Abstract: A method of preparing foundry shapes, e.g. molds and cores, by mixing a foundry aggregate with a foundry binder, shaping the mixture in a pattern, curing the mixture, and removing the mixture from the pattern. The foundry binder is a phenolic urethane binder that utilizes a phenolic resin prepared by reacting a phenol, an aldehyde, bisphenol-A-tar, and a divalent metal catalyst.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy novolac resin; (b) preferably a bisphenol F; (c) an acrylate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.

Abstract: This invention relates to a polyurethane-forming no-bake foundry binder comprising a (a) polyol component comprising (1) a polyol selected from the group consisting of polyether polyols, aminopolyols, polyester polyols, and mixtures thereof, and (2) a hydrogenfluoride of aminosilanol, (b) a polyisocyanate component, and optionally (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.

Abstract: This invention relates to a polyurethane-forming no-bake foundry binder comprising a (a) polyether polyol component comprising (1) a polyether polyol, (2) hydrofluoric acid, and (3) an aminoalkoxysilane, (b) a polyisocyanate component, (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.

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 foamable, ashless investment casting replica composition comprises a foaming compound and a polymer. The foaming compound contains an ammonium salt of a polycarboxylic acid, at least one suspending agent, and may contain at least one carrier resin. During the molding of the replica, the foamed composition avoids shrinkage and thereby maintains its intended shape. In addition, thermal decomposition of the foaming compound yields only volatile gases and therefore leaves no ashes on the interior surface of the ceramic mold.

Abstract: The invention provides methods for producing semi-permanent casting tooling, as well as semi-permanent casting tooling apparatus. Casting tooling including a blend of high char resin and refractory powder; casting tooling prepared from a blend of sol-gel ceramic precursor and refractory powder; and a preform including a leachable core as well as methods for their production are provided. The casting tooling of the invention can be used in casting processes including die casting, permanent mold casting and pressure infiltration casting. Also provided is an investment mold casting technique compatible with a pressure infiltration process.

Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat.

Abstract: The invention relates to amine modified polyisocyanates having urea linkages and their use in foundry binder systems. The modified polyisocyanates are prepared by reacting a polyisocyanate with an aliphatic primary or secondary amine. These amine modified polyisocyanates, along with a phenolic resole resin, are added to a foundry aggregate to form a foundry mix which is shaped and cured with an amine curing catalyst.

Abstract: An implantable article having on at least a portion of its exterior surface an integral, as-cast macrotextured surface with macropores having undercut edge profiles. A complex macrotextured surface is provided by forming a casting mold so that the mold has complementary macrotextured surface features formed by three-dimensional printing techniques, and casting a molten metal within or in contact with the casting mold to form the implantable article. In a hybrid process, one or more printed surface mold plates are attached by hand, or in a wax molding process, to a simpler wax preform, and an investment is made in which the plates are incorporated into the investment mold. A casting is then made, with each preform yielding one cast article, and the incorporated plate forming the desired surface macrotexture on a region of the east article.

Abstract: The invention relates to the use of tripotassium citrate monohydrate and other alkali metal salts of polybasic acid as bench life extenders in heat curable hot box foundry mixtures comprising sand, thermosetting binder resin, and a latent acid catalyst composition. In one embodiment, the thermosetting binder resin is a phenolic resole resin modified with urea formaldehyde resin. In another embodiment, the thermosetting binder resin is a furfuryl alcohol resin modified with urea formaldehyde resin.

Abstract: A submarine buoyant cable antenna having positive buoyancy comprising a cunications antenna electronics package encased in a polymer composition, the polymer composition comprising from about 80 percent to about 85 percent by weight of a room temperature curable thermosetting polymer having a viscosity, before curing, in the range of from about 700 to about 900 centipoise, and from about 15 percent to about 20 percent by weight of microballoons of a size ranging from about 20 to about 100 microns in diameter, the specific gravity of the composition being in the range of from about 0.51 to about 0.65 grams per cubic centimeter to provide the positive buoyancy.

