Abstract: A method for forming a mold for encapsulating glass sheets with a gasket which includes the steps of positioning a rigid member 18 having a finishing surface 19 and a seal 30 adjacent a model 2, forming a first mold section 10 about the rigid member 18, the seal 30, and the model 2 and adjacent the first side of the model 2, forming a second mold section 12 adjacent a second side of the model 2, and then separating the first mold section 10 and the second mold section 12 and removing the model 2. In one embodiment of the invention, the rigid member 18 is prepared by forming an initial member 24 corresponding at least in part to the shape of the model 2, using the initial member 24 to prepare a cast, casting the rigid member 18 in the cast, and then preparing a finishing surface 19 of the rigid member 18.

Abstract: Compound concrete composition for the manufacture of moulds, comprising: (1) a binder which comprises an alkaline-earth mineral substance, a constituent made up of fine particles of a compound other than an oxide, 90% of which have a particle size of between 1 and 150 .mu.m with a median diameter of between 3 and 20 .mu.m, these fine particles comprising particles of a substance which has a thermal conductivity higher than approximately 30 W/mK, chosen from silicon carbides, silicon carbonitrides, silicon nitrides, boron carbides, titanium carbides and tungsten carbides and a constituent made up of ultrafine particles at least 70% of which have a particle size smaller than 1 .mu.m with a median diameter of between 0.3 and 0.8 .mu.m, (2) water optionally with the addition of a dispersant, and (3) fillers comprising metal granulates and metal fibres, wherein the water/binder ratio is lower than 0.20 and the concrete composition has a thermal conductivity at 200.degree. C.

Abstract: The invention concerns a method for the preparation of moulds and cores used in the casting of metals. In the method the moulds and cores are prepared out of a granular moulding material as well as out of a binder agent that binds the moulding-material granules together. The binder agent used for the moulding mix is an anorganic salt, sodium aluminate, soluble in water and having a high melting point, as a rule higher than the casting temperature, which said salt is mixed with the granular moulding material as binder-agent solution dissolved in water. In the moulding process the binder agent is crystallized out of its water solution by microwave energy so that the binder agent forms a solid bridge between the granules of moulding material, said bridge binding the granules of moulding material together.

Abstract: Individual mold sections are injection molded from a slurry of ceramic particles and a binder. Each of the green individual mold sections is low temperature fired to remove therefrom a major portion of the binder while leaving therein a minor portion of the binder sufficient to afford structural strength thereto, and the individual mold sections are assembled together to form a mold. Finally the mold is high temperature fired to complete removal of the binder.

Abstract: A novel method of making a ceramic core for use in casting a metal component includes freezing a ceramic slurry comprising a ceramic powder filler, a freezable liquid and a gelling agent in a mold to form a frozen core shaped body. The frozen core shaped body is removed from the mold and thawed to room temperature. A high viscosity gel is provided in the core shaped body at room temperature that is strong enough to retain the core shape until the body can be fired to form a porous, sintered ceramic core. The gel present at room temperature may be formed as the ceramic slurry is cooled in the mold cavity to form the frozen article shaped body and/or as the frozen core shaped body is thawed to room temperature.

Abstract: The binder serves to produce foundry moulds and comprises a solution (preferably an aqueous solution) of aldehyde reactive phenol substances and gaseous acetals (preferably dimethyl formal) as reaction partners and strong acids, e.g. sulphuric acid and sulphonic acids as a catalyst. The acetal is in this system hydrolysed by the acid, the basic aldehyde being formed, which will react with the aldehyde reactive phenol substance accompanied by cross-linking. The acid serves thereby simultaneously as a cross-linking catalyst. In principle, it is possible to regard as "aldehyde reactive phenol substances" any phenolic compounds which can in the acid range cross-link more or less spontaneously with aldehydes. Preferably, these are resorcinol or resorcinol products, e.g. resorcinol pitch or precondensates formed with a shortfall of aldehyde, e.g. based on resorcinol formaldehyde, phenol resorcinol formaldehyde or resorcinol melamine formaldehyde.To produce foundry moulds, a granular basic moulding material, e.g.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: A core machine is arranged to automatically refine the shape of a sand core upon removal of the core from the machine. The core machine uses a core box to form a core. After formation of the core and separation of the core box halves a shaping member is moved into a space between the core box halves. As the core is ejected from the core box and removed from the machine it passes through the shaping member which refines the shape of the core. The machine may also be used for dimensional tolerancing about the parting line of the core box.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: For the fabrication of a disintegratable sand core, refractory particles such as silica sand are mixed with two binders, one consisting of an inorganic substance such as a silicate and the other consisting of a starch, and, preferably, with water. The two binders function to cancel the disadvantages arising from the use of only either. The mixture is introduced into a core box molded essentially of materials pervious to microwave energy. Exposed to microwave energy through the core box, the mixture hardens in the shape of the core box cavity. For the production of cores having greater surface stability at room temperature, the starch and water are first mixed together into a paste, and this paste is added to the refractory particles together with the inorganic binder, thereby assuring uniform dispersion of the starch throughout the mixture.

