Press release ASK Chemicals: Efficiency

Aachen and Hilden, May 2019. MAGMA GmbH, specialist in virtual optimization of casting processes, and ASK Chemicals GmbH, one of the world's leading suppliers of foundry chemicals and consumables, are involved in a joint development project on binder decomposition in sand cores and associated gas formation. The aim is to provide the MAGMASOFT® users with validated data on quantitative prediction of process-relevant effects for ASK products. With a new database, joint customers should be even better supported in the interpretation of the venting behavior of sand cores and the prediction of core gas-related casting defects. 

During the casting process, gases form and expand in cores and molds amongst others due to the decomposition of binder components and other volatile components. This is closely related to the basic sand binder mixture used and its compaction as well as its specific gas permeability. Different volumes of gas are produced at different times depending on the type and quantity of the volatile components, the thermal exposure and the respective decomposition behavior. Relatively high gas pressures at the interface to the melt can result in gas inclusions in the casting. In the cases of complex cores or even core packages, it is difficult in practice to determine if core gases are the cause of defects due to the numerous and diverse influencing factors.

Newly developed simulation models in MAGMASOFT® virtually depict gas formation, gas flow, and venting through core prints or the penetration into the melt. This functionality enables accurate prediction of the risk of defects due to gases from cores and molds. The availability of practical quantitative data already during simulation-based design of castings and cores therefore contributes significantly to the prevention of defects.

ASK Chemicals and MAGMA have agreed on a collaboration as part of a development project to quantify the decomposition behavior and gas formation of different ASK binder systems. To this end, ASK Chemicals will carry out extensive research in their laboratories and Technical Center. Respective laws of decomposition behavior and resulting gas formation will be quantitatively determined for different binder systems and heating characteristics. Product-dependent kinetic models will be derived from these data that will make the formation of gas volumes and the resulting effects in MAGMASOFT® quantitatively predictable.

"For MAGMA, this project is an important step in the direction of 'robust process design for casting technology'. The possibility of systematically avoiding core gas-related casting defects through quantitative consideration of different ASK binder systems already at the project planning stage represents a significant benefit for our customers," confirms Dr.-Ing. Jörg C. Sturm, Managing Director of MAGMA GmbH. "We are pleased to have gained a competent development partner with ASK Chemicals, who are interested in quantifying the behavior of their binder systems during casting."

"With the possibility to predict the behavior of our products with any core geometries during casting, we can support our customers in a more targeted manner. Comprehensive customer service therefore already has the highest priority for us in the planning stage of production processes," confirms Jörg Brotzki, Executive Vice President Europe at ASK Chemicals. "The user-friendly integration of our data in MAGMASOFT® is thus decisive for the quality of planning."

Both partners will present the first results of the joint development project at the GIFA trade fair. The collaboration is designed for the long-term.

ASK Chemicals at the GIFA trade fair Hall 12 A22
MAGMA at the GIFA and METEC trade fairs  Hall 12 A19/20 and hall 4 E29

•  Website ASK Chemicals

Optimizing Environmental Protection and Occupational Health and Safety, Increasing Productivity

Hilden, May 6, 2019. Protecting the environment and employees from emissions: This is one of the biggest challenges currently in the foundry industry. ASK Chemicals uses its innovative product portfolio to help customers produce sustainably – with additional advantages for economic efficiency and quality. Foundries can therefore meet stringent regulatory requirements, without having to make big investments in additional filter and exhaust systems. 

ASK Chemicals helps to improve environmental protection and occupational health and safety and optimized economic efficiency by developing more powerful and environmentally-friendly solutions. Innovative technology platforms, such as ECOCURE BLUE and INOTEC, as well as product packages, such as the Low Formaldehyde System (LFS), offer answers to typical challenges of the foundry industry regarding  emissions.

