Abstract: Disclosed are a high-boron high-vanadium high-speed steel and a method for preparing the same. Pig iron, scrap steel, ferrochromium, ferromanganese, ferroboron, ferrovanadium, industrial pure iron, ferromolybdenum, ferrotungsten, ferrosilicon and ferrotitanium are subjected to smelting at 1580-1600° C. and refining to obtain a liquid steel. The liquid steel is subjected to superheating, and directional solidification at a casting temperature of 1420-1430° C., and cooled to room temperature to obtain the directionally solidified high-speed steel.

Abstract: A tool includes a flexible section; a head that extends form the flexible section; and an exciter within the head. A method of additively manufacturing a component including burrowing a tool into a conglomerated powder within an internal passage of an additively manufactured component, the tool vibrating in a manner to facilitate removal of the conglomerated powder.

Abstract: Tubular metal articles such as pipe and cylinder liners are produced by centrifugal casting on a permanent metal mold coated by refractory glass on the active surface. A coating suspension mix is evenly distributed onto the mold to form a uniform layer of insulation on the surface of the mold. The material for the coating includes essentially a waterborne suspension mix of glass particles. The suspension is given time to dry on the surface of the mold. The glass particles dispersed in the suspension are both non-crystalline and nonporous. The glass particles in the suspension and forming the coating are not dissolved and do not chemically attract the polar water molecule or cause it to bond to the surface of glass in the suspension or to the mold active surface. Articles cast as such are smooth surfaced and require only limited machining.

Abstract: The present invention provides a structure for casting containing an organic fiber, an inorganic fiber, inorganic particles (A) having an average particle diameter of 50 to 150 ?m, and a binder (a), having a surface layer containing refractory inorganic particles (B) having an average particle diameter of 1 to 100 ?m selected from metal oxides and metal silicates, a clay mineral, and a binder (b), on the surface of the structure.

Abstract: An article includes a first portion having a first grain pattern and a second portion having a second grain pattern different from the first grain pattern. The article is a cast article such as a turbine engine blade.

Abstract: The invention relates to a casting mould for the casting of metals, wherein a layer consisting of a material which absorbs harmful substances on at least sections of gas outlet surfaces of the casting mold, in particular the top side thereof. The invention also relates to a coating composition, to a process for producing the casting mold and to the use thereof for casting of metals.

Abstract: A ceramic core is produced by introducing a fluid ceramic core material, such as a ceramic slurry, into a core-shaped cavity formed at least in part by one or more fugitive core tooling liners residing in a back-up body, removing the ceramic core from the cavity, and removing the one or more fugitive tooling liners from the back-up die body and discarding them. The fugitive tooling liners and optional tooling inserts are used in one or more production cycles (e.g. ceramic slurry injection cycle) to make a single or multiple ceramic cores and then replaced with fresh (un-used) tooling liners and optional inserts to make other ceramic cores.

Abstract: A slurry suitable for forming facecoats, facecoats formed by such a slurry, and processes using such facecoats. The slurry is formed of a particulate refractory material, an aqueous suspension containing a particulate inorganic binder, a thixotropic organic binder, a dispersant, and possibly optional constituents excluding particulate refractory materials and inorganic binders. The particulate refractory material constitutes at least about 60 weight percent of the slurry and consists essentially of yttria. The aqueous suspension containing the particulate inorganic binder constitutes at most about 35 weight percent of the facecoat slurry. The dispersant is present in the slurry in an amount sufficient to stabilize the slurry at a pH of up to about 10, and has the general formula Hx[N(CH2)yOH]z, where x has a value of 0, 1 or 2, y has a value of 1 to 8, and z=3?x.

Abstract: Investment casting shells are manufactured by incorporating fumed metal oxide dispersions, or doped fumed metal oxides as a binder into the casting shell. The investment casting shells containing the fumed metal oxides have improved characteristics, such as increased strength and a reduced surface roughness.

Abstract: A plasticizing barrel for a plastics processing machine includes a body having a hollow cylindrical configuration and defining an axis; and a coating formed on an inner wall surface of the body and including at least one groove extending in axial direction of the body. The coating, e.g., a wear-resisting protective layer, may be produced through centrifugal casting, whereby the grooves are formed by projections of a negative mold inserted in the hollow-cylindrical body.

