Abstract: The present invention relates to the field of 4D printing, and particularly to an electro-responsive folding and unfolding composite material for 4D printing, a method for manufacturing the same, and a method for regulating shape memory behavior thereof. In the process of layer-by-layer printing, conductive layers are embedded into a pre-designed shape memory polymer matrix through spray-coating and laser-irradiation nano-fusion welding, to manufacture a folding and unfolding structure with electro-responsive shape memory behavior. The distribution and range of heat affected zones in the electro-responsive shape memory folding and unfolding structure are controlled by adjusting the number of electric heating layers energized and the value of an energizing voltage. The speed of shape recovery and the degree of shape recovery of the structure are regulated according to a magnitude relationship between a shape recovery force Frecovery and a resistance Fresistance to shape recovery of the structure.

Abstract: A method for demolding a casting from a casting mold having at least one casting core which images a passage opening in the casting connecting two outer sides of the casting and is produced from a molding material bound by a binder which decomposes under the influence of temperature, wherein the casting mold undergoes a heat treatment in a furnace for the demolding, during which it is heated to a temperature at which the binder loses its binding effect. In the furnace, hot gas is flowed through a passage formed in the casting core of the casting mold, the temperature of the hot gas corresponding at least to the temperature at which the binder of the molding material loses it binding effect such that the casting core decomposes into fragments or separate sand particles as a consequence of the influence of the hot gas.

Abstract: Provided are an organic binder for a mold, which can advantageously extend the pot life without causing uneven curing, reduction in mold strength and an increase in the amount of use of a catalyst; a molding sand composition which is obtained by using the organic binder for a mold, and which exhibits an extended pot life; and a mold produced by curing such a molding sand composition through gas hardening. The urethane-curable type organic binder for a mold, which is used for production of a urethane-based mold, is constituted by comprising a specific alkoxysilyl group-containing ketimine compound, together with a polyol compound and a polyisocyanate compound.

Abstract: A method for manufacturing a monolithic hollow body by means of a casting or injection molding process, the manufacturing method contemplating the steps of: producing at least one lost ceramic core that reproduces the shape of at least one internal cavity of the hollow body, introducing the ceramic core inside a first mold that reproduces in negative the external shape of the hollow body, feeding a molten material inside the first mold by means of a casting or injection molding process, letting the material inside the first mold solidify, extracting the hollow body from the first mold, and destroying and removing the ceramic core located inside the hollow body.

Abstract: An investment casting method for a cast ceramic core (110), including an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50) and an integral shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.

Abstract: To provide a casting mold manufacturing apparatus using steam heating. The apparatus includes a forming die having a cavity, a resin-coated sand supply section for supplying a resin-coated sand into the cavity, a steam supply section for supplying steam into the cavity, and a steam discharge section for discharging the steam from the cavity. At least a portion of the forming die is composed of a porous material having pores with an average diameter smaller than an average particle diameter of the resin-coated sand. At least a portion of the steam is supplied into the cavity through the porous material. Since it is possible to uniformly supply the steam into the cavity, a homogeneous casting mold can be manufactured.

Abstract: An apparatus and a method for producing a casting mold are provided, according to which the casting mold having a complex shape can be obtained with stable quality. The apparatus comprises a mold having a cavity therein, a steam supply unit, a steam supply passage connected to the cavity, steam discharge passages, flow regulators disposed in the steam discharge passages to regulate an amount of the steam discharged from the cavity, and a control unit for controlling the flow regulators. After a resin-coated sand prepared by coating a refractory aggregate with a binder resin is injected into the cavity of the heated mold, superheated steam is supplied into the cavity. At this time, the control unit controls the flow regulators such that the cavity is uniformly filled with the superheated steam.

Abstract: A foundry core or mold comprised of sand admixed with an inorganic binder is hardened by passing a treatment gas through a first heater and heating it therein to a relatively low temperature and, in a first hardening stage, passing the gas at the low temperature from the first heater through a second heater and heating it therein to a relatively high temperature and thereafter passing the gas at the high temperature from the second heater to and through a core box holding the core or mold to harden same. Thereafter in an after-treatment stage passing the gas at the low temperature from the first heater substantially directly to and through the core box holding the core or mold to after treat same.

