Inorganic core production

Inorganic core production

What are foundry cores?

What are foundry cores?

Foundry cores are shapes designed to create holes, cavities or projections inside the moulds used for metal casting. They are made from mixtures consisting of silica or quartz sand and various types of chemical binders.

At the beginning of the moulding process, the mixture is fed by the core-shooting machine into what we core makers call the "core box", i.e. a mould which reproduces the desired shape through one or more cavities. At this point, the most important phase of the process takes place, during which the mixture hardens and the actual core is formed.
At Zetakern we use two types of process: Inorganic and Cold Box.
Foundry cores production
Eco friendly
Inorganic process: zero environmental impact
Zetakern
Eco friendly

Inorganic process: zero environmental impact

Our focus on the environment has long guided our choices, supporting us in a constant transition towards production processes with an increasingly reduced environmental impact. This awareness has led us to choose the Cordis Inorganic Process as the main production system for our cores.

In this production system, the mixture of silica sand and inorganic binding additives is fed into the mould and cured by the heat generated by an oil circuit combined with a flow of dry, heated air. At the end of the process, the core is ready.

The major advantages of this process

This system has been designed for the production of moulds subject to high thermal stress and makes it possible to achieve:
  • virtually zero environmental impact during the core-making and casting phases, which take place without gas emissions
  • a significant reduction in the formation of pitch deposits in the mould
  • excellent casting surfaces
  • absence of gas porosity
  • high resistance to erosion and metal penetration
  • remarkable cooling capacity compared to other processes
  • excellent dimensional and geometric stability during casting
  • good shake-out
  • possibility of storage in humid and relatively warm environments
Post-production: rigorous checks and careful packaging
Post-production
Post-production: rigorous checks and careful packaging
Once the core has been formed, it is left to cool and then subjected to strict quality checks by our Quality Control department. It may then undergo any necessary assembly operations or reworking.

Once the final core has been obtained, carefully designed, customised packaging ensures optimal durability during storage: first in our warehouses, then during transport by our trusted carriers and, finally, at the customer's premises.