Abstract: A method for making hollow metal tubes includes a step combining a polyphenylene sulfide-containing resin with a water soluble carrier resin to form a resinous mixture. The resinous mixture is then extruded to form an extruded resinous mixture. The extruded resinous mixture includes polyphenylene sulfide-containing fibers within the carrier resin. The extruded resinous mixture is contacted (i.e., washed) with water to separate the polyphenylene sulfide-containing fibers from the carrier resin. The polyphenylene sulfide-containing fibers are then coated with a metal layer. The hollow metal tubes are then formed by removing the polyphenylene sulfide-containing fibers.

Abstract: A casting core resulting from alkaline earth metal oxide particles having an average particle size of 0.8-4 mm being dispersed in a water-soluble alkali metal salt matrix. The casting core can be efficiently produced using a method of dispersing alkaline earth metal hydroxide particles having favorable disintegration properties and a particle size in the range of 1-5 mm in a molten water-soluble alkali metal salt, converting to alkaline earth metal oxide particles by means of dehydration, and casting in a mold, cooling, and hardening.

Abstract: A method for the high pressure die casting of an engine block assembly having at least one cast in place cylinder bore in the engine block and a closed head deck surface, and the resultant engine block are disclosed. This closed deck high pressure die cast engine block assembly will preferably have at least two cast in place cylinder bores in the engine block formed by using a composite core of salt core material supported by at least one cylinder bore to be cast in place. The cylinder bores have a lower outer surface preferably defining at least one surface area that interfaces with the engine block during casting such that the at least one cylinder is cast in place in the engine block. An engine block water jacket—as defined by the salt core portion of the composite core—will preferably provide an open passage between each cylinder bore such that water may flow around and entire outer circumference of the upper outer surface of the cylinder bores.

Abstract: A core or foundry sand that can be used for the production of cores and casting molds for the casting of molten metals includes a basic molding material, a layer of an adhesive agent coating the basic molding material, and a layer of water glass lying over the adhesive agent layer. The core or foundry sand has a water content in the range of ? approximately 0.25% by weight to approximately 0.9% by weight in relation to the overall weight of the core or foundry sand.

Abstract: A melt is made by heating a salt mixture containing a salt of sodium. The melt is set at a temperature higher than the liquidus temperature of the salt mixture, and poured into a mold for expendable core molding. The temperature when the melt is completely poured into the mold is set within a range not exceeding the liquidus temperature of the salt mixture by 30° C. An expendable salt core for casting is molded by solidifying the melt inside the mold. This makes it possible to more stably obtain the strength of a water-soluble expendable salt core for casting made of a salt cast product obtained by melting and molding salts of sodium and the like.

Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.

Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.

Abstract: The invention provides water-soluble salt cores which are produced by compacting a mixture of water-soluble salts and a binding agent, under pressure and subsequently subjecting them to heat-treatment. The binding agent is an inorganic phosphate or a mixture of inorganic phosphates having a proportion of between 0.5 and 10 wt. % of the mixture.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Abstract: The present invention relates to a core or foundry sand that can be used for the production of cores and casting moulds for the casting of molten metals, comprising a basic moulding material, coated with a layer of an adhesive agent and a layer of water glass lying over the latter and a water glass content in the range of?approximately 0.25% by weight to approximately 0.9% by weight in relation to the overall weight of the core and foundry sand.

Abstract: A binder, a composition, a product and a kit, as well as a process for preparing the binder and composition, are directed to a composition useful as an inorganic phosphate binder, which binder is characterized as having calcium silicate sites which are connected the one with the other by alumina-silica phosphate bonds, and a filler.

Abstract: A process for the casting of metals includes the steps of providing a mold, delivering a molten metal into the mold, solidifying the molten metal, and removing at least a portion of the mold. The step of removing at least a portion of the mold begins before the step of solidifying the molten metal has been finished. An apparatus to deliver a solvent to a mold is also provided.

