Abstract: A method and product improve the positioning of loose anti-skulling material in the outlet nozzle zone of a metallurgical pouring vessel. The formation of skull in the outlet nozzle zone of a metallurgical pouring vessel is inhibited by positioning in the outlet nozzle zone an elongated container containing loose anti-skulling material, the container being formed of an intumescent material so that when heated it expands to fill the gap between itself and the walls of the nozzle and releases the anti-skulling material.

Abstract: A lightweight ceramic material is provided, useful for example as thermal insulation, kiln furniture or for metallurgical applications.Accordingly, a lightweight fired ceramic material comprises a set porous material in the form of a freeze-gelled ceramic sol composition containing hollow microspheres bonded together in a ceramic matrix.A method of making a lightweight fired ceramic shaped product is also provided in which a freeze-gellable ceramic sol composition is formed containing hollow microspheres, the composition is placed in a tool (21) of high thermal conductivity, the tool is cooled to irreversibly gel the sol composition, the monolith so formed is demoulded and allowed to thaw and is then fired to form a product comprising the microspheres bonded in a ceramic matrix.

Abstract: A binder composition for producing articles of bonded particulate material such as foundry molds or core comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and an ethylene glycol monoalkyl ether. The binder composition has an alkali to phenol molar ratio of from 1.5:1 to 2.5:1 and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin ad the oxyanion. Bonded articles are produced by passing carbon dioxide gas through articles formed from a mixture of particulate material and the binder composition so as to produce stable complex formation and curing of the resin.

Abstract: A mould for metal casting which is vertically parted into two parts, comprises one or more mould cavities and a plurality of feeder cavities each communicating with a mould cavity, and has a feeder unit comprising a plurality of interconnected feeder sleeves therein, each of the feeder sleeves surrounding one of the feeder cavities. The mould may be a vertically parted permanent mould or die, or particularly a vertically parted sand mould.

Abstract: A binder composition for producing articles of bonded particulate material such as foundry molds or cores comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and a phenyl ethylene glycol ether. The binder composition has an alkali to phenol molar ratio of from 1.5:1 to 2.5:1 and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin and the oxyanion. Bonded articles are produced by passing carbon dioxide gas through articles formed from a mixture of particulate material and the binder composition so as to produce stable complex formation and curing of the resin.

Abstract: A metallurgical flux is provided as bonded particulates in granular or briquette form, which contains fluxing ingredients, binder and an expanding agent whereby action of heat in contact with molten metal causes expansion of the expanding agent to break down the bonded particulates into particulate form.

Abstract: An improved refractory support (kiln furniture) and a method of manufacture. The composition of the refractory support reduces the likelihood that it will adhere to the article which it is supporting during manufacturing. The kiln furniture is formed from bound ceramic fibers of aluminosilicate and alumina with a ground particulate filler of aluminosilicate and alumina, and refractory reactive binder of alumina and silica in a colloidal form.

Abstract: A foamable lining composition to be used as an expendable lining over a permanent refractory lining in a molten metal handling vessel, e.g. a tundish, comprises a particulate refractory filler material, a binder, a foaming agent and water. Calcined magnesite is the preferred refractory filler material and the binder is preferably an acid phosphate or acid sulphate. The water is included in the composition in an amount of from 5 to 15 per cent by weight.

Abstract: An insulation sheath for a pipe in a furnace is provided. The sheath has excellent insulation properties together with adequate resistance to the corrosive environment and thermal shock conditions. A pre-formed, substantially C-shaped, elongate member shaped to conform to the pipe over a portion of its circumference, the member comprising an inner layer of bonded insulating material integrally-bonded to a protective outer layer of refractory material. The inner layer is preferably formed of bonded ceramic fibre.

Abstract: A binder composition for producing articles of bonded particulate material such as foundry moulds or cores comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and pyrrolidone or an N-substituted pyrrolidone, and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin and the oxyanion. Bonded articles are produced by passing carbon dioxide gas through articles formed from a mixture of particulate material and the binder composition so as to produce stable complex formation and curing of the resin.

Abstract: A ceramic foam filter, particularly for filtering molten iron, is formed from a composition comprising silicon carbide, alumina, silica derived from colloidal silica sol and alumino-silicate fibres, which has been fired at such a temperature that the filter has a ceramic matrix in which the alumino-silicate fibres are substantially dissolved. The filter is fired at a minimum of 1150.degree. C. and preferably within the range from 1200.degree. to 1300.degree. C. Preferably the filter is formed from an aqueous slurry having a solids content comprising by weight 20-50% silicon alumina, 20-50% alumina, 1.5-5.0% silica derived from colloidal silica sol and 1-3% alumino-silicate fibres.