Abstract: A resin composition for investment casting contains a moderate boiling temperature liquid inert diluent, having a boiling point in the range of about 200.degree. to 300.degree. C. The presence of the liquid inert diluent allows the resin to be used as a pattern, or model, in investment casting by preventing breaking of the mold during burnout of the resin. Any of the conventional resins suitable for stereolithography may be employed in the practice of the invention. To the resin is added a moderate boiling point solvent in the amount of about 5 to 30 wt %. Use of the moderate boiling point solvent in conjunction with the resin allows the pattern to shrink and crack at moderate temperature before final burnout. The shrinkage occurs faster and at a lower temperature as compared to the prior art.

Abstract: A method and apparatus are shown for improving the collapsibility characteristics of foundry cores and molds after being contacted with a heated, cast product. The foundry cores/molds are contacted with an oxidant impregnating liquid after being formed and prior to contact with the heated, cast product. The heat of the cast product is sufficient to sustain combustion of the chemical coating of the sand particles making up the cores/molds to facilitate removal with a minimum of force after casting.

Abstract: This invention relates to a process for the preparation of foundry cores and molds by mixing a filler and a casting resin mixture and then curing the resultant mixture. The casting resin mixture is made from (a) 25 to 99.9% of at least one organic polyisocyanate, (b) 0.1 to 50% of at least one organic compound containing at least two epoxide groups, and (c) up to 50% of a polyhydroxyl compound, the quantities being based on the total quantity of resin.

Abstract: The present invention provides methods for treating reclaimed sand obtained from dismantled foundry molds and cores which contain a cured binder derived from an ester cured alkaline phenolic resin. Treatment of the reclaimed sand with a silane solution, particularly an aqueous solution, enhances the tensile strengths of foundry molds and cores produced therefrom beyond those obtained with untreated reclaimed sand. Methods for producing foundry cores and molds which incorporate such a treatment process are also provided by this invention as are raw batch formulations.

Abstract: Sand cores are removed from metal or plastic coatings by exposing the cores to a humid atmosphere for a sufficient time to weaken the binder of the sand cores. The sand is then shaken from the casting. Metal or plastic castings with hollow passages are produced by forming a casting around the sand core bound with a suitable binder followed by exposing the casting and sand core to a humid atmosphere and then shaking the sand from the casting.

Abstract: The invention relates to foundary moulding compositions useful for producing moulds for the manufacture of metal castings wherein the moulds are capable of giving castings with good surface finish without the need for conventional separate blacking applications. A foundary moulding composition of the invention comprises refractory material such as sand, alkali phenol-formaldehyde resole resin solution, carbonifiable material such as styrenated phenol, and an effective amount of an organic ester for hardening the composition. In another embodiment, the invention is a binder composition comprising alkali phenol-formaldehyde resole resin solution and carbonifiable material capable of being hardened by reaction with organic ester. In another embodiment, the invention is a curing additive for a foundry binder comprising carbonifiable material and liquid ester such as gamma-butyrolactone, and the like.

Abstract: This invention relates to a no-bake process for preparing foundry shapes which utilizes polyurethane-forming binders containing selected polyester polyols. The resulting foundry shapes are particularly useful in preparing castings from low melting metals.

Abstract: A binder composition which comprises an aqueous alkaline solution of a phenolic resole resin and an additive wherein the additive is phenoxyethanol or a derivative of phenoxyethanol.

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: 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: An adhesive paste for adhering two or more objects, a composite assembly comprising two or more elements bonded by such paste, and a process for preparing cast metal articles using such paste are provided. The adhesive paste comprises an aqueous solution of a specific alkali phenol-formaldehyde resin and a hardener for that resin, wherein the paste prepared by mixing the resin and hardener has a viscosity, as mixed, in the range of about 1,000 cps to about 15,000 cps. The composite assembly comprises at least two separate elements bonded by the adhesive paste of the invention. The process uses a mold or core assembly having at least two separate elements.

Abstract: Certain carboxylic acids are used in polyurethane-forming binder compositions to extend the bench life of such compositions. The binder compositions are particularly useful for preparing sand castings used for making foundry parts.

Abstract: An alkoxy-modified phenolic resole resin providing an improved binder for foundry cores and molds. The resin has predominantly ortho-ortho benzylic ether bridges joining the phenolic nuclei in the resin and at least one alkoxymethylene group for every 20 phenolic nuclei.

