Abstract: A volumetric builder machine for enhanced fabrication of sand-casting molds, cores and/or 3-dimensional shapes in printed layers within a build box. A bi-directional layer builder assembly passes back-and-forth over the build box, and with each pass deposits an even layer of loose sand while printing a water-based binder agent according to a pattern representing the mold and/or core to be formed. Heater banks carried on the traveling layer builder assembly accelerate the binder drying module process. The build box has a build plate that is incrementally lowered by a lift unit to accommodate each new sand layer. A strategic heating system preheats the sand, heats the build plate, and directs heat to the sand layer after it has been printed with binder. A ventilation system removes vapors driven from the binder. A sand filling station periodically refills the layer builder assembly. A cleaning station removes binder residue from the printheads.

Abstract: A tool-less method for making molds, cores, and temporary tools includes the steps of providing a volumetric build system, making a CAD model of a three-dimensional object, selecting a build material including an untreated sand, selecting a binder comprising a polymeric carbohydrate, and applying, by the volumetric build system, the binder onto the build material to three dimensionally print the object, wherein the object is adapted for being a mold, a core, or a temporary tool.

Abstract: A thermally-activated exhaust treatment device, such as a catalytic converter, for vehicles includes a core having an inner housing and a catalytic material. A jacket includes an outer housing enclosing the inner housing, but characteristically not contacting the inner housing. The inner and outer housings include walls forming a vacuum-drawn sealed insulation cavity around the inner housing. A temperature-activated variable insulator device is positioned within the outer housing and includes a hydrogen source and controls for controlling the variable insulator device. A vacuum-maintenance device is incorporated into the insulation cavity, and includes a small container, getter material positioned in the container, and a porous member allowing gas in the insulation cavity to communicate with the getter material. A multi-layered radiation shield is positioned in the vacuum space and is loosely coupled to the inner housing. A vacuum detector includes a visible indicator of the vacuum in the insulation cavity.

Abstract: A thermally-activated exhaust treatment device, such as a catalytic converter (20); for vehicles includes a core having an inner housing (21) and a catalytic material (27, 27?). A jacket includes an outer housing (22) enclosing the inner housing (21) but characteristically not contacting the inner housing (21). The inner and outer housings (21, 22) includes walls (30, 31) forming a vacuum-drawn scaled insulation cavity (26) around the inner housing (21). A temperature-activated variable insulator device is positioned within the outer housing (22) and includes a hydrogen source (32) and controls for controlling the variable insulator device. A vacuum-maintenance device is incorporated into the insulation cavity (26), and includes a small container, getter material positioned in the container, a porous member allowing gas in the insulation cavity (26) to communicate with the getter material. A multi-layered radiation shield is position in the vacuum space and is loosely coupled to the inner housing (21).

Abstract: An exhaust treatment device, such as a catalytic converter assembly (20) for vehicles includes an inner housing (21) having an inlet and an outlet defining a longitudinal direction (63) and having a catalytic material (27, 27?) therein chosen to reduce undesirable emissions from the exhaust of a combustion engine as the exhaust passes from the inlet to the outlet. The catalytic converter assembly (20) further includes an outer housing (22) enclosing the inner housing (21) but characteristically not contacting the inner housing (21), the outer housing (22) including an inlet and an outlet that align with the inlet and outlet of the inner housing (21), the inner and outer housing (21, 22) including walls (30, 31) forming a sealed cavity (26) around the inner housing (21), the cavity (26) having a vacuum drawn therein. The catalytic converter assembly (20) further includes supports (25) of various configurations and materials that extend radially between the inner and outer housings (21, 22).

Abstract: The present invention broadly relates to novel aluminum nitride matrix ceramic composite bodies for use as refractory materials and methods for making the same. The refractory materials are useful in environments which are corrosive, erosive, abrasive and/or which generate thermal shock. Such environments include furnaces, and associated apparatus which house or contact molten masses including, for example, molten metals, molten glasses, etc. The preferred method for making the aluminum nitride matrix ceramic composites comprises a directed oxidation of molten metal.

Abstract: The present invention broadly relates to novel aluminum nitride matrix ceramic composite bodies for use as refractory materials and methods for making the same. The refractory materials are useful in environments which are corrosive, erosive, abrasive and/or which generate thermal shock. Such environments include furnaces, and associated apparatus which house or contact molten masses including, for example, molten metals, molten glasses, etc. The preferred method for making the aluminum nitride matrix ceramic composites comprises a directed oxidation of molten metal.

Abstract: A method of making self-supporting ceramic composite structures having filler embedded therein includes infiltrating a permeable mass of filler with polycrystalline material comprising an oxidation reaction product obtained by oxidation of a parent metal such as aluminum and optionally, containing therein non-oxidized constituents of the parent metal. The structure is formed by placing a parent metal adjacent to a permeable filler and heating the assembly to melt the parent metal and provide a molten body of parent metal which is contacted with a suitable vapor-phase oxidant. Within a certain temperature region and optionally, aided by one or more dopants in or on the parent metal, molten parent metal will migrate through previously formed oxidation reaction product into contact with the oxidant, causing the oxidation reaction product to grow so as to embed the adjacent filler and provide the composite structure.

Abstract: The present invention broadly relates to novel aluminum nitride matrix ceramic composite bodies for use as refractory materials and methods for making the same. The refractory materials are useful in environments which are corrosive, erosive, abrasive and/or which generate thermal shock. Such environments include furnaces, and associated apparatus which house or contact molten masses including, for example, molten metals, molten glasses, etc. The preferred method for making the aluminum nitride matrix ceramic composites comprises a directed oxidation of molten metal.

Abstract: A metal matrix composite is formed by contacting a molten matrix metal with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix metal will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. The directionally solidified metal matrix composite may be heated to a temperature in excess of the liquidus temperature of the matrix metal and quenched. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: A metal matrix composite is formed by contacting a molten matrix alloy with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix alloy will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.