Abstract: A mold for the casting of metals including an aggregate comprising a refractory particulate material and a soluble binder which provides for minimal heat transfer between the mold and the molten metal during filling. The aggregate preferably includes at least a proportion of particulate material having a heat diffusivity at least as low as silica sand to reduce the chilling effect of the mold. The mold is removed from the casting the action of a solvent, which simultaneously cools and solidifies the casting at a maximum rate. Processes for forming the mold and the casting of metals using the mold are also disclosed.

Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.

Abstract: In a water-soluble casting mold according to the present invention, after casting sand is obtained by adding a water-soluble binder containing an inorganic sulfate compound such as magnesium sulfate or the like easily solved in water and water to a refractory granular material for casting sand, the casting sand is dried by microwave radiation or the like in such a manner that the inorganic sulfate compound in the binder is kept retaining at least a portion of crystal water and accordingly, since the inorganic sulfate compound exists in hydrate state in the mold, the mold after drying is provided with good water-solubility and a sufficiently high strength as well, thereby it is possible to recover easily and use repeatedly the binder.

Abstract: Disclosed is a method for manufacturing a disintegrative core for use in high pressure casting. The disintegrative core can be applied where a light metal such as an aluminum alloy or magnesium alloy is subjected to high pressure casting, such as die casting or squeeze casting and is manufactured from a water-soluble salt which is high in latent heat and ranges, in melting point, from 280 to 520° C. and, in heat transfer coefficient (&kgr;), from 9.8×10−2 to 1.2×10 W/m·° C. The water-soluble salt, alone or in combination with a fine hard powder, is melted and solidified in a core mold. Alternatively, the melt is processed into a fine powder which is then molded in a core mold. The method can be applied for the manufacture of complex shapes of cores. Also, disclosed is a method for extracting such a core from a high pressure molded product.

Abstract: In a method of making a molded article for use in a casting process, sand particles are mixed with protein and water to effect a coating of protein on the sand particles. Then, the protein coated sand particles are dried and blown into a pattern mold to form a molded article without active cooling of the coated sand particles. Steam is then passed through the molded article to hydrate and melt the protein, thereby forming bonds between contiguous sand particles. Finally, hot, dry air is passed through the molded article to harden the protein bonds between the contiguous sand particles. This forms a protein coated sand core for use in casting molten metals.

Abstract: An inorganic binder system for foundry compositions includes a silicate and added phosphate. The composition produces a binder having the advantageous strength properties of a silicate binder system with the dispersibility properties of a phosphate binder system. Methods of making and using the binder systems and the resulting products are of particular interest to the foundry art.

Abstract: A water-soluble ceramic core is prepared which can be advantageously used in the die casting, gravity casting, and investment casting of precision aluminum alloy objects. The ceramic core contains: (a) 60 to 70% by weight of alumina (A1.sub.2 O.sub.3) flour; (b) about 15 to 25 by weight of zircon (ZrSiO.sub.4) flour; (c) about 5 to 15 by weight of sodium hydrogen phosphate (Na.sub.2 HPO.sub.4); and (d) about 5 by weight of sugar. In preparing the ceramic core, sodium hydrogen phosphate and sugar are first dissolved in water to form a sodium hydrogen phosphate/sugar solution. Then alumina flour and zircon flour are added into the sodium hydrogen phosphate/sugar solution to form a slurry, which is caused to form a precursory ceramic core using an injection molding or slip casting process. After blow-drying the precursory ceramic core is calcined at temperatures between 70 and 800.degree. C.

Abstract: An improved soluble core for die casting metals or metal matrix composites is formed of a mixture of salt and about more than 0 weight % and less than 20 weight % of ceramic material blended together to produce a homogeneous mixture and compacted under pressure to produce a soluble core having little or no porosity. The ceramic material can be in the form of fibers, particulates, whiskers, and/or platelets, and has a melting temperature greater than that of the salt. The core can include a thermally insulating outer ceramic coating to enable the core to withstand higher die casting temperatures than conventional salt cores. The improved soluble core is removable with hot water and/or steam and the core material can be reclaimed for reuse.

