Abstract: The present disclosure includes binder systems for making foundry articles. The binder systems may comprise a humic substance-containing component that comprise lignite, an isocyanate component, and a catalyst component. The binder systems may be mixed with an aggregate (e.g., sand) for making foundry articles such as molds and cores. Also disclosed herein are methods of making foundry articles using the binder systems.

Abstract: Compositions useful for green sandcasting are discussed, as well as methods of preparing and using such compositions. Binder compositions may comprise a carbonaceous material, an inorganic binding agent, and a high aspect ratio silicate, wherein at least one of the carbonaceous material or the inorganic material in the binder composition may be oxidized. For example, the inorganic binding agent may be oxidized with a ratio of ferrous iron (Fe2+) to ferric iron (Fe3+) less than 1.2. or less than 1. Green sand prepared from such binder compositions may exhibit a reduction in emissions during sandcasting.

Abstract: The present disclosure includes binder systems for making foundry articles. The binder systems may comprise a humic substance-containing component that comprise lignite, an isocyanate component, and a catalyst component. The binder systems may be mixed with an aggregate (e.g., sand) for making foundry articles such as molds and cores. Also disclosed herein are methods of making foundry articles using the binder systems.

Abstract: Clay materials useful as binding agents in green sandcasting and other molding processes are discussed, as well as methods of preparing such clay materials. The clay materials may be chemically treated. For example, a natural clay may be combined with one or more reducing agents, such that an amount of iron present as ferric iron (Fe3+) in the natural clay is at least partially reduced to ferrous iron (Fe2+) in the chemically-treated clay. The chemically-treated clay may exhibit greater water absorption, binding properties, and/or sintering properties as compared to an untreated, natural clay.

Abstract: Compositions useful for foundry processes such as green sand casting are discussed. The compositions may comprise an aggregate, at least one inorganic binding agent, and at least one high aspect ratio silicate. For example, the composition may comprise sand, one or more clay materials serving as a binding agent, and a high aspect ratio silicate chosen from mica, talc, or a combination thereof. The composition may be formed into a green sand mold for use in casting molded articles. Incorporation of the high aspect ratio silicate may help to improve the quality of the casted article.

Abstract: Systems and methods for improved molding sand performance through use of recovered additives from the existing waste stream in a foundry. Sand, clay, and carbon-containing organic components are wet recovered from a green sand mold foundry dust recovery system. The sand and non-sand fractions may be further treated to reduce water content or adjust the levels of various components to generate a pre-mix additive for the generation of new green sand molds, that may display improved properties at ambient and high temperatures when compared to commonly employed traditional pre-mix. In some examples, pre-mixes having reduced sulfur content are obtained. In several embodiments, the non-sand fraction obtained from bag house dust or dust from mechanical reclamation includes increased levels of bentonite clay and carbon.

Abstract: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. A pattern coating composition is disclosed wherein the composition is an emulsion including oil, water, graphite, a water dispersible amine, and a clay reactive with the amine to form an organophylic clay.

Abstract: A method for producing silica sand-based foundry shapes useful in forming metal castings and for reducing veining defects in sand-based foundry shapes by providing a foundry sand, adding an anti-veining composition that comprises bentonite to the foundry sand to form a mineral composition, then adding a foundry resin to the mineral composition to form a sand-based foundry composition and shaping the sand-based foundry composition to form a desired pattern.

Abstract: A sand casting foundry composition reduces thermal defects that cause veining in metal parts cast from sand casting foundry shapes formed from the foundry composition. Foundry sand grains are mixed substantially uniformly with thermally collapsible clay mineral particles, and a curable binder coats the sand grains and the thermally collapsible clay mineral particles to establish core and mold foundry shapes used to cast the metal part. Anti-veining capability occurs because the thermally collapsible clay mineral particles exhibit an inherent characteristic of crystal structure collapse upon exposure to temperatures encountered in casting the metal part. The crystal structure collapse yields space which is consumed by thermal expansion of the sand grains in the foundry composition. This compensatory effect avoids the creation of mechanical forces and stresses within the foundry shape that cause the cracks and fissures in the foundry shape that lead to veining.

Abstract: A method for producing silica sand-based foundry shapes useful informing metal castings and for reducing veining defects in sand-based foundry shapes by providing a foundry sand, adding an anti-veining composition that comprises bentonite to the foundry sand to form a mineral composition, then adding a foundry resin to the mineral composition to form a sand-based foundry composition and shaping the sand-based foundry composition to form a desired pattern.

Abstract: A sand molding medium for the use in founding of iron. The medium includes wettable uintaite as a carbon source supplemental to sea coal. The wettable uintaite is included in a carbon additive that is combined with sea coal to formulate the carbon component of an a pre-mix. The pre-mix also includes a clay component. The pre-mix is combined with sand to formulate the sand molding medium.

Abstract: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. Despite many available pattern coating compounds, mineral seal oil, and a mixture of mineral seal and clay, have been the commercial choices. But they are not without their disadvantages. The properties of mineral seal oil are not entirely desirable, particularly its low flash point and toxicity. Hereby the advantages of mineral seal oil-clay pattern coating compositions are retained without its detriments.