Abstract: The present invention relates to A method and apparatus for making a sand core (112) utilizing purge air through a core box (100 and 100?) to harden the binder in the sand core (112) proximate the ejection pins (106 and 106?). The sand core (112) may be removed from the core box (100 and 100?) prior to drying the binder completely thereby resulting in an improved production rate of the sand core (112).

Abstract: A method of drying a sand mold mixture containing moisture includes restraining the sand mold mixture and exposing the sand mold mixture to a vacuum. The vacuum flashes off the moisture within the sand mold mixture thereby drying the sand mold mixture to create a solidified sand mold. The restraining member prevents voids from forming in the sand mold during exposure to the vacuum.

Abstract: A method for producing sand cores for foundry, comprising the operations of: defining a molding cavity; blowing in a mixture of sand and hydrated binder into said molding cavity so as to produce a mass of sand, which reproduces in a complementary way the shape of said molding cavity; and producing the passage, through said mass of sand, of a flow of aeriform along at least one principal direction. The method comprises the operation of generating through said mass of sand a flow of aeriform, directed at least in part in a radial direction with respect to said principal direction.

Abstract: A thermally efficient method for the heating a gas permeable wall of a bonded refractory mold wherein the mold wall defines a mold cavity in which molten metal or alloy is cast. The mold wall is heated by the transfer of heat from hot gas flowing inside of the mold cavity to the mold wall. Hot gas is flowed from a hot gas source outside the mold through the mold cavity and gas permeable mold wall to a lower pressure region exterior of the mold to control temperature of an interior surface of the mold wall.

Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.

Abstract: A method for making sand particle foundry mold members. Sand particles are coated with an aqueous dispersion of a suitable binder material such as a gelatin gel. The moist gelatin coated particles are gravity fed into a pattern box for the mold member and subjected to multi-axis vibration to pack the sand in the pattern box. The moist sand is then heated with radio frequency energy to promote binder flow to the corners of the particles, and air flow is initiated to transport water from the mass of particles to harden the mass of particles into the mold member.

Abstract: A method for producing sand cores for foundry, comprising the operations of: defining a moulding cavity; blowing in a mixture of sand and hydrated binder into said moulding cavity so as to produce a mass of sand, which reproduces in a complementary way the shape of said moulding cavity; and producing the passage, through said mass of sand, of a flow of aeriform along at least one principal direction. The method comprises the operation of generating through said mass of sand a flow of aeriform, directed at least in part in a radial direction with respect to said principal direction.

Abstract: A method is disclosed for making sand particle foundry mold members. Sand particles are coated with an aqueous dispersion of a suitable binder material such as a gelatin gel. The moist gelatin coated particles are gravity fed into a pattern box for the mold member and subjected to multi-axis vibration to pack the sand in the pattern box. The moist sand is then heated with radio frequency energy to promote binder flow to the corners of the particles, and air flow is initiated to transport water from the mass of particles to harden the mass of particles into the mold member.

Abstract: The present invention relates to a method and apparatus for making a sand core (112) utilizing purge air through a core box (100 and 100′) to harden the binder in the sand core (112) proximate the ejection pins (106 and 106′). The sand core (112) may be removed from the core box (100 and 100′) prior to drying the binder completely thereby resulting in an improved production rate of the sand core (112).

Abstract: The present invention relates to a method and apparatus for making a sand mold (112) utilizing reverse purge air through a core box (100 and 100′) to harden the binder in the sand mold (112) proximate the ejection pins (106 and 106′). The sand mold (112) may be removed from the core box (100 and 100′) prior to drying the binder completely.

Abstract: A method for producing a sand core includes the following steps: (a) providing a casting mold having a mold cavity, the casting mold including at least one first conduit and at least one second conduit; (b) providing a sand core disposed in the mold cavity; (c) providing a supply of conditioning gas to the casting mold, the conditioning gas being supplied to the casting mold through at least one of the first and second conduits; (d) providing a controller connected to the first conduit and the second conduit to selectively control the supply of conditioning gas; (e) providing a gas exhaust unit operatively connected to the casting mold; (f) operating the gas exhaust unit to cause the conditioning gas to be moved through the sand core; and (g) removing the sand core from the casting mold.