ASK’s sustainability approach is to reduce the emissions of phenol, formaldehyde, VOC and aromatic hydrocarbons (BTX) and to increase the effect of its products. “Innovative and more sustainable products ensure the competitiveness of a company in the long term,” emphasizes Dr. Jens Müller, Global Head of Research & Development at ASK. “Countries in East Asia, especially China, are also increasingly investing in innovative processes and sustainable products.”

INOTEC - The Completely Emission-Free Binder System
The patented inorganic binder technology is currently the optimum in terms of environmental protection. The INOTEC procedure for aluminum casting developed by the Hilden company is characterized by an impressive environmental balance and increased productivity in production processes. It is completely free of emissions. No additional measures are required to filter or treat the exhaust air.

Together with the development partners from the automotive industry, ASK Chemicals is working on making it possible to use inorganic binders as a forward-looking technology in the future for iron and steel casting on an industrial scale.

Using LFS to Comply with New Formaldehyde Limits
Increased regulatory requirements – such as the amendment to the TA Luft [Clean Air Guidelines] – concern, for example, formaldehyde emissions in the exhaust air of foundries. In Germany, these must be reduced to a quarter by no later than February 2020.

ASK Chemicals is supporting its customers here with the Low Formaldehyde System (LFS). This is a package of ECOCURE BLUE LFS binder, MIRATEC LFS coating and VEINO LFS additive specially tailored to the respective requirements. Users can therefore precisely comply with the new emissions limits and improve occupational health and safety without having to invest in secondary measures, such as scrubbers or RTOs.

Innovations with a Holistic Approach
The new ECOCURE BLUE, which combines efficiency with a significant reduction in emissions, stands for the holistic approach of product innovations at ASK Chemicals. With the phenolic resin ECOCURE BLUE, ASK Chemicals has introduced the first label-free, Cold Box part 1 component in the history of binder chemistry. It saves up to 66% of BTX emissions and reduces the required amount of binder by up to 22% .

Given this success, ASK Chemicals has expanded the ECOCURE BLUE families: ECOCURE BLUE is now called ECOCURE BLUE Pure, and there is also ECOCURE BLUE ULTRA, which contains even less formaldehyde than ECOCURE BLUE PURE. The product family is complemented by ECOCURE BLUE ICE, which can withstand storage at temperatures as low as -18 degrees.

New PU No-Bake Reduces Phenol Emissions
Modern foundries are increasingly relying on the PEP SET process due to the processing properties, the better casting results and higher productivity. ASK Chemicals has recognized this trend and is now presenting a new solution at GIFA for reducing phenol emissions in the PU No-Bake process: The new generation of the self-curing PEP SET binder system on a polyurethane basis – PEP SET SILVER.

This is characterized by a particularly low proportion of environmentally-friendly monomers, especially phenol. In practical applications, it is shown that the phenol concentrations in the regenerate are significantly reduced with the help of PEP SET SILVER. In addition to advantages for the environment, this also means a clear plus for economic efficiency, because the landfill costs are also reduced. In addition, employees as well as residents in adjacent residential areas will appreciate the use of the new technology due to the reduced smoke pollution.

ASK Chemicals will be presenting this and other solutions on the topic of environmental protection from June 25-29 at GIFA 2019 in hall 12, stand A22.

•  Website ASK Chemicals

High efficiency with low dosage

Hilden/Germany, 03.04.2019 – ASK Chemicals is launching a new additive at GIFA that makes it possible to reduce the application of release agents and increase tool availability through longer cleaning intervals. The new hybrid additive was developed especially for use in the Cold Box process. 

The increase in material efficiency - that is the ratio of production quantity to material input - is an important factor in reducing production costs and increasing competitiveness. New product developments can contribute to increasing efficiency, that is to say achieving the same or higher performance at lower dosages, or they offer the additional benefit of saving other materials in the process or reducing their consumption.

Thanks to its special formulation, the new additive VEINO ULTRA 2000 offers an excellent release effect at a dosage of only 0.5-2%, leading to lower amounts of release agent usage and increased tool availability. Initial experience in series application shows that application of the release agent can be reduced by approx. > 25 % depending on the amount of additive and the tool design.

