Abstract: A molding material mixture for producing casting molds for metal processing, particularly for non-ferrous metals, such as aluminum or magnesium, is intended to reduce problems such as metal-mold reaction and/or shrinkage porosity defect. The free-flowing refractory molding material in the molding material mixture is coated with a mixture of inorganic salts exhibiting a eutectic melting point in the range of about 400 C to about 500 C, particularly in the range of about 420 C to about 460 C. Preferably this coating occurs by contacting the inorganic salt mixture with the molding material mixture at a temperature between 500 C and 700 C, in a manner that maintains the free-flowing nature of the coated product. One mixture of inorganic salts that is used is a mixture consisting of, by weight: 74% potassium fluoroborate; 15% potassium chloride; and 12% potassium fluoride. This mixture has a eutectic melting point of 420 C.

Abstract: A “no-bake” process allows the forming of larger metal castings, by providing longer work times, in the range of about 45 to about 60 minutes. This is achieved using a liquid curing catalyst that is a pyridine, substituted at the second or third position with a moiety having a molecular weight in the range of about 30 to about 100 mwu. Examples of the liquid curing catalyst include 2-ethanolpyridine, 3-chloropyridine and 2-methoxypyridine. When combined with a two-part polyurethane binder precursor and a foundry aggregate, the liquid curing catalyst provides not only the longer work time, but also a strip time that is less than about 167% of the work time, as measured from the point of activating the polyurethane precursors by mixing them in the presence of the curing catalyst.

Abstract: A “cold box” process for forming a foundry shape by curing a binder in a foundry mix operates by sequentially introducing a first vaporous curing catalyst to a pattern containing the formed foundry mix, followed by introducing at least a second vaporous curing catalyst. By arranging the amounts of the respective vaporous curing catalysts and the contact times, as well as by using the less active vaporous curing catalyst first, the total amount of curing catalyst used to effect the cure is reduced. Carrier gas may be used with the respective vaporous curing catalysts. Typically, the vaporous curing catalysts are tertiary amines having between three and six carbon atoms.

Abstract: A “cold box” process for forming a foundry shape by curing a binder in a foundry mix operates by sequentially introducing a first vaporous curing catalyst to a pattern containing the formed foundry mix, followed by introducing at least a second vaporous curing catalyst. By arranging the amounts of the respective vaporous curing catalysts and the contact times, as well as by using the less active vaporous curing catalyst first, the total amount of curing catalyst used to effect the cure is reduced. Carrier gas may be used with the respective vaporous curing catalysts. Typically, the vaporous curing catalysts are tertiary amines having between three and six carbon atoms.

Abstract: A furfuryl alcohol derivative having the general formula X[—CH(OR)2]m is prepared by an aldehyde with a furfuryl alcohol in the presence of a copper catalyst. In this formula, X is an aliphatic, cycloaliphatic, aromatic or araliphatic group, R is a 2-furyl group, 2-(5-methylol) furyl group or a mixture thereof, and m is in the range of from 1 to 5. Reaction conditions allow a product having less than 25% free furfuryl alcohol, providing a composition that is suitable as a binder for foundry aggregate in producing a foundry mix.

Abstract: A composition comprising (a) an epoxy resin; and (b) a hydroperoxide composition comprising a t-butyl hydroperoxide solution that contains no more than 7 weight percent water, and use of the compositions to prepare foundry shapes, the foundry shapes prepared by the process, the use of the foundry shapes to prepare cast metal articles, and the cast metal articles prepared by the process.

Abstract: Disclosed is a foundry mix containing a sulfate and/or nitrate salt and its use to make foundry shapes by the warm-box, hot-box, no-bake, and cold-box process, the use of these foundry shapes to make metal castings, and the metal castings prepared by the process.

Abstract: The invention relates to microspheres coated with a phenolic novolak resin, a process for preparing them, and their use in making foundry shapes, e.g. molds, cores, sleeves, pouring cups, etc., which are used in casting metal parts.

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: Compositions comprising (1) a refractory and/or a binder, and (2) bis-cyclopentadienyl iron cyclopentadienyl manganese tricarbonyl, derivatives thereof, and mixtures thereof.

Abstract: A test casting is useful for predicting the severity of skin that will form when compacted graphite iron or ductile iron is cast using a selected foundry mix. The mold is made from the foundry mix and has a gating system with at least two ingates, and with a hollow cylindrical shape associated with each ingate. The hollow cylindrical shapes are substantially the same height, but the diameter of each varies by at least 20% from the diameter of any of the other cylindrical shapes. Molten metal poured into the gating system fills each of the hollow cylindrical shapes. When the metal cools and solidifies, a solid cylinder of the metal is produced in each hollow cylindrical shape. The solid metal cylinders, each with a distinct diameter, are cut and inspected to measure the skin formed thereon.

Abstract: This invention relates to filters made from a refractory material, preferably an insulating material, and chemical binder. The filters are used in the foundry industry to filter molten metal. The invention also relates to a process for preparing the filters.