Abstract: Some embodiments provide methods and systems for casting articles. One example of a method includes providing and positioning a thermal blanket within a mold cavity and then introducing a molten material into the mold cavity and into contact with the thermal blanket. The method allows the molten material to remain in a molten state during a dwell time that extends from the introduction of the molten material at least until the mold cavity is filled. In another example, a method of using a thermal blanket includes keeping a molten material in a molten state during a dwell time extending from first introduction of the molten material until pressurization. Systems including a variety of mold types, one or more thermal blankets, and in some cases preforms and/or inserts are also provided. Also described is a novel thermal blanket and method of manufacturing the same.

Abstract: A computer implemented system for optimization of sand for reducing casting rejections in a foundry utilizing the existing foundry components or machinery. The system is accessible online via a computer network. The system is enabled to provide a predicted or prescribed solution for the optimization of sand using at least a parameter relating to the aforementioned sand. Further, the system is enabled to determine the parameters contributing to casting rejections and provide a corresponding solution for reducing the rejections in the next casting batches for the particular foundry. The system includes a user interface module for enabling users to upload foundry related data into the system, a reporting module enabling the user to generate and understand current statistics of the foundry, and a processing engine which enables the system to perform mathematical computation of user queries and provide the desired predicted or prescribed solution to the user for the foundry.

Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions, intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded, where the mold comprises calcium hexaluminate.

Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.

Abstract: A new investment material for the pressing loss wax technique for dental glass ceramics. It has been found that the addition of fillers to a magnesium phosphate investment, specifically metal oxides with elevated melting points ranging from 1800 to 2800° C., provides a protection barrier against the reaction between the high alkaline content of the glass ceramic and the investment during the pressing process in the range of 800 to 950° C. Specifically, it has been found that the addition of aluminum oxide of about 2 to 5 percent of the total dry mix in combination with any of the zirconium oxide, yttrium stabilized zirconium, titanium dioxide and boron nitride in proportions of about 3.5%, enhances the barrier against a surface reaction and improves the thermal properties of the investment.

Abstract: Slurry which contains a) from (50) to (80)% by weight of refractory particles having an average particle size of from (0.5) m to (150) m, b) from (5) to (35)% by weight of aluminum oxide particles having an average particle diameter of less than (300) nm and c) from (5) to (35)% by weight of water and d) a pH of from (5) to (12). Process for producing the slurry using a dispersion, and also the dispersion itself. Process for producing a casting mold, and also the casting mold itself.

Abstract: A foundry coating composition for molds and cores, a process for preparing coated foundry molds and cores, and coated molds and cores obtainable by the process. The foundry coating composition comprises a liquid carrier; a binder; and a particulate refractory filler. The particulate refractory filler comprises a first (relatively coarse) fraction having a particle size of d>38 ?m and a second (relatively fine) fraction having a particle size of d<38 ?m. No more than 10% of the total particulate refractory filler has a particle size of 38 ?m<d<53 ?m and no more than 50% of the second (relatively fine) fraction is constituted by calcined kaolin. The foundry coating composition is applied to molds and cores to assist in the removal of the casting from the mold and prevention of casting defects.

Abstract: The disclosure relates generally to mold compositions comprising calcium aluminate and calcium titanate. The disclosure also relates to methods of molding and the articles so molded using the mold compositions. More specifically, the disclosure relates to calcium aluminate/calcium titanate mold compositions and methods for casting titanium-containing articles, and the titanium-containing articles so molded.

Abstract: A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer.

Abstract: A process for conversion of conventional sand granules (or other particulates) to a ‘core-shell’ adsorbent granules in which GO (or GO-f) coating imparts nano structural features on the surface of the sand granules (or other particulates). Such materials are useful in a variety of engineering applications such as water purification, catalysis, capacitors, proppants, casting, and magnetic shielding.

Abstract: The present disclosure relates to a titanium-containing article casting mold composition comprising calcium aluminate and an X-ray or Neutron-ray detectable element. Furthermore, present embodiments teach a method for detecting sub-surface ceramic inclusions in a titanium or titanium alloy casting by combining calcium aluminate, an element more radiographically dense than the calcium aluminate, and a liquid to form a slurry; forming a mold having the calcium aluminate and the radiographically dense element from the slurry; introducing a titanium aluminide-containing metal to the radiographically dense element-bearing mold; solidifying said titanium aluminide-containing metal to form an article in the mold; removing the solidified titanium aluminide-containing metal article from said mold; subjecting the solidified titanium aluminide-containing article to radiographic inspection to provide a radiograph; and examining said radiograph for the presence of the radiographically dense element on or in the article.