Moreover, the new hybrid additive combines the well-known advantages of organic and inorganic additive solutions with significantly reduced odor and emission loads: It has a very good anti-veining effect and makes it possible to replace expensive special sands partially, or completely. VEINO ULTRA 2000, similar to VEINO ULTRA 3010, the flagship additive for coating-free casting applications, can – under certain conditions - also be used for coating-free applications.

"Finally, VEINO ULTRA 2000 is particularly suitable for use in filigree geometries, as it offers very high image accuracy due to the good flowability of the core moulding material mixture," adds Ismail Yilmaz, technical product manager for additives, mentioning the advantages of the product. "When developing our products, we always make sure that we offer our customers valuable, additional benefits in order to make even more efficient casting production possible."

ASK Chemicals is presenting this and other efficiency enhancing solutions at the GIFA in Duesseldorf from June 25-29, 2019 in Hall 12, booth A22.

Further information about GIFA is available at www.gifa.ask-chemicals.com.

Sustainability is more than (simply) taking care of the environment

In this interview, Dr Jens Müller, Global Head of Research & Development at ASK Chemicals GmbH, sets out the case for holistic sustainable operations. Because, in his opinion, sustainable entrepreneurial activities extend beyond simple environmental awareness. At the forthcoming GIFA, the world’s leading trade fair for foundry technology, which will be taking place in Düsseldorf from 25 to 29 June 2019, ASK Chemicals full colors will be on display for environmentally sound and sustainable solutions.

The demands to reduce CO2 or, ideally, to achieve CO2 neutrality are becoming increasingly louder. How is ASK Chemicals responding to these demands?

•  Interview with Dr. Jens Müller

ASK Chemicals presents new binder-additive-coating system for compliance with formaldehyde limits

Hilden/Germany, 22.03.2019 – German foundries are faced with the challenge of reducing formaldehyde emissions in the exhaust gas flow of their existing plants from 20 mg/m3 (mass concentration) to 5 mg/m3 by February 2020 at the latest. At GIFA 2019, ASK Chemicals will present a specially designed binder-additive-coating package that allows foundries to comply with this new limit value without investing in additional secondary measures. 

ASK Chemicals has developed a new concept to provide foundries with a solution that greatly reduces the formaldehyde emissions by more than 70% and does not require investment in washers or RTO (i.e. regenerative thermal oxidation).

Analyses have shown that, in particular, the exhaust gas flow from coating drying furnaces plays a special role in the reduction of formaldehyde emissions. Cores produced in the cold box process have residual amounts of formaldehyde per se, but can, in conjunction with an additive and coating, emit additional formaldehyde, especially at temperatures around 150°C, so that the limit of 5 mg/m3 is easily exceeded.

The newly developed low-formaldehyde system (LFS) from ASK Chemicals is a specially designed package of binder, additive and coating that, due to its design, develops only a very low basic-load and thus a greatly reduced formaldehyde potential. Furthermore, the new system absorbs released formaldehyde, so that the first users of this technology have the ability to undercut the 5mg/m3 limit.

"I am convinced that we offer users real added value with this new system. With the application of the ECOCURE BLUE LFS binder, MIRATEC LFS coating and VEINO LFS additive tailored to the specific requirements, the LF system meets the legal formaldehyde limits with pinpoint accuracy. This is a clear advantage for foundries that do not want to invest in secondary equipment at this time", says Frank Lenzen, Technical Product Manager at ASK Chemicals, summarising the benefits of the new system.

ASK Chemicals presents these and other efficient and equally environmentally friendly solutions from 25-29 June, 2019 at the GIFA in Dusseldorf in Hall 12, Booth A22.

Powerful, safe and simply efficient

Hilden/Germany, January 30, 2019 – With its innovative EXACTPORE 3D filters, ASK Chemicals offers investment casters as well as iron and steel foundries new and more efficient filtration options for the highest casting quality. Thanks to their particularly sophisticated and well thought-through design, EXACTPORE 3D filters provide the highest structural integrity and thus safety and efficiency in use. 