Abstract: In a method of making a molded article for use in a casting process, sand particles are mixed with protein and water to effect a coating of protein on the sand particles. Then, the protein coated sand particles are dried and blown into a pattern mold to form a molded article without active cooling of the coated sand particles. Steam is then passed through the molded article to hydrate and melt the protein, thereby forming bonds between contiguous sand particles. Finally, hot, dry air is passed through the molded article to harden the protein bonds between the contiguous sand particles. This forms a protein coated sand core for use in casting molten metals.

Abstract: In a method of making a molded article for use in a casting process, sand particles are mixed with protein and water to effect a coating of protein on the sand particles. Then, the protein coated sand particles are dried and blown into a pattern mold to form a molded article without active cooling of the coated sand particles. Steam is then passed through the molded article to hydrate and melt the protein, thereby forming bonds between contiguous sand particles. Finally, hot, dry air is passed through the molded article to harden the protein bonds between the contiguous sand particles. This forms a protein coated sand core for use in casting molten metals.

Abstract: A cope for a core box has a passage for passing sand into a core box cavity and a bore for passing catalyst into the core box cavity to harden a sand core formed therein. The bore may extend from an exterior surface of the cope to the cope passage. The cope may have structure for forming a seal with a sand injection tube following sand injection, such as a blow-up seal or an O-ring. A method of producing cores in a core box includes the step of providing a cope, a drag, and a cavity formed therebetween, the cope having a passage for receiving an injection tube and a bore for passing catalyst. Further steps include using the injection tube to inject sand through the cope passage into the cavity and passing catalyst through the bore in the cope into the cavity. A seal may be formed between the cope and the injection tube after sand injection.

Abstract: A core box has (i) a thermally conductive cope and drag resiliently sealingly mating at essentially a horizontal parting plane, and (ii) core defining walls enclosing an interior and perforated by sand-filtered ports. A sand, resin and liquid catalyst mixture is blown into the interior to form a sand body. At least the outer skin of the sand body is conductively heated to a first temperature (i.e., 300-400.degree. F.); and essentially simultaneously with the conductive heating, the remainder of the sand body is convectively heated by flowing a heated gas therethrough at a second temperature lower than the first temperature (i.e., 250-290.degree. F.). The heated gas enters the sand body from the drag and exits the sand body by way of the cope.

Abstract: A primary gas supply circuit and a secondary gas supply circuit are provided with the primary circuit having a part in common with the secondary circuit. The primary circuit is provided with a source of hardening gas. A sand foundry part containing a binding agent is provided in the part in common with the primary and secondary gas supply circuits. Through the primary gas supply circuit a hardening gas/carrier gas is circulated through the sand foundry part containing the binding agent. The primary gas supply circuit is closed when the quantity of hardening gas present in the part of the primary gas supply circuit common to the secondary gas supply circuit is an amount corresponding to, or slightly exceeding, the theoretical quantity for a complete hardening reaction. The secondary supply circuit is opened and the hardening gas/carrier gas is circulated through the secondary supply circuit until the hardening reaction has been completed.

Abstract: A method is provided for forming a sand core which is suitable for use in casting processes, and in particular squeeze casting processes, to form internal features and intricate external features of a cast article. The core forming method involves the use of a single-component gelatin binder whose degradation at elevated temperatures is catalyzed by additions of a ferric compound. The gelating binder is a mixture of proteins derived from amino acids such as glycine, alanine, L-glutamic acid, L-aspartic acid, and/or small percentages of others, such that the gelatin binder is water soluble and therefore easily eliminated from the core sand at the end of the casting process. Due in particular to the presence of the ferric compound, the gelatin binder readily degrades at low temperatures, such as those associated with aluminum casting processes, such that the core degrades sufficiently to permit the sand to freely flow from the cast article without the need for core removal operations.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying a disturbance to the stream, preferably an amplitude modulated disturbance, to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for disturbing the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.

