Tang Shenglai, a technical service engineer at Bonnie Chemical (Tianjin) Co., Ltd., conducted an in-depth analysis and comparison of the current status and performance of various mainstream sand binders used in China's cast steel industry. By integrating the latest developments in the sector, he evaluated the unique characteristics of different resin sands and proposed a technical upgrade plan tailored for small and medium-sized steel casting plants. He also provided real-world implementation examples to support his recommendations.
In recent years, the cast steel industry—considered one of the foundational sectors of China’s economy—has faced unprecedented challenges, marking a period of major transformation. External pressures have pushed domestic foundries to focus on improving casting quality and reliability, producing near-net shape components, enhancing environmental protection, achieving clean and sustainable production, reducing costs, and shortening delivery times.
Among the key factors supporting these goals, the quality and application of modeling materials play a crucial role. Since the 2000s, research and application of new casting binder materials have advanced rapidly. Today, both large and small steel casting enterprises are gradually adopting self-hardening sand technology. Traditional limestone sand and COâ‚‚ water glass sand are being phased out, replaced by more widely used processes such as water glass self-hardening sand, furan resin sand, alkali phenolic resin sand, and the newly developed Bonny resin sand process.
From an industry perspective, large steel castings often use alkali phenolic resins in heavy machinery factories like Double and Too Heavy, while ester-hardened water glass sand is commonly applied in companies like Tieda Machine and CITIC Heavy Industry. Railway system frame castings typically rely on mechanized molding lines using grease-hardened water glass sand. Stainless steel castings, on the other hand, mainly use various resin sand processes.
Geographically, steel casting mills in southern China tend to favor resin sands, whereas those in northern regions, including Henan, often use water glass sand. Some steel casting facilities, such as Shared Casting, use furan resin sand for large castings.
Many small and medium-sized steel casting plants in China lack awareness of resin sand technology and have limited product grades. Additionally, they often lack skilled casting professionals, so most continue to use traditional COâ‚‚ water glass sand processes. However, some plants in Jiangsu and Zhejiang provinces have successfully adopted eco-friendly adhesives through equipment upgrades, achieving remarkable results and setting a benchmark for others.
Bonny resin is a new environmentally friendly binder specifically designed for cast steel, recently introduced by Bonnie. Structurally, it belongs to a modified resol phenolic resin and is completely free of formaldehyde and phenol. It combines the best properties of conventional resins with high strength, collapsibility, and good reproducibility. It has been tested and used in over 30 steel casting companies across various types of castings, from tens of kilograms up to over 160 tons, with excellent outcomes.
As the foundry market evolves and influenced by domestic and international policies, continuous innovation in raw and auxiliary materials is essential to stay competitive and maintain value. While multiple binder technologies compete in the market, the key for any foundry lies in understanding the selected process and material properties deeply. Looking ahead, the development of binder materials will increasingly focus on being eco-friendly, efficient, and energy-saving—ensuring long-term sustainability and vitality in the industry.
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