Metal purity is one of the most important requirements in the foundry industry. Best practice in the field of molten metal filtration is the use of sintered ceramic foam filters. But the structure of the filter foams in particular means that this form of filtration also has its limits. During the ceramic coating and sintering process, tiny particles may form inside the filter structure, which are only slightly sintered with the base material. Flow through the filter can cause these particles to detach, which impairs the purity of the melt and can lead to inclusions in the casting.

The superior structural integrity of EXACTPORE 3D filters ensures the absence of loose particles and thus prevents the contamination of the melt by so-called filter bits and time-consuming reworking.

A further key advantage of the new filter generation is its higher flow capacity. Due to the uniformity of the pore design and the structurally consistent geometry, the flow capacity of the EXACTPORE 3D filters is significantly higher than sintered ceramic foam filters with the same filter and pore size and thus offers foundries an opportunity to further increase manufacturing productivity.

The uniformity of the pore design and the structural integrity of the new filters also significantly reduces turbulence compared to conventional solutions and greatly protects against reoxidation caused by entrained air. In fact, hardly any impurities get into the mold, which leads to less reworking, improved surface quality and lower rejection rates and ultimately increases profitability.

"Finally, our new filters are manufactured in such a way that the design possibilities are virtually limitless," adds Bob Gage, Market Manager Filters at ASK Chemicals, as a further advantage of the new EXACTPORE 3D filter generation. "With our new filters there are almost no limitations as to what we can offer our customers in terms of pore design: We can produce almost any pore size – even unconventional ones – in order to guarantee the best possible filter quality with constant flow properties".

ASK Chemicals will be presenting this solution as well as other innovative and equally efficiency-enhancing solutions from June 25 to 29, 2019 at GIFA in Düsseldorf in Hall 12, Stand A22.

•  Website ASK Chemicals

Well prepared for new challenges

Hilden/Germany, December 18, 2018 – To meet increasingly stringent carbon regulations, a rethinking of drive conceptsis required for the long-term. Until e-mobility can be used across the board, however, "conventional" drive technology will be further downsized in conjunction with ever more powerful turbocharger technology in order to be able to satisfy the aforementioned requirements.
To withstand higher exhaust gas temperatures, for example, turbocharger components are now cast in steel, a process which places new demands on coating technology. 

In steel casting, it is state-of-the-art to use zirconium-containing coatings, due mainly to the good refractory properties of zirconium. However, against the background of the rising zirconium prices, it makes sense to consider new solutions.

ASK Chemicals Research & Development has developed a new coating technology for turbocharger series casting, not only to meet the new requirement profile for turbocharger component casting, but also as a response to rising zirconium prices. MIRATEC TC is a zirconium-free coating technology, which nevertheless performs with excellent thermal stability. The technology gives the user more independence from rising raw material prices while benefiting from a product that is in no way inferior to the performance of zirconium coatings.

Due to the significantly lower density of the zirconium-free coating compared to zirconium-containing products, the MIRATEC TC series has a wider range. In other words, in addition to independence from high raw material prices, MIRATEC TC technology also provides the user with an extremely efficient coating solution.
The new technology shows good suspension behavior in the dipping plant and adapted (short) cycle times in the application. Relatively short drying times are typical for the products. Thanks to consistent further development, series applications show a significant reduction in gas and surface defects as well as safety in achieving the required surface values.

"It is our task as a partner and supplier to offer our customers sustainable solutions. This includes solutions for new materials, but also products that are viable against the background of constantly rising raw material prices. Of course, ASK Chemicals always keeps an eye on the efficiency of the solution," sums up Christian Koch, Technical Product Manager for coatings.

ASK Chemicals is presenting this and other efficiency enhancing solutions at the GIFA in Düsseldorf from June 25th to 29th, 2019 in Hall 12, Stand A22.

•  Website ASK Chemicals