Abstract: The present invention belongs to the field of the additives for molding sands used in the manufacture of casting molds and cores. More specifically, the present invention relates to an additive to prevent veining in the manufacture of metal parts, to a molding sand comprising said additive, to a core or mold prepared from said molding sand and to a metal part prepared by means of using one of said cores or molds.

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: Additives to foundry sand cores are provided for reducing or eliminating surface defects in metal castings. The additives general comprise an iron oxide component and a glass component which is preferably free of lithium oxide.

Abstract: Thermal expansion defects, i.e. veining, are reduced in iron, steel, and nonferrous castings by adding a lithia-containing material in a sufficient amount to the silica sand mold. Adjusting current formulations to maximize the use of lesser expensive raw materials and minimize the use of more expensive raw materials to lower the overall percentages of lithia/metallic oxide containing additives while still reducing or eliminating thermal expansion related defects in the metal casting process reduces the overall cost to manufacture the product.

Abstract: A molding material mixture for foundry purposes, comprising a mold sand, a sodium hydroxide solution, an alkali-silicate binding agent, and an additive suspension. The molding material mixture contains 0.1 to 10% by weight of sodium hydroxide solution with reference to the weight of the sand, 0.1 to 5% of binding agent with a solid matter percentage of 20 to 70%, and 0.1 to 3% by weight of the additive suspension. The additive suspension comprises 30 to 70% by volume of an amorphous, spherical SiO2 particles, which have a first grain size in the range of 1 to 5 micrometers, and a second grain size in the range of 0.01 to 0.05 micrometers.

Abstract: An additive to foundry sand molding and core aggregates is used to produce sand cores and molds comprising kyanite, spodumene, titanium dioxide, ilmenite and black iron oxide. The additive produces a sand-based foundry molding and core aggregate which resists the formation of some of the defects commonly associated with the production of castings produced by silica sand-based molding and core aggregates. In particular, the additive improves the quality of castings poured at temperatures higher than those of the pouring temperatures of molten iron, such as in steel castings, and in iron castings with “hot spots.

Abstract: Residual stress is reduced in light metal alloy articles, e.g. aluminum alloy articles, formed as castings against a sand casting mold body by incorporating a wax composition of suitable softening or melting temperature with the sand particles of the mold or core body. The hot cast metal heats adjoining surfaces of the mold body. As the cooling metal forms a solid shell, the surrounding sand particle and wax mixture are heated sufficiently to melt or soften the wax incorporated on or between sand particles. This softens portions of the rigid mold body that could otherwise restrain shrinking surfaces of the casting and produce unwanted stressed regions that are retained in the casting and must be removed by subsequent processing.

Abstract: Molding material mixture, molded part for foundry purposes and process of producing a molded part. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

Abstract: A sand casting foundry composition reduces thermal defects that cause veining in metal parts cast from sand casting foundry shapes formed from the foundry composition. A plurality of foundry sand grains are mixed substantially uniformly with a plurality of shale particles, and a curable binder coats the sand grains and the shale particles to establish core and mold foundry shapes used to cast the metal part. Anti-veining capability occurs because the shale particles include mineral components which have an inherent characteristic of crystal structural collapse upon exposure to metallurgical temperatures, and the crystal structural collapse yields space which is consumed by thermal expansion of the sand grains in the foundry composition. This compensatory effect avoids the creation of mechanical forces and stresses within the foundry shape that cause cracks and fissures in the foundry shape that lead to veining.

Abstract: The present invention is directed to processes for forming styrenic polymers, and their related end uses. In particular, the present invention is directed to processes for preparing patterns for use in metal castings.

Abstract: A ceramic mould slurry is disclosed for forming moulds and metal castings of improved surface quality. The slurry comprises a binder, a gelling agent, a first refractory material having a density of &rgr;1 and a mean particle size of &agr;1, and a second refractory material having a density of &rgr;2 and a mean particle size of &agr;2, wherein &rgr;1>&rgr;2 and &agr;1<&agr;2. The denser refractory material migrates downward through the slurry toward the upward-facing mould surface, thereby allowing formation of a smooth and accurate surface.

Abstract: A method for producing silica sand-based foundry shapes useful informing metal castings and for reducing veining defects in sand-based foundry shapes by providing a foundry sand, adding an anti-veining composition that comprises bentonite to the foundry sand to form a mineral composition, then adding a foundry resin to the mineral composition to form a sand-based foundry composition and shaping the sand-based foundry composition to form a desired pattern.

Abstract: The evaporative casting of molten metals has been shown to produce castings having smooth surfaces with significantly less signs of carbon deposits thereon by using an expandable vinyl aromatic polymer containing a bromine-attached aliphatic or aromatic flame retardant.

Abstract: A metal or metal alloy article is cast using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article. The metal or metal alloy article is then analyzed for inclusions by N-ray analysis.

Abstract: A mould is provided having a surface which defines a mould cavity, and the mould surface includes on at a least part thereof a compound comprising a nucleation agent. The mould is heated. A metal heated to a temperature 0-15.degree. C. above the liquidus temperature is poured into the heated mould cavity and the molten metal is solidified in the mould cavity.

Abstract: Thermal expansion defects, i.e. veining, are reduced in iron, steel, and nonferrous castings by adding a lithia-containing material in a sufficient amount to the silica sand mold to provide about 0.001% to about 2.0% of lithia. The addition of lithia is accomplished by adding lithium bearing minerals such as .alpha.-spodumene, amblygonite, montebrasite, petalite, lepidolite, zinnwaldite, eucryptite or lithium carbonate.

Abstract: The present invention pertains to a process for preparing ceramic shells as casting molds, wherein a) a pattern of a part to be cast, which pattern can be melted or dissolved out, is prepared, b) the pattern is dipped into a dip-coating composition of a slurry of a refractory material and a binder in order to form a wet coating on the pattern, c) a coarse refractory powder is sprinkled onto the coating, d) the coating is dried, and e) steps b), c) and d) are repeated until the mold shell has reached the desired thickness. A ceramic protective material is added to the dip-coating composition and/or to the coarse refractory powder. Carbon is introduced into the ceramic protective material during the preparation in the molten state. The carbon is able to chemically bind oxygen at the time of the cooling of the casting essentially at mold temperatures above the firing temperature of the casting mold and is thus able to prevent skin decarburization and surface defects in carbon-containing steels.

Abstract: The disclosure concerns a process of producing expendable coated cores for castings comprising mixing sand with a resinous binder, polymerizing the binder, and then washing the resulting bound sand core with an organic solvent to remove unpolymerized residuals from the surface of the core before applying a coating to the core.

Abstract: An improved composition and process for preparing plaster molds used in casting nonferrous metals is provided wherein plaster molds are prepared from particulate calcium sulfate molding plaster admixed with insoluble calcium sulfate anhydrite whisker fibers.

Abstract: A process is disclosed for the continuous casting of a lithium-containing alloy including casting the alloy through a mold and applying alpha-olefin oligomer to the mold. In one aspect, the process includes a lubricant containing alpha-olefin oligomer, preferably having a viscosity in the range of about 1-3 cs at 450.degree. F. In another aspect, the process includes a lubricant containing less than the varnish-film forming amount of fatty ester, fatty acid, or fatty alcohol.