Abstract: Method of making a cast-to-size mold for molding class A finishes on molded plastic articles including the steps of filling any pores in the molding surface with a conductive thermosetting resin and thereafter electroplating the surface.

Abstract: The mold formed of resin-bonded sand includes a vertical sprue in fluid flow communication with a horizontal chamber reservoir underlying the mold cavity defining the thin wall structure. The thin wall cavity portion is positioned about a common horizontal level above the reservoir. Vertical runners feed the metal from the horizontal reservoir up into the cavity. The number and location of these runners are such as to fill the cavity from several points of entry with uniform temperature metal before any solidification occurs.

Abstract: A process for producing multipiece complementary tooling castings is disclosed in which hollow internal surfaces are cast in a mold having a soft, low strength sand core piece to define such hollow portions and external surfaces are cast against hard, resin-bonded sand mold surfaces. The castings are removed from their respective molds while still warm and nested and pressed together to bring their working surfaces into conformance with each other. The result of this practice is a set of tool pieces that require little machining and display high accuracy in their as-cast condition.

Abstract: The resistance to wear-induced failures during forming operations of non-ferrous die tooling materials, such as epoxy-based and zinc-based materials, is improved by treating the surface of the die tooling. In one approach, the surface of an organic-containing or metallic substrate is coated with a silicon-modified organic materials and then implanted with ions of an inert gas to transform the organic material to a silicon carbide-rich layer. In the other, nitrogen ions are implanted into the surface of a zinc-based alloy.

Abstract: A lost foam metal casting process employs a chill member to reduce porosity within a region of a product casting. The chill is adhesively bonded to a fugitive pattern prior to jointly embedding within a particulate sand mold by fluidization, thereby conveniently and reliably arranging the chill and the pattern within the mold for casting.