Abstract: A method for inorganic binder casting, comprising: selecting a Shape-Forming Material based on pre-determined manufacturing and shape characteristics, selecting a casting shape based on pre-determined design characteristics, and forming the Shape-Forming Material into a mold. The mold is coated with an inorganic binder solution at a pre-defined weight ratio and is dehydrated the Shape-Forming Material. The method further comprises pouring a hot liquid metal into the mold and allowing said hot liquid metal to cool to form a molded part. The Shape-Forming Material may be washed from said molded part with a solvent, the inorganic material and Shape-Forming Material reclaimed, reused, and the Shape-Forming Material reformed to a mold. The method further comprises recreating a liquid inorganic binder solution using the reclaimed inorganic material and recoating the Shape-Forming Material with the reclaimed inorganic binder solution.

Abstract: A method of forming a headrest assembly includes providing a first mold that encloses a first cavity in a closed condition. A support is positioned in the first cavity. A first material is blow molded into the first cavity and around a portion of the support to form a core part. The core part and support are removed from the first mold. A second mold encloses a second cavity in a closed condition. The core part and the support are placed into the second mold in an open condition. A fluid is injected into the core part through the support. The second mold is converted to the closed condition. A second material is injection molded into the second cavity and around the core part to form an outer shell around the core part. A fluid is withdrawn from the core part through the support.

Abstract: A scale inhibitor includes a granular material composed of a particle containing a plurality of polyphosphate salts, the granular material has an asymmetric particle diameter distribution, and a particle diameter with a maximum frequency is smaller than an average particle diameter of the granular material.

Abstract: The invention relates to molding material mixtures containing barium sulfate in combination with refractory basic molding materials and a waterglass-based binder system for producing casting molds and cores for the foundry industry in order to obtain cast pieces, in particular aluminum ones, which have an improved cast surface.

Abstract: The invention relates to a method for producing core sand and/or molding sand for casting purposes. A granular mineral mold base material is mixed with at least one inorganic binder and additionally an inorganic expanding additive. Water glass may be used as the binder and expandable graphite may be used as the expandable additive.

Abstract: By mixing, stirring and kneading, with water glass (11) as a binder, sand (7), a surfactant (9), and water (10), foamed sand (S) is generated. The foamed sand (S) is packed in a cavity of a metallic mold and solidified to form a sand mold. By using the sand mold, aluminum is cast. By using water glass that is an inorganic binder, during casting, harmful gas and odor are not generated. Further, when a molar ratio n of water glass (Na2O nSiO2 mH2O) is adjusted in the range of 0.65 to 1.30, a quantity of water (H2O) generated by heating water glass with a high temperature melt during casting can be suppressed. Thereby, hydrogen gas (H2) according to a reaction between water (H2O) and aluminum (Al) can be suppressed from being generated and casting quality can be improved.

Abstract: Cores that are inserted into the mold during the die casting of workpieces from metal in order to keep the cavities provided in the workpieces free during the filling of the molds with the melt have to meet demanding requirements with regard to the dimensional stability and suitability thereof for removal from the cavities. Therefore, salt-based cores which can be produced by molding and compressing a core material mixture are provided according to the invention, the core materials thereof being selected from at least one salt, at least one binder system comprising a combination of binder/binding agent and optionally auxiliary substances such as additives, fillers, wetting agents and catalysts, wherein the salt, the binder system and the optionally used auxiliary substances of the core material mixture are inorganic, and these core materials are soluble with water as the solvent.

Abstract: A binder for the production of sand cores and/or molds for foundries that includes sand mixed with an alkyl silicate, preferably tetraethyl silicate; an aqueous solution of an alkali metal silicate, preferably sodium silicate, which solution also contains an alkali metal hydroxide, preferably sodium hydroxide, where the ingredients in such mixture are preferably in given percentage ranges and are mixed until the sand shows a homogeneous aspect and constitution. Also method of manufacturing sand molds for foundries that includes mixing foundry sand with the aforementioned binder, blowing the sand mixed with the binder, having still between 0.5% to 2.5% of water, into a cold box by means of air that is at room temperature, and once the cold box mold has been filled with the sand, passing a hot air current through the sand to dry and harden the binder thus obtaining the foundry mold.