Abstract: A foundry machine for forming molds or cores from a molding material such as sand provides completely automated loading and unloading of tooling elements (24). The tooling elements (24) comprising a sand magazine (36), blow plate (34), combined gassing manifold and top ejector unit (32), upper mold box (30), lower mold box (28) and bottom stool (26) are automatically transferred, in stacked, separable relationship, by tracks (40) to a vertically displaceable, work table. Vertical displacement of the work table (42) sequentially elevates the tooling elements (24) to positions within a mainframe (10) where automatically operated clamping means secure the appropriate tooling elements (24) in respective operating positions. The gassing manifols (32) includes an ejector pin assembly (274, 280) mounted therewithin.

Abstract: A method and apparatus for producing flaskless foundry molds made up of copes and drags of wet casting foundry sand, which is blasted into a cavity to form the mold with the use of vacuum. The sand is pressed mechanically while aspirating air therefrom. The gap coming into existence between the pressing plate and the back side of a mold during pneumatic impact compaction is filled with sand before pressing so that a flat back side is produced on the mold so that when casting takes place later there is not danger of the bottom of the mold fracturing or of deformation taking place.

Abstract: A process and apparatus for automating a hot-air baking cycle of sand molds. Such process and apparatus make it possible to regulate the hot-air baking or drying speed in a sand mold during a baking cycle. This regulation can be accomplished before casting, and in particular, before low-pressure casting. The process includes dividing the cycle into characteristic phases associated with particular baking parameters. The apparatus includes a calculator assembly for obtaining baking parameters. The invention can be used for the baking of foundry molds, and particularly, foundry molds for aeronautical parts.

Abstract: In the production of frozen moulds (12) or cores the freezing process is accelerated by drawing the liquefied freezing agent, such as nitrogen, used for freezing the water in the mould bodies, into or through the bodies by the application of a vacuum.

Abstract: An apparatus for hardening cores and/or molds made of sand with the addition of hardenable binding agents, which are used for casting molded bodies from flowable substances, is described, whereby an amount, predetermined by metering devices controlled via control valves, of the substance which causes the binding agent to harden is introduced into the core or mold by aid of compressed air the rate of flow of which is regulatable by a regulating valve, whereby this substance is mixed with this compressed air, and the regulating valve is automatically controlled according to a predetermined schedule. The apparatus can be carried out with considerably fewer components and the necessary control means can in particular be designed much more simply if, according to one embodiment, the regulating valve is controlled by means of a proportional pressure regulating valve which is operated by an external control means which also controls the other control valves.

Abstract: A process for making a foundry mold for use in metal casting, which comprises the steps of heating and drying mold sand composed of refractory particles and a water-soluble binding agent, charging a cavity formed in a mold pattern with the mold sand under dried condition, during the charging step, moisture being kept on the peripheral surface of the mold to be made, and heating the whole pattern of which the cavity has been filled completely with the mold sand to thereby cure mainly the peripheral surface of the mold.

Abstract: Binder, filler, and refractory compositions and methods of using and making these compositions are disclosed. The binder composition comprises colloidal silica, a liquid material containing Si--OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from phosphorus, sulfur, boron and nitrogen and which stabilizes the binder composition against self-gelling. The liquid material and the colloidal silica are present in a ratio by weight of from about 10:1 to about 1:10 respectively. The liquid material has at least about 20% by weight SiO.sub.2. The colloidal silica contains at least about 15% by weight SiO.sub.2.

Abstract: A refractory for use in casting of molten metal which essentially comprises refractory material comprising corundum and monoclinic zirconia as principal mineral phase and including Al.sub.2 O.sub.3 and ZrO.sub.2, silicon-containing powder and carbon-containing powder and which optionally includes first additional refractory material comprising mullite, baddellite and corundum as principal mineral phase and including Al.sub.2 O.sub.3, ZrO.sub.2 and SiO.sub.2, one or more second additional refractory materials and/or alumina.

Abstract: In the production of frozen moulds (12) or cores the freezing process is accelerated by drawing the liquefied freezing agent, such as nitrogen, used for freezing the water in the mould bodies, into or through the bodies by the application of a vacuum.

