Abstract: A riser sleeve (100) for use in a foundry molding operation has cylindrical body in which the side wall (14) that may be untapered or that may taper uniformly from the bottom to the top (12) of the body. The riser sleeve is characterized by a plurality of cavities (102) are formed on the side wall, extending from the top in an axial direction of the body. These cavities provide air gaps when the riser sleeve is inserted into a mold, decreasing heat loss at the interface between the riser sleeve and the mold.

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: 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: 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.

Abstract: Disclosed is a foundry mix containing an organic 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: Disclosed is a foundry mix containing a carbonate 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: 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: 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.

Abstract: This invention relates to a process for preparing detailed foundry shapes (e.g. molds and cores) used in casting metal articles. The process involves preparing foundry shapes from hollow ceramic microspheres bonded with organic or inorganic binders. The foundry shape is then detailed by machining, cutting, stamping, or otherwise removing material from the foundry shape to provide special shapes, letters, numbers, insignia, machine readable codes, etc. on the surface of the foundry shape. The foundry shapes are used to produce detailed metal castings. This detail can be unique to a single casting to provide a permanent traceable mark for casting identification from the time of manufacture to disposal.

Abstract: This invention relates to an improved process for casting a metal by pouring molten metal into and around a mold assembly, where a riser is a component of the mold assembly. The process comprises (a) inserting a riser insert into the cavity of the riser, and (b) then allowing molten metal to flow into the cavity of the riser containing the riser insert. The process is carried out in a manner such that the density and the shape of the riser insert enables the riser insert to float on the surface of the molten metal when the molten metal enters the cavity of the riser.

Abstract: The invention relates to an exothermic sleeve composition comprising (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and (b) an oxidizing agent capable of generating an exothermic reaction. The invention also relates to the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions, and the use of the sleeves to prepare metal castings.

Abstract: Insulating sleeve mixes that contain hollow aluminosilicate microspheres, an organic binder, and boric acid and/or a phosphate, and their uses.