Abstract: An yttria-based slurry composition comprising yttria, an aqueous silica binder system or an aqueous ammonium zirconium carbonate binder system and a fluorine compound, which is selected from ammonium fluoride, ammonium hydrogen difluoride, sodium fluoride, potassium fluoride, sodium hydrogen difluoride and/or potassium hydrogen difluoride and a method of stabilizing an yttria-based slurry composition comprising yttria and an aqueous silica binder system or an aqueous ammonium zirconium carbonate binder system which method comprises treating the composition, preferably treating the binder system, with a fluorine compound which is selected as indicated above.

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: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: A method of forming a porous ceramic body includes providing a moldable material that includes a ceramic material, a binder material and a filler material comprising carbon nanotubes. The moldable material is then formed into a desired shape of a green ceramic body. The green ceramic body is then thermally treated to remove the binder material and the carbon nanotubes. The thermally treated green ceramic body is then sintered to form the porous ceramic body with elongated nanopores.

Abstract: A foundry mix composition including silica sand, unexpanded perlite ore, and a binder material. The unexpanded perlite ore is present in the foundry mix composition from about 0.5 wt % to about 5.0 wt %. Exemplary embodiments of the present invention also contemplate methods of making a sand mold/core from such a foundry mix composition.

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: A sand core is prepared for use in defining a surface of a cast metal article. The core is formed of sand particles bonded with a polyurethane resin, preferably a polyol moiety-containing polyurethane resin. An alkali metal hydroxide, and optionally a glycol, is mixed with precursors of the polyurethane before they are mixed with sand particles for molding and curing the core. The hydroxide and glycol may be encapsulated to prevent interference with core molding. The hydroxide and glycol is distributed in the polyurethane binder resin and used to reduce the decomposition temperature of the core binder during casting. This practice is particularly useful in removing core sand from castings of light metal, lower casting temperature metal alloys.

Abstract: The invention relates to a mould material mixture for producing casting moulds for metal processing, a process for producing casting moulds, casting moulds which can be obtained by the process and their use. The production of the casting moulds is carried out using a refractory base moulding material and a binder based on water glass. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminium oxide, titanium oxide and zinc oxide is added to the binder, with particular preference being given to using synthetic amorphous silicon dioxide. The mould material mixture contains a surface-active material as further significant constituent. The addition of the surface-active material enables the flowability of the mould material mixture to be improved, which makes it possible to produce casting moulds having a very complicated geometry.

Abstract: The invention relates to a molding mixture for producing casting molds for metalworking, a process for producing casting molds, casting molds obtained by the process and also their use. To produce the casting molds, a refractory mold raw material and a binder based on water glass are used. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminum oxide, titanium oxide and zinc oxide is added to the binder, particular preference being given to using synthetic amorphous silicon dioxide. The molding mixture contains a phosphate as essential constituent. The use of phosphate can improve the mechanical strength of casting molds at high thermal load.

Abstract: The invention relates to a molding material mixture for production of casting molds for metalworking, to a process for producing casting molds, to casting molds obtained by the process and to the use thereof. For the production of casting molds, a refractory molding matrix and a waterglass-based binder are used. The binder has been admixed with a proportion of a particulate metal oxide which is selected from the group of silicon dioxide, aluminum oxide, titanium oxide and zinc oxide, particular preference being given to using synthetic amorphous silicon dioxide. The molding material mixture comprises a carbohydrate as a further essential constituent. The addition of carbohydrates allows the mechanical strength of casting molds and the surface quality of the casting to be improved.

Abstract: The invention relates to a moulding mixture for producing casting moulds for metalworking, a process for producing casting moulds, casting moulds obtained by the process and also their use. To produce the casting moulds, a refractory mould raw material and a binder based on water glass are used. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminium oxide, titanium oxide and zinc oxide is added to the binder. Particular preference is given to using synthetic amorphous silicon dioxide as metal 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 cost-effective starch/water-based binder composition and related method for forming silica sand cores and molds for foundries, wherein the sand grains are pre-coated with starch having additives making the coated sand effective for blowing said cores and molds. One or more additives are included with the starch; preferably sodium tripolyphosphate and silicon or Silres BS16. The preferred starch is a tapioca starch. The binder of the invention is highly competitive due to its low cost and effectiveness for forming silica-sand cores and molds, being particularly effective for use in aluminum foundries for the automotive industry.