Abstract: An improved soluble core for die casting metals or metal matrix composites is formed of a mixture of salt and up to about 20 weight % of ceramic material blended together to produce a homogeneous mixture and compacted under pressure to produce a soluble core having little or no porosity. The ceramic material can be in the form of fibers, particulates, whiskers, and/or platelets, and has a melting temperature greater than that of the salt. The core can include a thermally insulating outer ceramic coating to enable the core to withstand higher die casting temperatures than conventional salt cores. The improved soluble core is removable with hot water and/or steam and the core material can be reclaimed for reuse. The process is used to form hollow articles.

Abstract: A method is provided for forming a sand core which is suitable for use in casting processes, and in particular squeeze casting processes, to form internal features and intricate external features of a cast article. The core forming method involves the use of a single-component gelatin binder whose degradation at elevated temperatures is catalyzed by additions of a ferric compound. The gelating binder is a mixture of proteins derived from amino acids such as glycine, alanine, L-glutamic acid, L-aspartic acid, and/or small percentages of others, such that the gelatin binder is water soluble and therefore easily eliminated from the core sand at the end of the casting process. Due in particular to the presence of the ferric compound, the gelatin binder readily degrades at low temperatures, such as those associated with aluminum casting processes, such that the core degrades sufficiently to permit the sand to freely flow from the cast article without the need for core removal operations.

Abstract: A process of providing a disposable core for use in die casting processes. A salt material is molten and cast into a core of a desired configuration under exacting conditions. The fluidity of the molten salt is controlled enabling casting the salt material into a core by die casting methods. The die casting method provides a core with a high surface finish and strength. The core is evenly cooled subsequent to it being cast and is maintained at an elevated temperature to maintain its surface finish and structural integrity. The cast core is inserted into the dies of a metal die casting machine to facilitate casting a metal product having internal forms not otherwise attainable. The core is removed from the metal product by simply dissolving and flushing the core out of the casting. The salt material may be reclaimed by a de-salination process for further use.

Abstract: A method for the manufacture of salt cores is described. The cores are used for the production of cavities in articles which have been made by a pressure casting technique. The cores are resistant to impregnation and fracture during, for example, the application of pressure during squeeze casting. In particular, the method comprises mixing coarse and fine particle salt powders in the ratio from 50/50 to 70/30 coarse/fine, the coarse powder having a maximum particle size of 250 micrometers, the fine powder having a maximum particle size of 25 micrometers. A lubricant, for example, oleic acid is added, possibly the quantity thereof being in the range 0. 1 to 1.0 wt %. A surfactant, such as a silane, also may be added, possibly the quantity thereof being in the range 0.1 to 1.0 wt %. The mixture is pressed to form a core having a density of at least 1.90 g/cm.sup.3 ; and is sintered at a temperature between 650.degree. C. and 775.degree. C., for a time in the range 15 minutes to 1 hour.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as sand, bound together by a cured water soluble binder. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, after the product has been molded to rapidly disintegrate the core and remove it from the molded product.

Abstract: A mold element comprised of metallic pellets and a bonding agent to bond together the metallic pellets. The metallic pellets can be a mixture of ferrous shot and ferrous grit and the bonding agent can be a solvent or a resin. An associated method is also provided.

Abstract: A method of high pressure casting of hypereutectic aluminum-silicon alloys using a salt core to form wear resistant articles, such as engine blocks. To produce an engine block, one or more solid salt cores are positioned within a metal mold with the space between the cores and the mold defining a die cavity. A molten hypereutectic aluminum-silicon alloy containing more than 12% silicon is fed into the die cavity and on solidification of the molten alloy, precipitated silicon crystals are formed, which are distributed throughout the wall thickness of the cast part and also on the surface bordering the salt cores which constitute the cylinder bores in the cast block. The salt cores are subsequently removed from the cast block by contact with a solvent such as water.