Abstract: A mould (1) for the manufacture of a casting (2) using moulding material (3). In order to achieve simple and cheap manufacture, the mould (1) is provided with an outer first mould carrier (4), an outer second mould carrier (5), a mould body (6) arranged between said mould carriers (4, 5) and an inner layer (12) of moulding material (3) applied to said mould carrier (6) at least in areas, to form the mould cavity.

Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of ±0.060 inches.

Abstract: In a permanent casting die with an at least local ceramic lining, the ceramic lining at least partially forms surface contours of a die cavity. The ceramic lining is applied in a form-fitting manner to a metallic core and the ceramic lining with the core is anchored firmly or movably in the die cavity.

Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.

Abstract: A method and apparatus are provided to process collected sand. This method and apparatus allow the moisture content to be adjusted and the addition of a binder to be facilitated to renew the collected sand as casting sand for future use. Also, defective castings are prevented when they are made by a main mold using the renewed casting sand. The sand-collecting means can be compact. The method is performed and the apparatus is operated by separating a main mold of green sand, after casting is conducted, into parts unaffected and affected by the molten metal heat, adjusting the moisture content of the part unaffected by molten metal heat for use as facing sand in the next main mold making, and adding a binder and adjusting the moisture content of the part affected by the molten metal heat for use as back sand in making the next main mold.

Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.

Abstract: A technique for smoothing and otherwise changing the surfaces of porous bodies, such as ceramic molds, made using layer manufacturing processes, such as three dimensional printing processes. The surface finish of the mold can be smoothed by casting a slip of fine particles onto the surface to form a generally level, and preferably non-conformal, coating on the surfaces. In general, the fine particles of the slip are caused to be filtered out from the liquid, so that the fine particles come to rest at or near the surface of the body formed. They are typically, preferentially drawn toward concave regions of the surface, as compared to convex regions, thereby forming a non-conformal coating. Furthermore, other surface properties can be changed by tailoring the slip to produce those properties. The coating can be applied to external surfaces, and internal surfaces, such as would become the surface against which a molded part would be formed.

Abstract: A core material for making cores to be used in molds for the casting of metals and comprising a mixture of hollow ceramic particles uniformly distributed throughout a resin binder of organic material. The hollow ceramic particles are individually in intimate surface contact with adjacent individual hollow ceramic particles throughout the core materials to allow the heat of the casting to be conducted efficiently through the core material. The amount of resin binder being maintained at a minimum to reduce the amount of gas generated by the resin binder as it is exposed to the heat of the metal being cast. The hollow ceramic particles comprising about 99.0 to about 96.5% by weight of the core material and the resin binder comprising about 1.0 to 3.5% by weight, respectively, of the core material prior to the core material being cured, and the hollow ceramic particles preferably ranging in diameter from about 200 microns to about 450 microns, with a preferred mean diameter of about 325 microns.

Abstract: Articles such as molds for thermoplastics, having an insulating layer preferably of resin deposited on the metal core materials, have a second layer of metal suspended in resin deposited on said insulating layer. The second layer may contain metal in platelet form as the inner mold surface, or may contain metal in fiber, whisker or irregular form with a further metal coating deposited thereon to provide resistance to abrasion. In the latter case, the adhesion of the further metal coating to the mold surface is higher than is the case if no metal-containing resin layer is present.

Abstract: A method for producing a cast-iron cylinder liner for piston engines in which a metal chill mold (1) is used which has a tubular mold cavity (2) lined with a layer of a hardening molding material or green sand (3). The melt (7) is introduced into the mold cavity from above in such a manner that the cooling effect from the chill mold and the lining provides a frontage of solidification directed upwardly from the bottom.

Abstract: A new method for producing a composite ceramic mold for production of metal castings is disclosed. The composite mold is comprised of a backing layer and a facing layer. The backing layer is formed by pouring a mixture of a suitable refractory, a gelling agent, and a binder about an oversized pattern. After the backing layer hardens, it is fired and then baked. The facing layer is then formed integrally with the backing layer by pouring a mixture of comminuted highly refractory material, a gelling agent, and a binder between the oversized backing layer and a dimensionally-correct pattern. After the facing layer hardens, it is fired and then baked.

