Coldbox Process 101


"Very great instruction – I will be able to use what I’ve learned on a daily basis."


This course is an introduction to the coldbox coremaking process used in a metalcasting facility. Discussion will include terminology, common sands and binder systems used to make coldbox cores, the coremaking process, using and maintaining equipment, and considerations for identifying core defects.

Participants will complete the course with a broader knowledge of the coldbox process, gain ideas on how to utilize their current process more effectively, and explore different, perhaps unfamiliar, options for improving their process. Attendees will also learn the 12 key factors to consider when selecting a binder system.

Learning outcomes

Class participants will be able to:

  • Explain the benefits of using the coldbox process for coremaking.
  • Explain the coldbox coremaking process.
  • Explain the components of the three most common coldbox systems.
  • Identify how sand, binder and equipment selection can impact the quality of cores.
  • Describe the important safety measures and operating practices to use while making coldbox cores.
  • Identify the key aspects of well-designed tooling.
  • Identify common coldbox-related casting defects.

Course Length

1.0 day

CEU Units

0.60 CEU

Course outline

Module 1: Introduction
Module 2: Coldbox Overview

•    Cores
•    What Is Coldbox Coremaking?
•    Why Use the Coldbox Process?

Module 3: Sand

•    Sand Impacts and Types
•    Impacts of Temperature and Moisture

Module 4: Binder Systems

•    Terminology and Systems Overview
•    Phenolic Urethane Coldbox (PUCB)
•    Acrylic Epoxy Coldbox (AECB)
•    Ester-cured Alkaline Phenolic Coldbox (ECPCB)
•    Factors to Consider

Module 5: Equipment

•    Coldbox Equipment
•    Do’s and Don’ts
•    Equipment Maintenance
•    Personal Protective Equipment (PPE)

Module 6: Tooling

•    Well-Designed Tooling Results
•    Case Study: Which Design Is Better?

Module 7: Defects

•    Defect Causes

Module 8: Conclusion