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: Method of producing a mold from a ceramic composition which can be washed-out with water after use thereof in a molding process, the method including forming a ceramic composition by mixing from about 30 to about 80 weight percent of at least one hemihydrate including alpha-calcium sulfate hemihydrate or beta-calcium sulfate hemihydrate, from about 5 to about 45 weight percent of fire clay, and from about 5 to about 25 weight percent of at least one silicate-based filler. About 100 parts by weight of the ceramic composition are mixed under stirring into from about 46 to about 54 parts by weight of water to form a slurry. The slurry is poured into a formation mold suitable for forming the desired mold and the slurry contained in the formation mold is allowed to set and form a set body. The set body is then removed from the formation mold and dried to provide the mold.

Abstract: Disclosed are water soluble core wherein a particulate refractory material is combined with a binding agent comprising Na.sub.2 CO.sub.3, Na.sub.2 O . NSiO.sub.2 where n is 0.5 to 4, and SiO.sub.2 as ingredients and a process for producing the water soluble core. The process comprises mixing the particulate refractory material with a water glass, casting the mixture of the particulate refractory material and the water glass, hardening the casting by CO.sub.2 gas, and calcining the casting at between 100.degree. C. and a temperature less than that of an endothermic peak of the water glass in differential thermal analysis. Also, a process for die casting a metal is disclosed using the water soluble core which process comprises pre-heating the water soluble core from a temperature of 300.degree. C. below a melting point of the metal to a temperature of the endothermic peak.

Abstract: A fired ceramic core for use in aluminum investment casting, which will withstand steam autoclaving and which may be rendered water disruptible; comprising from about 20 to 50% by weight of one or more water soluble salts, together with inert ceramic fillers selected to meet desired thermoexpansion compatability for the shell with which said core is to be used; said core being vacuum impregnated with ethyl silicate and a cured phenolic resin.

Abstract: Disclosed is a method for making metal castings wherein a composite core assembly is utilized. The composite core assembly comprises at least one casting core and one temporary core which are in intimate contact wherein the temporary core is removed prior to casting. The improvement of the present invention comprises forming the temporary core comprising an aggregate and binder of materials such that the temporary core is sufficiently soluble in aqueous solvent for its removal prior to metal casting. The casting core is not removed by the aqueous solvent.

Abstract: A pattern, identically proportional in configuration to the salt core to be produced, is initially formed from an evaporable foam material. The evaporable foam pattern is positioned in a mold and surrounded with an unbonded flowable material, such as sand. The pattern is contacted with a molten salt and the high temperature of the salt will vaporize the pattern, with the vapor being captured within the interstices of the sand while the molten salt will fill the void created by vaporization of the foam to provide a salt core identical in configuration to the pattern. The salt core is subsequently used in a high pressure die casting operation to cast a metal part.

Abstract: A manufacturing method of a piston in used for an internal combustion engine. The method comprises a step of reinforcing a circumference of a top ring groove by an inorganic fiber assembly, a step of forming an oil cooking gallery by a soluble core, a step of fixing the soluble core by projections formed in a strut preventing a thermal expansion of the piston, a step of setting the soluble core in a position supported by a punch mold, and step of setting the inorganic fiber assembly in an annular groove of a lower mold.

Abstract: Casting cores are fabricated from a mixture comprising a molten salt having dispersed therein a particulate material which includes a first refractory material having a mesh size of 60-120 and a second refractory material having a mesh size of at least 200. The salts are preferably halides, carbonates, sulfates, sulfites, nitrates or nitrites of Group Ia and Group IIa metals and the refractory material may be selected so as to be non-reactive with the molten salt. Some preferred refractory materials include alumina and magnesium silicate.

Abstract: A core or insert primarily for the production of metal and alloy castings, e.g. of complicated internal shape, is a refractory body comprising essentially a water-soluble salt and a calcium silicate, the calcium silicate being present in amount of at least 45%, by weight, based on the total weight of calcium silicate and water-soluble salt, and the water-soluble salt and the calcium silicate having a particular particle size distribution. The calcium silicate is preferably a wollastonite.The core may be removed from the cast or moulded article by dissolution in water.