Abstract: A new and improved, non-porous carbon foundry sand and a method of treating a fluid coke, having a spherical or ovoid particle shape and a size suitable for a coating surface, or a core or mold surface in the foundry industry, wherein the carbon sand is processed by heating the carbon particles at a controlled rate to a temperature in the range of about 1900.degree. F. to about 2300.degree. F. during a period of time preferably of more than about 30 minutes, and preferably for a period of about 1 to 2 hours, particularly to about 2000.degree. F. to about 2200.degree. F., and a method of casting molten metal against the heat treated carbon particles wherein the non-porous carbon foundry sand is combined with a suitable binder with which mixture a mold is formed to cast metal parts. The non-porous carbon sand also is useful in forming molds, cores, shell molds and shell cores and otherwise in using the carbon sand to replace other molding an core-making sands used in the foundry industry.

Abstract: A new and improved carbon sand and a method of treating a petroleum fluid coke, having a spherical or ovoid particle shape and a size suitable for a core or mold surface in the foundry industry, by heating or roasting the carbon particles at a temperature in the range of about 1000.degree. F. to about 1500.degree. F., particularly about 1200.degree. F. to about 1400.degree. F., for a time sufficient to volatilize from the carbon particles substantially all of the organic contaminants volatilizable at the roasting temperature, and a method of casting molten metal against the heat treated carbon particles, combined with a suitable binder, to form cast metal parts. The carbon sand also is useful in forming shell molds and shell cores and otherwise using the carbon sand to replace other molding and coremaking sands used in any of the various molding and coremaking processes with any of the various binder systems practiced by the foundry industry.

Abstract: Disclosed is a collapsible core for use in a casting and a method for producing the collapsible core. The collapsible core comprises a main core body, a first layer formed over the core body, a second layer formed over the first layer, and a third layer formed over the second layer. The second layers includes a thermosetting resin such as low temperature decomposable resin. The low temperature decomposable resin comprises one of urea resin and phenol resin. The thermosetting resin is applied to the first layer by dipping, spraying or brush-painting. This thermosetting resin provides tight bonding to the neighbouring layers.

Abstract: Molds for injection molding are produced by providing a primary mold core, coating the primary mold core with a water-resistant coating layer, applying on the water-resistant coating layer a separating layer, spraying a metal shell on the separating layer, arranging a rear filling on the shell so as to form a tool part, and supplying water to the water-soluble layer so as to remove the tool part.

Abstract: A casting core adapted to be placed inside a molding cavity for defining a cored-out hollow inside a metal casting, which core comprises a first coated layer formed on an exterior surface of the casting core by coating a slurry containing powdery refractory material, and a second coated layer formed over the first coated layer by applying a solution containing graphite particles. A method of making a metal casting with the use of the casting core is also disclosed.

Abstract: A permanent casting mold has its casting cavity coated with a sand liner of varying thickness. The liner is thicker where the cast article section is thinner and the liner is thinner where the cast article section is thicker so as to permit the thicker sections to cool faster while the thinner sections cool slower. The different thicknesses of the liner are correlated so that the respective sections of the article are sufficiently cooled at about the same time for removal of the article from the mold. The mold is a cope and drag-type flask mold whose casting cavity halves are oversized relative to the cast article. The sand liner is formed therein by temporarily positioning a pattern within the permanent casting cavity halves and sand filling the space between the pattern and cavity wall. The exterior surface of the pattern corresponds to the cast surface of the article.

Abstract: Binder, filler, and refractory compositions and methods of using and making these compositions are disclosed. The binder composition comprises colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from P, S, B and N and which stabilizes the binder composition against self-gelling. The liquid material and the colloidal silica are present in a ratio by weight of from about 10:1 to about 1:10 respectively. The liquid material has at least about 20% by weight SiO.sub.2. The colloidal silica contains at least about 15% by weight SiO.sub.2. The solvent and the organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.

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: Reduction of porosity and control of graphitization in the centrifugal casting of tubular metal articles are achieved providing on the active surface of a metal mold by a densified and contoured lining of binderless particulate refractory material, at least 20% by weight of the particles in all of the lining being angular particles, at least 25% by weight of the particles in that portion of the lining in contact with the metal mold having predetermined particles size and/or thermal conductivity. The lining may comprise both a primary layer, formed of particles having good thermal conductivity and/or a relatively larger particle size, and a facing layer formed, e.g., of a milled refractory flour.