Abstract: A method of preparing a template for a product from a sample of the product. The ultimate template is either larger or smaller in size than the sample. Initially, a mixture of liquid rubber and a curing agent is prepared. The sample is then covered with the mixture and the mixture is permitted to harden to form a temporary mold. The sample is then removed from the mold to form a cavity, and the size of the cavity in the mold is altered to either increase or decrease its dimensions. Finally, a hardenable material, such as an epoxy resin, is poured into the mold to form the template. If an enlarged template is to be formed, the size of the cavity of the mold is increased by immersing the mold in an organic solvent bath. If the size of the mold is to be decreased, an organic solvent is added to the mixture before formation of the mold, and after the mold has been formed, it is heated to shrink the size of the mold.

Abstract: The method involves the disposition of a pair of walls in separated juxtaposition, to form a space therebetween, the walls having transverse, vane-cross-section shaped apertures formed therein; setting vanes in the apertures, across the space; filling the space with core material for solidification therein; and then separating the walls and vanes from each other after the material has solidified. The fixture provides a pair of walls so apertured, and a platform upon which, removably, to support the walls.

Abstract: A method of making an investment shell mold in such a way that the shell is protected from cracking on simultaneous firing and removal of the pattern. The method includes application of conventional molding materials in the first slurry and stucco coats. By conventional molding materials is meant molding materials that are transparent to microwaves and microwave energy. In the second slurry and/or stucco coats, and in later coats if necessary, a certain amount of microwave susceptible material, such as graphite or certain metal oxides including Fe.sub.2 O.sub.4, MnO.sub.2, NiO and cobalt oxide, is added. Then, if necessary to achieve sufficient mold strength, additional coats of conventional molding materials are applied. After drying is complete, the pattern and mold are exposed to microwave radiation. This radiation interacts with the microwave susceptible material to heat the pattern adjacent to the mold surface, while avoiding generalized heating of the pattern.

Abstract: A foundry process and associated apparatus for providing mixing of water, an additive, and a casting (investment) for the automated powder, which once mixed, are to be delivered to molds to form casting molds such as in the fabrication of microwave components (castings). The apparatus comprises a source of water, a source of additive and a source of the casting powder. There is provided a mixing bowl and automatic control means for coupling the water and additive to the mixing bowl and thereafter delivering the investment powder to the mixing bowl to provide for the thorough mixing of all of these components. The mixing bowl has associated therewith a manually operated valve which permits delivery of the mixed material into flasks disposed in a mixing chamber disposed under the mixing bowl. In accordance with the control provided in accordance with the invention, the mixing occurs initially without vacuum over a first predetermined period of time which may be on the order of 1-3 minutes.

Abstract: In the production of frozen moulds (12) or cores the freezing process is accelerated by drawing the liquefied freezing agent, such as nitrogen, used for freezing the water in the mould bodies, into or through the bodies by the application of a vacuum.

Abstract: A process for making a foundry mold for use in metal casting, which comprises the steps of heating and drying mold sand composed of refractory particles and a water-soluble binding agent, charging a cavity formed in a mold pattern with the mold sand under dried condition, during the charging step, moisture being kept on the peripheral surface of the mold to be made, and heating the whole pattern of which the cavity has been filled completely with the mold sand to thereby cure mainly the peripheral surface of the mold.

