Abstract: The invention relates to improvements of RCS and casting molds therefrom. The improvement resides that the resinous coating contains halogen-containing compound(s) which accelerate(s) carburizing of the resin during under heat subjected to the molten metal pouring step. Further, the resin coating comprises certain amount of pulverized metal capable of reacting under heat with separated halogen or halogen compound during the casting step and for avoiding ferrous element(s) in the castings and/or the mold(s).

Abstract: A composition containing furfuryl alcohol and an ester of a polyol and resin acid; and use thereof in foundry binders.

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: A binder composition for making molded products in conjunction with an aggregate includes in admixture a resin component comprising an organic solvent solution of a non-aqueous phenolic resin, a hardener component comprising a liquid polyisocyanate containing at least two isocyanate groups, the resin component and hardener component being curable by a curing agent, and an additional component comprising an oil-soluble phenolic resin dissolved in a drying oil and partially cross-linked therewith.

Abstract: A method and apparatus is disclosed for the high-speed production of foundry cores of the type in which a foundry aggregate is mixed with a curable binder, preferably an isocyanate or phenolic material, to form a core mixture which is carried within a hermetically sealed core box and is hardened by the introduction into the core box of a gaseous curing agent, preferably an amine. A positive displacement pump pumps a predetermined amount of liquid amine from a holding tank to a vaporizer where it is heated and completely vaporized. The vaporized curing agent is forced from the vaporizer by the introduction of an inert gas, preferably nitrogen, and the mixture of the inert gas and the vaporized curing agent is entrained in a low pressure air stream which carries it to the core box, thereby curing the core. After the core is cured, valves close to stop the flow of the low pressure air stream, the mixture of inert gas and curing agent to the low pressure air stream, and the flow of inert gas to the vaporizer.

Abstract: A method of mixing a gas and a vaporizable liquid to provide a gaseous mixture having a constant composition, regardless of change in rate of flow, except as hereinafter provided, comprising:(a) introducing a mixture comprising a gas and a vaporizable liquid in predetermined proportions into the tube side of a tube and shell heat exchanger at a flow rate sufficient to cause turbulent flow;(b) introducing a heating fluid into the shell side of the heat exchanger at a temperature sufficient to vaporize at least part of the vaporizable liquid whereby the vaporizable liquid separates into a vapor phase and a liquid phase; and(c) delivering the mixture of gas and vapor phase to a use point and recycling the liquid phase to a point at which it will be mixed with gas for introduction into step (a).

Abstract: A phenolic resin binder useful for hot coating foundry sand and comprising a mixture of a solid resol phenolic resin and a lubricant is provided in the form of beads or rods of diameter of about 0.5 to 7 mm and a length of about 0.5 to 30 mm. The beads or rods can be formed directly from a molten mixture of the components or the molten mixture can first be solidified and thereafter formed into such beads or rods. The process for the hot coating of foundry sand with the phenolic resin binder and the resulting foundry compositions, molds and cores are also disclosed.

Abstract: A resin-coated sand comprising:(a) particles of sand coated with from about 1% to about 8%, by weight of the sand, of a novolak resin consisting essentially of about 50% to about 98% of a phenol-formaldehyde novolak resin and about 2% to about 50% of a catechol-formaldehyde novolak resin; and,(b) a curing agent.The sands are especially useful for forming foundry cores and molds.

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

Abstract: Binders for foundry core sands and the like comprising furfuryl alcohol and an aromatic dialdehyde and optionally an aromatic alcohol.

Abstract: Binders for foundry core sand and other binder applications are produced from the tars resulting from production of bisphenol A.

Abstract: In the manufacture of moulds or mould cores, refractory sand, a resin binder and a catalyst are passed into a mixer to form a free-flowing mixture from which the moulds or mould cores are made. As the sand is fed into the mixer it is cooled by contact with an atmospheric gas in liquid or solid state or the cold vapor of such a gas so as to keep the temperature of the sand as it enters the mixer below that at which the resin cures. To enable the sand to be delivered below a chosen temperature from a quarry to a foundry where the sand is used, the sand after quarrying and drying is fluidized by air, an atmospheric gas in liquid or solid state being introduced into the fluidizing air so as to lower its temperature.

Abstract: A lubricant-containing binder for the dry hot coat foundry method comprising a solid resol type phenolic resin and a lubricant in an amount of about 0.5 to 10 percent by weight with respect to said phenolic resin.

Abstract: Ceramic cores suitable for use in investment casting operations are molded from a mixture containing comminuted refractory which includes partially dehydrated gypsum and a sublimable binder. When the sublimable binder has been sublimated from the molded core, it is soaked in water in order to hydrate the gypsum and cause it to set.