Abstract: The present invention provides a method for manufacturing a thin-walled ceramic casting mould which is particularly suitable for casting directionally solidified articles in which rapid cooling of the cast material is required. The mould is transfer moulded around a disposable pattern material and includes an integral core. The mould has an outer wall thickness of the order of 0.5 mm to 2.0 mm. The mould and core may be made of the same or different ceramic materials chosen for their strength or thermal conductivity. The method further provides for a series of high temperature disposable supports embedded in the disposable pattern material, providing support for the outer wall of the mould during the firing process. The disposable supports are disposed of at a temperature at which the mould has acquired self-supporting strength.

Abstract: A method for forming metal base composite use a retainer made of water soluble salt with a high melting point. Molten metal and a reinforcement are compounded in the retainer and then solidified. After solidification the retainer is dissolved away by water.

Abstract: A squeeze formed aluminum alloy article, such as a piston, is formed with a re-entrant cavity (14) by locating an isostatically compacted salt core (10) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (14) is subsequently dissolved from the squeeze formed article to provide a corresponding shape to the article which does not require subsequent machining.

Abstract: The invention provides an improved method for the preparation of a porous ongy body of a metal or alloy having an open cell structure. The basic principle of the method is the pressurized casting of a melt of the metal or alloy with a preheated powder compact of an inorganic compound soluble in a solvent to fill up the pores and dissolving away the inorganic compound with a solvent after solidification of the melt.

Abstract: A refractory mould core for producing metallic castings of complicated internal shape formed from a water-soluble salt having the following particle size distribution:100% by weight of the particles have a size less than 750 .mu.m;90% by weight of the particles have a size of 8-600 .mu.m;80% by weight of the particles have a size of 5.5-500 .mu.m;70% by weight of the particles have a size of 4-400 .mu.m;60% by weight of the particles have a size of 2.8-350 .mu.m;50% by weight of the particles have a size of 2.0-280 .mu.m;40% by weight of the particles have a size of 1.6-220 .mu.m;30% by weight of the particles have a size of 1.0-180 .mu.m;20% by weight of the particles have a size of 0.3-160 .mu.m;10% by weight of the particles have a size of 0.1-125 .mu.m.

Abstract: A water soluble core comprises a mold product prepared by a mixture of sand, potassium carbonate as a first binder and at least one of barium carbonate and alkali silicate as a second binder. This water soluble core is utilized for a method of manufacturing a cast rotor for forming ventilation ducts of an induction motor.

Abstract: In a method for producing a mold for metal casting capable of being easily disintegrated by water which comprises the steps of kneading alumina sand with hydrous sodium aluminate as a binder, forming the kneaded mixture into the desired mold shape and then passing carbon dioxide gas through the mold to decompose sodium aluminate and harden it; the improvement wherein the kneading of alumina sand with the binder before mold formation is carried out in an atmosphere of carbon dioxide gas to decompose 50 to 80% of the sodium aluminate in advance.

Abstract: A casting core for the creation of difficultly accessible cavities in castings of aluminum or of one of its alloys, produced from a water-soluble salt as base substance and burnt sugar as binding agent, and a process for the production of such a casting core wherein the base substance is mixed with burnt sugar in aqueous or organic solution, pressed in molds, and baked at elevated temperature.

Abstract: A rapid method for dehydrating a water-sand mixture containing sodium or potassium silicate to produce a strongly bonded sand core is disclosed. The silicate is mixed in a water/silicate ratio of 1.45-3.22:1 and is limited to 0.25-3% of the weight of the mixture. The core box is semi-foraminous and partially transparent to micro-wave energy whereby generated vapor is reduced due to the heated inner surface of the core box (some degree of lossiness) and due to some escape through limited core-box openings. The controlled supersaturated environment about the core serves to prevent micro-porosity and surface defects when controlled micro-wave energy is used to heat cure the mixture. To promote resistance to humidity after curing, the mixture may contain 0.5% zinc oxide, chromic oxide, or aminoaldehyde.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as .[.sand-bound.]. .Iadd.sand, bound .Iaddend.together by a cured binder of a water soluble carbohydrate alone or mixed with a silicate is disclosed. The silicate is preferably an alkali earth metal silicate, preferably sodium silicate, and the carbohydrate is preferably a saccharide or starch. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, to rapidly disintegrate the core and remove it from the molded product.