Abstract: The molding material or molding part for foundry purposes, comprising 1-10% of binding agent based on alkali silicate, an aggregate containing 1-10 percent by weight of amorphous silicon dioxide, remainder quartz sand with a grain size range of 0.01 to 5 mm, and to a process of producing a molding material and molding parts. 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.

Abstract: A foundry core or mold comprised of sand admixed with an inorganic binder is hardened by passing a treatment gas through a first heater and heating it therein to a relatively low temperature and, in a first hardening stage, passing the gas at the low temperature from the first heater through a second heater and heating it therein to a relatively high temperature and thereafter passing the gas at the high temperature from the second heater to and through a core box holding the core or mold to harden same. Thereafter in an after-treatment stage passing the gas at the low temperature from the first heater substantially directly to and through the core box holding the core or mold to after treat same.

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 casting mold which is molded by heating mulled sand including a mixture of refractory molding sand particles, an inorganic water soluble binder and water, wherein the inorganic water soluble binder is made of a combination of a sulfate compound such as magnesium sulfate heptahydrate and a borate compound such as sodium tetraborate decahydrate. The casting mold is formed by baking the mulled sand in such a manner that at least part of the sulfate compound retains water of crystallization therein and the borate compound is once fused and then cured.

Abstract: An improved phosphate-type refractory investment material and method for making solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, a water soluble acidic constituent, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or acidic constituent can be combined with the refractory powder at the time of mixing with water.

Abstract: This invention relates to polyisocyanate compositions comprising (a) polyisocyanate, and (b) a monomeric carbodiimide. The polyisocyanate compositions are particularly useful in phenolic urethane foundry binder systems. The invention also relates to foundry mixes prepared with (a) a phenolic urethane binder containing the polyisocyanate composition, and (b) a foundry aggregate, as well as foundry shapes prepared by the no-bake and cold-box processes, which are used to make metal castings.

Abstract: A foundry sand binder formed by reacting a smectite clay containing exchangeable calcium ions with an acid to enhance the ability of the clay to bind sand in forming a metal casting sand mold. The acid-treated clay is an excellent sand binder for metal casting molds and produces cast metal parts having improved surface finish with the elimination or substantial reduction in carbonaceous, e.g., coal, foundry sand additive, while reducing VOC emissions from the foundry.

Abstract: A foundry sand binder formed by reacting a smectite clay containing exchangeable calcium ions with an acid to enhance the ability of the clay to bind sand in forming a metal casting sand mold. The acid-treated clay is an excellent sand binder for metal casting molds and produces cast metal parts having improved surface finish with the elimination or substantial reduction in carbonaceous, e.g., coal, foundry sand additive, while reducing VOC emissions from the foundry.

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: An improved phosphate-type refractory investment material and method for marking solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, one or more water soluble organic acids, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or organic acid can be combined with the refractory powder at the time of mixing with water.

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 molding body for the production of a cavity in a metal casting such as a piston of an internal combustion engine, the molding body being composed of calcium silicate fibers held together in a solid form by a soluble binding agent.

Abstract: A sand casting facing composition comprises a dry mixture of about 77% fine sand, 5% binder, 6% green system sand and 12% burned system sand. The fine sand is mulled with 5.8% wt/wt oil per total dry mixture and catalyst at about 0.5% wt/wt. Preferably, fine sand and binder are mulled with oil, catalyst, green system sand and screened burned system. The mulled mixture is rested, mulled again and rested again before use as facing sand for achieving accurate reproduction of the pattern's fine detail. A method of preparing the mold and preserving fine detail comprises riddling the pattern with a thin layer of the facing sand composition, compacting, riddling with dry system sand and riddling with system sand before compacting about the periphery of the pattern. Final layers of system sand are applied and compacted over the entire pattern.

Abstract: A process for forming a mould or a core for casting molten metal by machining (eg cutting or drilling) to the desired shape a bonded particulate refractory material wherein the shear strength of the refractory particles is less than the shear strength of the bonds between the particles. The preferred particulate is aluminosilicate microspherers (eg “flyash floaters”) and the binder is preferably based on silica (eg fumed silica/sodium hydroxide). The bonded particulate material is easily machined to form accurately dimensioned moulds or parts thereof.