Abstract: In a process for compacting foundry mold making material, that is loosely heaped in a closed mold space over a pattern, the surface of the material is acted on by a compressed gas with a pressure of at the most 8 bar. This gas is caused to undergo expansion out of an inlet space through a valve in an opening at a gas flow rate of over 50 kg/sec and with a pressure increase rate of over 300 bar/sec, into the mold space. The maximum pressure in the inlet space or antichamber is 20 bar. An apparatus for use in the method is made up of a pressure vessel, a mold flask placed thereunder having a filling frame and a pattern plate. The opening cross section of the valve is 50 to 150% of the horizontal cross section of the mold flask and is opened in a short time of the order of milliseconds.

Abstract: A process for making an investment mold wherein a paste composition is used as the separating layer between the investment mould of refractory material and the surface of the metal container in which the investment mould itself is located. The composition is constituted by an organic component which can be eliminated by thermal degradation at temperatures above 200.degree. C. and a refractory mineral component which is stable at the casting temperature of the alloy used in the casting process. In a preferred embodiment, the composition comprises vaseline, talc and kaolin.

Abstract: In the production of frozen moulds (12) or cores the freezing process is accelerated by drawing the liquefied freezing agent, such as nitrogen, used for freezing the water in the mould bodies, into or through the bodies by the application of a vacuum.

Abstract: Method of forming or shaping a resin-bound mass (e.g., core-making or mold-making pattern or core box, particle board, etc.) in or from shaping means having shaping surfaces and releasing the shaped resin-bond mass from the shaping surfaces, which comprises coating the shaping surfaces of the shaping means with an improved, substantially stable, alcoholic dispersion or solution of a release coating suitable for repeated use, heating the coated shaping surfaces of the shaping means for sufficient time to convert the coating thereon to a stable, cured, abrasive-resistant release coating, placing a curable resin-bound mass of solids to be shaped against the release-coated shaping surfaces, curing the resin-bound mass, and separating the cured resin-bound mass from contact with the release coated shaping surfaces. The coating composition comprises a substantially stable alcoholic dispersion or solution of a substantially pure silanol of the formula RSi(OH).sub.

Abstract: A method for making a mold employing a flexible pattern and a microwave radiation. A flexible pattern is formed with a material which allows microwave to pass therethrough and which pattern is then coated with a liquid facing agent, including a dielectric material to the microwave, a thermosetting resin, and refractory material powders, by either dipping or spraying. The coated pattern is covered by a molding material, including a thermosetting resin and a dielectric material to the microwave, and then the molding material covered pattern is exposed to a microwave radiation for a time sufficient to harden the molding material, and finally the pattern is separated from the hardened molding material leaving a facing agent covered mold behind.

Abstract: In a closed system a shock pressure wave of a burning gas is used for packing granular mold material loosely distributed around a model. Before the shock pressure is produced, the pore volume of the upper layer of the granular material exposed to the pressure is reduced. Through the pore volume reduction, the active surface of the granular material is increased, so that the gas pressure acts on an increased working surface and, consequently, greater mold hardness is achieved.

Abstract: A process for making sintered metal articles of high strength in which a flowable mass of metallic particles is initially formed into a green compact having shape stability in a forming machine of the type used in the fabrication of sand cores in the metal casting field. The green compact is then subjected to sintering and the sintered body may be pressed, forged or mechanically shaped in other ways. The core blowing or core-sand slinging machine used to produce the green metal compact is surprisingly effective in producing a dense, reproducible structure in light of the fact that sand cores for casting purposes are intentionally made frangible to enable them to be removed effectively from the casting.

Abstract: To produce frozen casting moulds or core boxes the binder is cooled till freezing at least partly before or during the moulding process. This allows the production rate to be increased to such a level that the working rate of automatic machines for the production of casting moulds and core boxes can be fully obtained.

Abstract: Aggregate-containing products bonded by an aluminosilicate hydrogel are disclosed. A system of two-part mixing and blending of binder components with various granular-like aggregates, modifiers and/or fillers is described in which the resulting compositions are temporarily fluid and formable for short, controllable periods of time but which thereafter become strong, rigid, adherent, erosion resistant composites, requiring little or no external heat supply to achieve full set. The compositions can be formulated for molding on suitable forms or patterns, and may also be prepared in slurry form suitable for spray coating or sealing applications. A wide variety of products can be manufactured of the compositions, including investment molds and cores for foundry use, as well as non-foundry products such as heat and electrical insulators, construction blocks, panels, coating slurries, etc. which may be of essentially solid or foamed (cellular) construction.