Abstract: The present invention belongs to the field of the additives for molding sands used in the manufacture of casting molds and cores. More specifically, the present invention relates to an additive to prevent veining in the manufacture of metal parts, to a molding sand comprising said additive, to a core or mold prepared from said molding sand and to a metal part prepared by means of using one of said cores or molds.

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: Method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern, wherein said yttria-based refractory composition is obtainable by (a) mixing particles of a yttria-based ceramic material and a fluorine containing dopant, and (b) heating the resulting mixture to effect fluorine-doping of said yttria-based ceramic material.

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 claim and carbon.

Abstract: Slurry which contains a) from (50) to (80) % by weight of refractory particles having an average particle size of from (0.5) m to (150) m, b) from (5) to (35) % by weight of aluminium oxide particles having an average particle diameter of less than (300) nm and c) from (5) to (35) % by weight of water and d) a pH of from (5) to (12). Process for producing the slurry using a dispersion, and also the dispersion itself. Process for producing a casting mould, and also the casting mould itself.

Abstract: A coating system for a mould for the directional solidification of silicon. The coating is applied as an aqueous slurry of silicon nitride particle, carbon black and microsilica.

Abstract: Thermal expansion defects, i.e. veining, are reduced in iron, steel, and nonferrous castings by adding a lithia-containing material in a sufficient amount to the silica sand mold. Adjusting current formulations to maximize the use of lesser expensive raw materials and minimize the use of more expensive raw materials to lower the overall percentages of lithia/metallic oxide containing additives while still reducing or eliminating thermal expansion related defects in the metal casting process reduces the overall cost to manufacture the product.

Abstract: An additive to foundry sand molding and core aggregates is used to produce sand cores and molds comprising kyanite, spodumene, titanium dioxide, ilmenite and black iron oxide. The additive produces a sand-based foundry molding and core aggregate which resists the formation of some of the defects commonly associated with the production of castings produced by silica sand-based molding and core aggregates. In particular, the additive improves the quality of castings poured at temperatures higher than those of the pouring temperatures of molten iron, such as in steel castings, and in iron castings with “hot spots.

Abstract: Methods of producing silicone hydrogel ophthalmic lenses include contacting one or more delensed silicone hydrogel ophthalmic lens with a liquid composition that contains alcohol, water, and a surfactant. The methods can be steps of an extraction/hydration procedure used in the production of silicone hydrogel contact lenses. In some examples, contacting silicone hydrogel ophthalmic lens products with a liquid composition that contains alcohol, water, and a surfactant can significantly reduce or prevent surface distortion of the ophthalmic lens resulting from the extraction procedure. Some methods include subsequently contacting the silicone hydrogel ophthalmic lens with a liquid composition consisting essentially of water and a surfactant.

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: 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: Additives to foundry sand cores are provided for reducing or eliminating surface defects in metal castings. The additives general comprise an iron oxide component and a glass component which is preferably free of lithium oxide.

Abstract: A silicone mold comprising and oxidized, patterned surface and a layer of perfluoroether silane release agent is described. The mold enables 2nd generation silicone molds to be replicated, i.e. silicone molds from silicone molds.

Abstract: The invention relates to a mould material mixture for producing casting moulds for metal processing, a process for producing casting moulds, casting moulds which can be obtained by the process and their use. The production of the casting moulds is carried out using a refractory base moulding material and a binder based on water glass. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminium oxide, titanium oxide and zinc oxide is added to the binder, with particular preference being given to using synthetic amorphous silicon dioxide. The mould material mixture contains a surface-active material as further significant constituent. The addition of the surface-active material enables the flowability of the mould material mixture to be improved, which makes it possible to produce casting moulds having a very complicated geometry.

Abstract: The invention relates to a molding mixture for producing casting molds for metalworking, a process for producing casting molds, casting molds obtained by the process and also their use. To produce the casting molds, a refractory mold raw material and a binder based on water glass are used. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminum oxide, titanium oxide and zinc oxide is added to the binder, particular preference being given to using synthetic amorphous silicon dioxide. The molding mixture contains a phosphate as essential constituent. The use of phosphate can improve the mechanical strength of casting molds at high thermal load.

Abstract: A composition for use in producing a foundry mold. The composition has a binder, which may include a smectite clay. The composition also has a modifier, which may include a metal carbonate. The composition also includes a foundry sand.

Abstract: The present invention relates to a coating and a method for producing a casting mold. The method provides for castings whereby gas defects are largely or completely suppressed.