Abstract: The subject invention relates to a hot box process for forming foundry shapes. The foundry shapes are formed with a mixture of an aggregate and certain aqueous basic solutions of phenolic resole resins which act as binders. The use of these binders results in foundry shapes which are cured by heating at elevated temperatures without requiring an acid-generating curing catalyst.

Abstract: There is disclosed a mould for lost pattern casting. The shell of the mould comprises a graphite coating and a hydrocarbon binder. The binder comprises a polyol with at least three alcohol functions such as pentaerithritol.

Abstract: Esters of alkoxy acids, particularly those of 3-alkoxypropionic acids are used as part or all of the polar solvent in solvent systems for binder compositions containing phenolic resins and polyisocyanates.

Abstract: Molding material composed of casting sand coated with a thermosetting resin and hydrous magnesium silicate clay mineral which may be impregnated with an acid and/or coated with a thermosetting resin, and a shell mold produced from the molding material. This material and mold minimize generation of smoke and irritating gases at the time of mold making and casting.

Abstract: The present invention provides a binder for foundry sand which comprises a hydrolyzate of a butadiene/maleic anhydride copolymer, a neutralized or a partially neutralized substance of the hydrolyzate, a modified substance prepared by modifying the hydrolyzate with a basic organic compound, or a mixture thereof.

Abstract: A high temperature mold assembly particularly adapted for thermit reaction welding, and mold components and mold compositions therefor, based on a mined aggregate containing carbon and silica and thermosetting, non-hygroscopic resinous binder.

Abstract: The addition of the metal drier to the phenolic urethane binder enhances the breakdown of the binder when the system is subjected to the elevated temperatures caused by pouring the molten metal into the mold and enhances the subsequent shake out of the sand from the cores and molds.

Abstract: A binder is used for binding foundry sand to form a mold and a core for casting, and consists of a condensation-reactive first compound (resin) having at least one methylol group in a molecule, amounting to 100 parts by weight. An additive component is added to the resin to improve the strength and the sand removability of the mold and the core while improving the production yield of the mold and the core. The additive component includes at least one of calcium hydroxide and barium hydroxide in particle form. The particle surface of the at least one of calcium hydroxide and barium hydroxide is coated with a second compound having a melting point not lower than 50.degree. C. and a boiling point ranging from 250.degree. to 400.degree. C., the second compound ranging from 0.5 to 35 parts by weight.

Abstract: A binder composition containing a phenolic resin, a polyisocyanate, a phosphorus based acid and optionally an acid halide and/or a base, and methods of making and using the same.

Abstract: A binder composition containing a phenolic resin in an organic solvent, a polyisocyanate, wherein said organic solvent is substantially free from polar solvents, and methods of making and using the same.

Abstract: A refractory for use in casting of molten metal which essentially comprises refractory material comprising corundum and monoclinic zirconia as principal mineral phase and including Al.sub.2 O.sub.3 and ZrO.sub.2, silicon-containing powder and carbon-containing powder and which optionally includes first additional refractory material comprising mullite, baddellite and corundum as principal mineral phase and including Al.sub.2 O.sub.3, ZrO.sub.2 and SiO.sub.2, one or more second additional refractory materials and/or alumina.

Abstract: A method of accelerating the breakdown of phenolic resin bonded cores by means of adding a basic salt of alkali metals in powder form to phenolic resin coated sand is disclosed. The basic salt is selected from the group consisting of alkali metal carbonates, bicarbonates and organic acid salts, and mixtures thereof, and is microcapsulated with plastic.

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: A polyisocyanate component useful in polyurethane binder compositions is provided. The polyisocyanate component incorporates organic phosphorous compounds that impart longer bench life to the binders making them more useful for prepraring moldable compositions such as foundry cores and molds.

Abstract: Foundry sand grains coated with a binder composition which comprises 100 wt. parts of methylolmelamine or alkylated methylolmelamine and 5 to 100 wt. parts of a water-soluble organic compound having a hydroxyl group. The sand grains coated with the composition are effective in a low-temperature foundry, especially for forming a core in an aluminum-alloy foundry.