Abstract: Coating foundry sand with a thin layer of an oxidation-promoting catalyst. Preferred catalysts comprise ferric and cupric oxides. The catalysts promote the oxidation of any polymeric binder or residues admixed with the sand. The sand is coated by wetting the grains with a solution of a catalyst precursor, drying the sand and baking the sand in air to convert the precursor to the catalyst.

Abstract: A foundry binder is obtainable by surface modification of a) colloidal inorganic particles with b) one or more silanes of the general formula (I) Rx—Si—A4−x  (I) where the radicals A are identical or different and are hydroxyl groups or groups which can be removed hydrolytically, except methoxy, the radicals R are identical or different and are groups which cannot be removed hydrolytically and x is 0, 1, 2 or 3, where x≧1 in at least 50 mol % of the silanes; under the conditions of the sol-gel process with a below-stoichiometric amount of water, based on the hydrolysable groups which are present, with formation of a nanocomposite sol, and further hydrolysis and condensation of the nanocomposite sol, if desired, before it is brought into contact with the foundry sand.

Abstract: A foundry exothermic assembly is formed by mixing hollow glass microspheres and an inorganic or organic binder with matrix forming constituents including an oxidizable metal, an oxidizing agent, a foundry refractory aggregate and, optionally, a pro-oxidant, and shaping and curing the mixture. The hollow glass microspheres are dispersed and embedded in the assembly matrix.

Abstract: The invention relates to a method for the production of core preforms for foundry in which a) a mixture of inorganic, refractory foundry sand and a water glass-based inorganic binder is produced, b) the mixture is poured into a heated core box c) the water contained in the mixture is withdrawn by a physical method and d) the core preform is taken out of the core box. The process is characterized by the fact that e) the heated core box is subjected to a depression during filling f) the temperature/dwell time is adjusted after the closing of the core box so that a dimensionally stable and good bearing shell is formed on the edge of the preform g) the preform is immediately removed after opening of the core box and, under the effect of microwaves, is subjected to a complete drying.

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: 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: 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 water-dispersible mold for making a casting comprises a water-insoluble particulate material, such as foundry sand, a binder which includes polyphosphate chains and/or borate ions, and at least one fine particulate refractory material such as one selected from finely particulate silica, silicates and aluminosilicates. The incorporation of the fine particulate refractory results in improvements in the strength and related properties of the mold, when hot, prior to casting.

Abstract: This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate components: (A) mono-aluminum phosphate in an aqueous solution containing specified phosphoric acids, and (B) magnesium oxide; and certain specified zinc compounds in either the Component A, Component B or both. The components of the binder system react when they are mixed with a foundry aggregate to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

Abstract: This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate Part A and Part B components: (A) an aqueous solution of specified phosphoric acids, and (B) a mixture comprising (1) an iron oxide selected from the group consisting of (a) ferrous oxide, (b) ferroferric oxide, and (c) mixtures thereof and (2) magnesium oxide. The binder systems are used to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

Abstract: Molten metal is cast into a mold cavity formed of sand held in a predetermined mold configuration by a binder comprising a plurality of sodium bentonite clays. A blend of two or more sodium bentonite clays obtained from different areas as a foundry sand binder synergistically and unexpectedly improves the foundry sand used as a mold cavity for casting metal objects by unexpectedly improving one or more of the following foundry sand properties beyond the level of either of the blended sodium bentonites alone: green compressive strength; hot compressive strength; dry compressive strength; wet tensile strength; flowability; surface finish; activation speed and shakeout.

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: An improved refractory investment material for use in making refractory molds is provided. The material comprises an investment powder including a binder, a refractory selected from calcined mullite and pyrophyllite, additives for controlling setting and about 0.01 to about 0.04% by weight of a sulfate salt. The investment powder is formed into a slurry with a solution of a water based colloidal silica in an amount providing about 3% to about 6% by weight colloidal silica based on the weight of the water and a chloride salt in an amount of at least about 0.5% by weight based on the weight of said investment powder.