Abstract: A method for forming an article is described. The method includes the step of applying a precursor material to at least one surface of a mold structure for casting the article, and curing the applied precursor material. The precursor material includes facecoat-forming constituents which can be curably converted into a facecoat; and a protective coating-former for the article being cast. Molten material is then introduced into the mold structure, so as to come in contact with the facecoat formed from the cured precursor material. The molten material is cooled, to form the article. The cured precursor material, which is in contact with a surface of the cast article, is then reacted with the article, to form the protective coating on the surface of the article. Related mold structures are also described.

Abstract: The present disclosure relates to a quench mold that may include an interior cavity and a coating on the interior cavity. The coating may include a plurality of particles such as metal-coated particles.

Abstract: A binder, a composition, a product and a kit, as well as a process for preparing the binder and composition, are directed to a composition useful as an inorganic phosphate binder, which binder is characterized as having calcium silicate sites which are connected the one with the other by alumina-silica phosphate bonds, and a filler.

Abstract: In order to produce a dental cast product having the flat surface, by blending a dispersant with a phosphate-based investing material to improve the dispersability of an aggregate powder and a binder powder so as to prevent a agglomeration of the aggregate powder and the binder powder thereby forming a wall surface of an cavity in a mold to be flat, and also to make more various kinds of powders available for the aggregate powder without restriction to quartz, cristobalite and tridymite, the phosphate-based dental investing material comprising a mixed powder including an aggregate powder and a phosphate-based binder powder, and a liquid, with an alkaline metal salt of phosphoric acid being added to at least one of the mixed powder and the liquid.

Abstract: The present invention discloses a mold and a method of manufacturing the mold. The mold includes a mold matrix and a number of boron nitride nanotubes sintered together with the mold matrix. Each boron nitride nanotube capsules a number of fullerenes therein respectively. The mold further includes an amount of noble metal powder sintered together with the mold matrix and the boron nitride nanotubes. The fullerenes preferably include C60 molecules. In addition, the method for manufacturing a mold includes the steps of: providing a number of boron nitride nanotubes, each boron nitride nanotube capsuling a number of fullerenes therein respectively; mixing a mold matrix with the boron nitride nanotubes capsuling the fullerenes to form a complex; molding the complex to form a mold preform; and sintering the mold preform, thereby attaining a mold.

Abstract: Ceramic composite material that has excellent mechanical properties within a range from room temperature to high temperature and high die release with respect to glass, resins, ceramics, and similar substances. The ceramic composite material is composed of a ceramic phase and a phase containing 2 to 98 wt. % carbon and/or boron nitride as the main component, and that has a mean particle size of 100 nm or less, wherein the thermal expansion coefficient is within a range of 2.0-9.0×10?6/° C. and the surface roughness after surface polishing is 0.05 ?m or less. The sintered body of the material is obtained by sintering a mixture of powdered starting materials at a sintering temperature of 800-1500° C. and a sintering pressure of 200 MPa or higher.

Abstract: A method of making an imprint lithography template includes applying a curable material to a patterned surface of a master imprint template, allowing the curable material to cure and thereby forming a second imprint template having a patterned surface which is the inverse of the patterned surface of the master imprint template; removing the second imprint template from the master imprint template; applying inorganic sol-gel to a substrate; imprinting the inorganic sol-gel with the second imprint template; allowing the inorganic sol-gel to cure; and removing the second imprint template from the cured inorganic sol-gel, such that the inorganic sol-gel forms a third imprint template having a patterned surface which corresponds with the patterned surface of the master imprint template.

Abstract: The casting-mold material designed to manufacture casting molds used in casting high melting-point substances. The casting mold formed from a powder component containing magnesium oxide and aluminum oxide and a liquid component. The powder component additionally contains a calcium aluminate and an alkali fluoride or an earth alkali fluoride and the liquid component contains a polyelectrolyte and a basic component, the latter determining the liquid component pH value between 10 and 14. A fluid slip is prepared by mixing the powder and liquid components and is dried, hardened and sintered to produce a hollow mold.

Abstract: A composition and method for forming investment casting shells includes using colloidal silica, zircon flour, and fused silica in a slurry which is applied to a pattern. After the slurry is applied to the pattern, it is allowed to partially or completely solidify. After the shell has solidified, the pattern may be melted or otherwise removed. A molten material is introduced into the shell and allowed to cool to form an article. Finally, the shell is broken away or otherwise removed from the article. The improved shell slurry composition and corresponding method minimizes pattern-to-pour cycle times and is environmentally friendly.

Abstract: An improved phosphate-type refractory investment material and method for making solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, a water soluble acidic constituent, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or acidic constituent can be combined with the refractory powder at the time of mixing with water.