Abstract: A hot top lining assembly for an ingot mould or for an ingot mould head box is made up of four boards of refractory material and fixed together by means of a guide bar incorporated in a wedge-shaped portion in the lateral edge of one of the boards mating with a slot in a lateral edge of an adjacent board.

Abstract: An exothermic composition comprises a particulate readily oxidizable metal such as aluminum, magnesium or silicon and an organic fluorine-containing compound, and usually an oxidizing agent for the readily oxidizable metal. The preferred organic fluorine-containing compound is polytetrafluoroethylene. The composition may also contain a binder, a particulate refractory material, refractory fibres and/or organic fibres. The composition may be used in the casting of molten metal, either in particulate form or as a preformed shape such as a sleeve or board, to cover or surround molten metal in the feeder of a casting mould or in the head or head box of an ingot mould.

Abstract: A method for producing nodular or compacted graphite iron castings in a mould having a sprue, an ingate and a mould cavity, having a first part below and a second part above the level of the ingate, comprises delivering particulate magnesium-containing and silicon-containing treatment agent from a dispenser into a stream of molten metal entering the sprue such that the treatment agent is added at a constant rate of addition while the first part of the mould cavity is filled with iron, and at a decreasing rate while the second part is filled. The addition of the treatment agent is controlled by means of apparatus comprising a container, a measuring and data capture device connected via signal transforming means to a control means, conveyor means located below the container and connected to the signal transforming means, and means for injecting the particulate treatment agent into the metal stream.

Abstract: A support unit, e.g. a setter, is designed for convenience of stacking both in use and in the stored condition. Each unit (10, 20, 20A) is of circular plan outline and has a rim (13) having alternate upwardly-and downwardly-disposed castellations (14 and 15 respectively) whereby a pair of units (20, 20A) can be stacked closely together with their upper castellations (24, 24A) contiguous and their lower castellations (25, 25A) contiguous or can be stacked in the `use` position with the lower castellations (25A) of an upper unit (20A) resting on the upper castellations (24) of a lower unit (20).

Abstract: Filters for filtering molten light metals comprise a reticular foam having a composition comprising graphite, wollastonite, silica and an alkali phosphate glass. The filters have a low hardness and can readily be machined accurately from large pieces of the filter material. In a preferred embodiment the exterior surfaces of the large pieces of filter are coated with a composition comprising graphite and a binder prior to firing and then machined.

Abstract: Foundry sand cores are produced by a method comprising the steps of:(1) providing a core box to contain the core(2) injecting into the core box a mixture of sand and a binder capable of being cured by means of carbon dioxide gas so as to form the core(3) passing carbon dioxide gas under pressure into the core box so as to fill the core box(4) holding the core in contact with the carbon dioxide gas so as to cure the binder(5) releasing the pressure and allowing carbon dioxide gas to escape from the core box and(6) removing the cured core from the core box.The method can also be used to produce moulds and is of particular use in the production of cores or moulds from a mixture of sand and a binder consisting of an alkaline aqueous solution of a phenol-formaldehyde resin and an oxyanion such as borate capable of forming a stable complex with the resin.

Abstract: The invention relates to the provision of an expendable inner lining (13) over the relatively permanent refractory lining (11) of a molten metal handling vessel (10), in which venting means (25) are provided to aid venting and drying of the slurry from which the expendable lining is formed.Strips (12) of removable material are applied to the surface of the permanent lining (11) and the slurry is applied over the strips and over the remainder of the surface of the permanent lining. After drying of the slurry, the strips (12) are removed to leave vent channels (25).The removable strips may be of heat-consumable material so that they are destroyed by heating. Alternatively they may be removable and re-usable.

Abstract: A preformed expendable lining of high density, erosion resistant, castable refractory material is provided for a metallurgical vessel, such as a tundish. The lining is integrally formed in one piece and has a floor, walls, and at least one integrally formed flow control device. The flow control device may comprise a pair of upright baffles with apertures (some of them angled to the horizontal) for the passage of molten metal; or may comprise dams and weirs. The lining is particularly useful for the pour area of a T-shaped tundish, or a similar area for a conventional trough shaped tundish.