Abstract: A method and composition for forming a dry free-flowing particulate solid is disclosed which utilizes a novel binder system for bonding particles of carbon, sand and/or other solid aggregate materials. The solid, non-sticky binder system comprises furfural, a phenolic novolak resin, and a liquid amine having free hydrogens on the amine nitrogen which is capable of reacting with furfural. This system is capable of adhering to such particles while retaining the free-flowing characteristics of the particles. The method involves mixing the aggregate with the furfural-phenolic novolak resin until tacky, and adding methylene chloride to the tacky mix while continuing to mix. The mix is cooled by the rapid evaporation of the methylene chloride and quickly forms the free-flowing characteristics of a powder or granulated material.

Abstract: The process for preparing a resin-coated casting sand by coating sand grains with a binder comprising a liquid phenolic resin component and a polyisocyanate component, the improvement of which comprises coating sand grains with an organic solvent prior to coating of the sand grains with the binder, thereby prolonging the bench life of the resulting resin-coated casting sand and enhancing the strength of a casting mold prepared from this resin-coated casting sand. Furthermore, this process enables the utilization of sand of a low grade or reclaimed sand having a high alkaline component content, that has not been used in the conventional process, and the supply of an excellent resin-coated casting sand which is capable of providing a casting mold having a high strength and has a long bench life.

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: A catalyst composition and a foundry method for the rapid production of cured, high tensile strength foundry sand shapes from a foundry mixture containing a furan-based binder and polyvinyl alcohol are disclosed. The polyvinyl alcohol is incorporated into a special thermally-activated strong acid salt catalyst prior to admixture of the catalyst composition with the sand and a furan-based binder. The sand-binder-catalyst composition is then shaped and the sand shapes are heated, resulting in exceptionally high tensile strengths in short times. In foundry methods involving in situ heating of the sand shape within the pattern, clean release (without sticking) from the pattern after cure is achieved.

Abstract: A hydrogen peroxide system or composition for use in resin polymerization comprises a mixture of a major part of concentrated (70%) hydrogen peroxide admixed with minor amounts of phosphoric acid, a halo-substituted acid, such as hydrochloric acid, fluoboric acid or hydrofluoric acid, and sodium perborate. The peroxide composition is characterized by its storage stability, resistance to detonation, zero flammability, ease of handling and improved catalytic properties in the polymerization of certain resins. This hydrogen peroxide composition is compatible for use with a variety of organic peroxides which have been used for resin condensation polymerization and may be used in conjunction therewith. This hydrogen peroxide composition may be safely mixed with resins and resin prepolymers on the sand prior to use.

Abstract: No Bake foundry cores and molds for casting metals are prepared by using a binder comprising a polyol generally derived from alkoxylating an amine compound and a polyisocyanate. The binder is especially useful for casting non-ferrous metals, for example, the casting of aluminum, magnesium and other light weight metals. The cores and molds produced for casting aluminum and other light weight metals exhibit excellent shakeout while retaining other desirable core and mold properties. In addition the binders of this invention would have been observed to have an autocatalytic nature.

Abstract: An improved polyurethane binder system is provided which incorporates organic phosphorous compounds that impart longer bench life to the binders making them more useful for preparing moldable compositions such as foundry cores and molds.

Abstract: Binders for foundry core sand and other binder applications are produced from acetophenone.

Abstract: A fast curing shell molding composition having the tensile strength of a conventional novolac resin when cured contains a fast curing novolac resin comprising a methylene chained polyphenylol wherein a major portion of the methylene linkages are coupled to adjacent phenylol groups of the o-o' and p-p' position, wherein at least about 19% of the methylene linkages are coupled to adjacent phenylol groups at the o-o' portions, and wherein at least about 3% of the total number of methylene linkages are coupled to adjacent phenylol groups at the p-p' positions. The shell molding composition is produced from the fast curing novolac resin by uniformly coating refractory granules with the fast curing resin. The fast curing novolac resin can be prepared by blending a conventional novolac resin with a novolac resin having a large proportion of methylene linkages coupled to adjacent phenylol groups at the o-o' position.

Abstract: In-situ formation of metal sulfonate curing agents for foundry sand binders.