Abstract: A method for making foundry moulds and cores where after preparation of the moulds and cores having a sand composition of a low strength up to 0.03 MPa, a cooling medium is introduced into the mould cavity, preferably liquid nitrogen, in an amount to provide hardening of only the surface layer of a required sufficient to reproduce the shape of the mould cavity.

Abstract: Phosphosilicate compositions are disclosed for treating foundry molds and like products to enhance mold strength and refractoriness. The phosphosilicates, characterized more specifically as silicyl metaphosphates, may be used in combination with select refractory aggregates and other additives to form mold surface treating compositions, or may be combined directly with foundry sand or other comminuted refractory material for compacting into a mold form.

Abstract: An adjustable filler means for molds and method thereof which comprises a molding flask adapted to adjustably receive and support a plurality of mold-contouring fingers arranged to be functionally held in spaced relation to a pattern within the flask, so as to be readily moved and adjusted to conform to any irregular contour of such pattern or core print disposed within the flask, and wherein a contour medium is provided between the fingers and the surface of the pattern to establish a contoured space between the fingers and pattern, whereby molding sand is provided therein to form the face of a mold or core.

Abstract: Particulate material for forming molds produced by mixing particulate refractory material with one material selected from the group consisting of colloidal silica, colloidal alumina, colloidal zirconia and ethyl silicate, drying the mixture and allowing same to set, and crushing the dried mixture into particulate form again. The particulate material includes refractory particles provided with a coat of silica or alumina or zirconia on the surface and increases the strength and surface precision of a mold.

Abstract: A method of preparing an assembly and an assembly useful in making a mold for casting one-piece impellers in which a master model of one of the vanes of the impeller is made in a polished metal having, on its inner end a shoulder with a height and depth approximately equal twice the width of the vane at its inside edge, the vane being tapered from inside to outside; from the master model a plurality of identical, flexible vanes are prepared from a material selected from the group consisting of flexible rubber and flexible plastic; a member having a truncated conical part containing therein a plurality of slots sized to match the inner edge of the vanes and a base plate having a plurality of slots therein equal in number to the slots in the truncated conical part with the slots in the truncated conical part and the base plate in alignment is formed; the flexible vanes are inserted from inside the truncated conical part through the slots therein with the bottom portion of the vanes in the slots in the base plat

Abstract: A casting mold manufacturing process and apparatus, which sand of the mold contains water-soluble paste of binder. The sand is previously heated in a sand storage tank by micro-wave heating or high frequency. The sand temperature and humidity, and volume of the binder contained in the sand are freely controlled. The preheated sand is blown by a preheated air to supply it to a molding flask placed under the storage tank. The preheated air is controlled in its humidity and warmness.

Abstract: A method of producing a mould of particulate material comprises admixing the particulate material with a controlled quantity of water, compacting the mixture to the required shape on a pattern or the like, removing the compacted mass from the pattern, and directing at at least the surface of the compacted mould to be contacted by molten metal a stream of coolant, whereby at least that surface is frozen to a depth sufficient to withstand the conditions imposed during the pouring of molten metal into the mould.

Abstract: This invention involves a method of making a unitary pattern assembly which is useful in forming investment shell molds for the conventional and directional solidification of molten metals and alloys. It comprises providing a fixture having first and second pattern capturing means, providing a mold structure having a cavity, positioning the mold structure and fixture to expose the capturing means to the cavity, forming a pattern in the cavity and removing the mold structure from the pattern. A unitary pattern assembly comprising a fixture and pattern fixedly captured therein is obtained. Multiple patterns may also be captured in the fixture. The method is especially suitable for making a pattern assembly useful in the production of gas turbine engine blades by the "lost wax" process.

Abstract: Metal casting components, e.g. molds and cores, are produced from a compacted mass of plaster by a two-stage drying treatment in a microwave oven with an intermediate cooling step whereby the plaster is completely calcined, and the resulting component will promote cast reproduction of its surface pattern with maximum fidelity of detail.

Abstract: An ingot mold has been devised which instead of utilizing a full protective thickness or section of sand within the spacing between a metal core bar and a metal flask, employs a refractory lining for the flask and a refractory coat for the bar that respectively have a cross extent or thickness that occupies a greater portion of the spacing than the casting sand. The casting sand is utilized as a minimum inner thickness to define the casting mold and as imposed between the refractory lining and coat.