Abstract: Method and apparatus for establishing a layer of particulate material on at least a portion of the internal surface of a centrifugal casting mold by confining a quantity of the particulate material in a cavity, inserting the cavity into the mold, rotating the mold and the cavity at substantially the same rate adequate to apply substantial centrifugal force to the particulate material in the cavity, and opening the cavity to release the particulate material while continuing to rotate the mold and the cavity.

Abstract: A process for producing a casting mould with chemically bound moulding material using a pattern is intended to make it possible to forego the use of clay-bound sand, in particular for the mass production of cast members, and to provide a casting mould of adequate gas permeability, which is simple to produce, with a low level of consumption of moulding material, and inexpensive, and which also provides a high level of casting quality wth a low degree of environmental pollution. For that purpose, the moulding material which has become pourable or fluid due to the operation of casting a cast member is removed from a first casting mould comprising a single moulding material, whereas the remaining portion of the moulding material is left, and the hollow space formed when the pattern is re-fitted is filled with moulding material. In addition, the moulding material which has been reduced in strength may be also removed, being for example blown or brushed out.

Abstract: A method of producing a pattern for use in the manufacture of a mold which is adapted to be cured by microwave irradiation. The method comprises forming a rolled-over male pattern, forming a rolled-over female pattern having a scale-off layer along a boundary thereof with the male pattern, removing the scale-off layer, pouring a silicone RTV rubber into a cavity of the female pattern to form a match plate therein, setting a metallic frame on the match plate, filling the interior of the metallic frame with a mixture of microwave-pervious resin and dry silica sand, causing the mixture to be thermally cured thereby forming a reinforcing layer on the peripheral surface of the match plate, placing the male pattern within the reinforcing layer after removing the match plate therefrom, and injecting a microwave-pervious silicone rubber into the gap formed between the reinforcing layer and the male pattern thereby forming a mold defining layer on the inner surface of the reinforcing layer.

Abstract: A mold facing for producing a gas-permeable, non-gassing and, in view of its small thickness and its porosity, heat-conductive cladding of a centrifugal ingot mold for copper and its alloy contains pulverulent material in a dispersing agent, particularly water, evaporating without residue. The pulverulent material has titanium dioxide (TiO.sub.2) as the main constituent or the sole constituent, preferable with an average particle sizes of about 15 .mu.m. A process for cladding a centrifugal ingot mold by using such a mold facing contemplates at first preheating the mold and subsequently applying the mold facing by spraying to the inner wall of the centrifugal ingot mold rotating around its axis in form of a suspension free of binding agents and surface active agents as a thin layer of, as far as possible, uniform thickness of preferably 0.1 to 0.3 mm and subsequently evaporating the dispersing sheet of the mold facing without leaving any residue for obtaining a porous layer.

Abstract: A composition for coating the molding surfaces of molds for casting metal parts comprising an aqueous dispersion containing finely divided zirconia, a colloidal silica composition, finely divided mica, finely divided zircon, finely divided bentonite and, optionally, an inert coloring agent. While capable of protecting the molding surfaces against high temperature molten metal and producing castings having substantially defect-free surfaces, the coating composition provides cleaner castings by partially attaching to the casting and spalling off as the casting cools.

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: A dispersion composition and a method for coating the surface of steel casting dies for molten metals are described. The dispersion composition comprises boron nitride powder dispersed in a peroxide-modified aqueous dispersion of a water-dispersible film-forming polymer. The coating composition provides thermal insulation to the mold surface, thereby minimizing premature solidification of the cast metal.

Abstract: Centrifugal casting apparatus for casting cylinder liners and other tubular articles, characterized by recovery of at least a major portion of the particulate refractory material used to line the mold, with the recovered refractory material being suitable for re-use. The apparatus provides a chamber having aligned openings through which the cast article moves as the article is withdrawn from the mold by a puller. Particulate refractory material from within the mold and from the surface of the cast article is collected in the chamber and conveyed from the chamber to separator means for removal of debris.