Abstract: The present invention is directed to a colloidal aqueous silicate dispersion containing silica and alumina, the molar ratio between silica and alumina being 2-12, as well as to a method for its preparation. Said method is characterized by dissolving a particulate mineral material, such as a mineral wool or fiber product containing silica and alumina in a molar ratio of 2-12 in an aqueous solution, nucleating and stabilizing the so obtained solution, and optionally adjusting the dry matter content of the dispersion so obtained. The said dispersion can also be made to gel. The invention is also directed to the use of the dispersion as a binder.

Abstract: A foundry sand binder formed by reacting a smectite clay containing exchangeable calcium ions with an acid to enhance the ability of the clay to bind sand in forming a metal casting sand mold. The acid-treated clay is an excellent sand binder for metal casting molds and produces cast metal parts having improved surface finish with the elimination or substantial reduction in carbonaceous, e.g., coal, foundry sand additive, while reducing VOC emissions from the foundry.

Abstract: The invention provides a method with which high-quality complex-shaped castings can be manufactured and with which, after the end of the casting process, the casting mould parts can be easily removed out of or from the casting without any risk.

Abstract: An improved phosphate-type refractory investment material and method for marking solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, one or more water soluble organic acids, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or organic acid can be combined with the refractory powder at the time of mixing with water.

Abstract: A coating for a mold surface of a casting mold includes a metallic bond coat bonded to the mold surface and having a continuous, uniform thickness of between about 0.002 to 0.005 inch on the mold surface. A topcoat of yttria stabilized zirconia is located on top of the metallic bond coat and has a continuous, uniform thickness of between about 0.005 to 0.030 inch. The topcoat has a porosity between 5-15%. The topcoat has a surface layer having a thickness of between about 0.001 to 0.002 inch and a porosity of less than 1%.

Abstract: The present invention is directed to a colloidal aqueous silicate dispersion containing silica and alumina, the molar ratio between silica and alumina being 2-12, as well as to a method for its preparation. Said method is characterized by dissolving a particulate mineral material, such as a mineral wool or fiber product containing silica and alumina in a molar ratio of 2-12 in an aqueous solution, nucleating and stabilizing the so obtained solution, and optionally adjusting the dry matter content of the dispersion so obtained. The said dispersion can also be made to gel. The invention is also directed to the use of the dispersion as a binder.

Abstract: Coating foundry sand with a thin layer of an oxidation-promoting catalyst. Preferred catalysts comprise ferric and cupric oxides. The catalysts promote the oxidation of any polymeric binder or residues admixed with the sand. The sand is coated by wetting the grains with a solution of a catalyst precursor, drying the sand and baking the sand in air to convert the precursor to the catalyst.

Abstract: Refractory investment material for forming a positive replication of a tooth structure on which a high-alumina based porcelain tooth restoration is to be formed, the material being formed from a refractory powder which includes alumina mixed with a liquid carrier comprising an aqueous dispersion of silicon dioxide.

Abstract: A ceramic product containing at least 70% lithium aluminium silicate of 100% total mass weight percent; and a non-wetting agent in the form of barium sulphate. Most preferably, the lithium aluminium silicate includes petalite in finely divided form which has been fired to a temperature between 1150° C. and 1210° C.

Abstract: A coating for a mold surface of a casting mold includes a metallic bond coat bonded to the mold surface and having a continuous, uniform thickness of between about 0.002 to 0.005 inch on the mold surface. A topcoat of yttria stabilized zirconia is located on top of the metallic bond coat and has a continuous, uniform thickness of between about 0.005 to 0.030 inch. The topcoat has a porosity between 5-15%. The topcoat has a surface layer having a thickness of between about 0.001 to 0.002 inch and a porosity of less than 1%.

Abstract: An investment composition is described for use in investment casting (also called lost wax casting). The composition is a phosphate bonded material that contains mono-ammonium phosphate (MAP), magnesium oxide and silica filler (quartz, cristobalite, or a mixture thereof). It has been discovered that controlling the amount and ratio of these components has a significant impact on gas permeability (porosity), set time, cast smoothness and cast softness. The most outstanding feature of the new investments is the short mold fabrication and processing time that they allow due to their high gas permeability. The investments can be placed in a bum out furnace while still wet and can be heated rapidly to the firing temperature. The casts can be broken by sandblasting the casts with glass beads. Molds made from the casts have smooth surfaces indicating that the casts are free of visible inclusions and other defects.

Abstract: The object of the present invention is to provide a construction and coating composition that effectively utilizes vermiculite as a natural resource and is able to satisfy requirements for humidity control and/or deodorizing as well as an attractive appearance, while also offering superior balance between the amount and rates of moisture absorption and release, in particular. This object is achieved by a composition in which non-expanded vermiculite is blended into a base material so that the blended amount is 5-70 wt % of the total composition (solid portion). In addition, the above construction material can be converted into soil by crushing when it has become a waste construction material.