Abstract: A method and an apparatus is provided for casting molten metallic materials through runners in the form of casting gates, flow-through tubes, feeders, rising gates and the like. The method basically comprises casting the molten metals through runners defined by bodies of porous calcium hydro-silicate such as gas concrete. A filler, such as quartz, may be used. The runner bodies are formed of gas concrete and provided with a moisture ratio of 3 to 30% so as to afford progressive evaporation of the moisture during casting to thereby produce a cooling effect on the runner walls. The runner bodies can be reinforced.

Abstract: The invention provides shaped, refractory, heat-insulating articles, for use in a metallurgical vessel, comprising particulate refractory material, binder and particulate de-fibred bagasse or the like. The articles may be made by mixing the ingredients, pressing them in a former and causing or allowing the binder to set. The articles may be slabs for lining the head of a mould for steel ingots.

Abstract: A method of making molds, wherein facing sand prepared by using a binder which will retain its plasticity for a long time is spread into a thin sheet, which is then cut into suitable pieces according to the shape of a pattern, which pieces are then placed on the surface of the pattern or applied thereto while being connected together, thereby forming a layer of facing sand of uniform thickness, whereupon backing sand is charged to fill the cavity and rammed around, thereby making a mold. This method is effective to reduce the amount of facing sand used, improve the dissipation of gases and heat and uniform the pressure-resisting strength in the various portions, thereby eliminating various casting defects.

Abstract: A composition and method for coating the surface of steel casting dies for molten metals are described. The composition comprises a dispersion of boron nitride powder, an elastomeric polymer and an organic solvent or diluent. The elastomeric polymer consists of two fractions, a high-polymer fraction and a low-polymer fraction. The treatment provides thermal insulation to the mold surface, thereby minimizing premature solidification of the cast metal.

Abstract: A covering film containing a thermoplastic resin productive of burnt dregs and a thermoplastic resin not productive of burnt dregs moderately disperses in the refractory filler of the mold and forms a relatively thin shell layer near the wall defining the mold cavity in order to successfully avoid generation of mold destruction and sand inclusion and streamline the whole casting process.

Abstract: Materials suitable for lining vessels designed to hold molten iron or steel are provided herein. These materials are made of burned dolomite, containing 1-6% of a natural glyceride oil or a mixture of such oils and 2-6% by weight of a dry inorganic particulate bonding agent, such as potassium silicate or phosphate.

Abstract: A protective coating includes fire clay, graphite, water glass, water and alumina-containing material, the ingredients being present in an amount of up to a half the weight of the total mixture. Used as the alumina-containing material are such substances as commercial alumina, abrasive slurry, catalyst wastes from the production of synthetic rubber. The protective coating may also include in its composition a boron-containing material in an amount of from 0 to 10 percent by weight of the total weight of the composition, such as datolite and danburite concentrate, ascharite, boric acid, colemanite, pandermite, borocalcite, boronatrocalcite, as well as soda ash in an amount of from 0 to 5 percent by weight.

Abstract: A process for applying a coating to a centrifugal casting mold for casting copper or alloys thereof in which prior to introducing the molten metal into the mold, an aqueous suspension of powdery material is introduced into the mold and applied on the internal surface thereof in the form of a thin layer. The constituent components of the suspension are zirconium oxide (ZrO.sub.2) and an inorganic binder material, preferably non-sintered alumina (Al.sub.2 O.sub.3), so that a heat-conductive and gas-permeable layer is formed on the surface of the mold.

Abstract: A metallurgical vessel having a tap hole containing a plug comprised of a hardened composition comprising a granular inorganic oxidic material other than glass powder and 1 to 30 weight percent, based on the weight of said material, of glass powder, especially a composition additionally containing a hardenable thermo- or cold-setting phenolic resin, which composition does not disintegrate at high temperatures and retains compressive strength.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.

Abstract: A chill preventing arrangement is used in a metal mold employed in centrifugal casting. The metal mold is provided, at its spigot portion, with an end plate which has a central opening smaller in diameter than the internal diameter of the metal mold main body and which includes a metallic base plate, an intermediate layer of metallic alloy formed by flame or plasma spraying on a surface of the metallic base plate contacting the molten metal for casting, and a coating of ceramic material more than 0.7 mm thick formed on the intermediate layer by flame or plasma spraying for preventing chill formation at the corresponding end portions of tubular castings.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.