Abstract: A process and apparatus for automating a hot-air baking cycle of sand molds. Such process and apparatus make it possible to regulate the hot-air baking or drying speed in a sand mold during a baking cycle. This regulation can be accomplished before casting, and in particular, before low-pressure casting. The process includes dividing the cycle into characteristic phases associated with particular baking parameters. The apparatus includes a calculator assembly for obtaining baking parameters. The invention can be used for the baking of foundry molds, and particularly, foundry molds for aeronautical parts.

Abstract: A method of compacting particulate material includes providing a primary fuel mixture of air and natural gas in a closed chamber enclosing a surface of the material to be compacted. An additive gas, such as hydrogen, having a higher combustion velocity is added to the primary fuel/air mix and ignited, creating an exothermic reaction which compacts the material. The additive gas increases the gradient of the pressure rise curve of the combustion. Various fuels and additive gases and disclosed.

Abstract: A foundry composition adaptable to forming cores and molds comprising a foundry aggregate, a binder therefor, a catalyst and an amine, the binder being a substituted phenol.

Abstract: In a method for producing a mold for metal casting capable of being easily disintegrated by water which comprises the steps of kneading alumina sand with hydrous sodium aluminate as a binder, forming the kneaded mixture into the desired mold shape and then passing carbon dioxide gas through the mold to decompose sodium aluminate and harden it; the improvement wherein the kneading of alumina sand with the binder before mold formation is carried out in an atmosphere of carbon dioxide gas to decompose 50 to 80% of the sodium aluminate in advance.

Abstract: A process for producing hollow items, for instance foundry cores by reacting a catalyst gas with binder coated on mineral granular material includes providing a core box having a pattern formed of microporous material and investing binder-coated granular material into a volume defined by the pattern. The core box is then sealed so that the volume encloses a gas, for instance air at atmospheric pressure, within the granular material. A catalyst gas is applied at a predetermined pressure through the pattern so that the catalyst gas exerts a uniform pressure from the interior surface of the pattern against the enclosed air volume. The catalyst gas will penetrate a distance through the granular material for curing same determined by an equilibrium condition being reached between the applied catalyst gas pressure and air pressure which results from contraction of the volume.

Abstract: The present invention concerns the use of an aqueous solution of a silicate as a binder, particularly for hardening foundary molds and cores without the use of acid or other reagents to convert the silicate into a silican gel. According to the present invention, the silicate binder is not reacted but instead is rapidly dried, preferably enough within the space of 5 seconds to 10 minutes to reduce the initial water content of the aqueous silicate solution by at least 25%. In the preferred embodiments, this is achieved by forcing air through opposed porous sides of the mold box and the green sand contained therein. The present invention is also applicable to other composite forms such as the manufacture of plywood, particle board, briquettes, and the like.

Abstract: A method of making molds, wherein facing sand prepared by using a binder which will retain its plasticity for a long time is spread into a thin sheet, which is then cut into suitable pieces according to the shape of a pattern, which pieces are then placed on the surface of the pattern or applied thereto while being connected together, thereby forming a layer of facing sand of uniform thickness, whereupon backing sand is charged to fill the cavity and rammed around, thereby making a mold. This method is effective to reduce the amount of facing sand used, improve the dissipation of gases and heat and uniform the pressure-resisting strength in the various portions, thereby eliminating various casting defects.

Abstract: The improved process comprises placing in an open top, walled enclosure a pattern plate carrying the pattern for the core or mold part to be produced. The height of the pattern plate is adjustable relative to the tops of the walls of the enclosure so that when sand coated with a polymerizable resin is poured onto the top of the pattern the excess sand flows over the tops of the walls, covering the pattern with a mound of sand the slope of the walls of which is determined by the angle of least repose of the sand. A squeeze head having a surface corresponding to the surface of the pattern is now pressed downwardly onto the top of the pile of sand, to compact the sand about the pattern. While thus held by the squeeze head, material such as gas is passed from the bottom of the mold or core up through the now compacted sand, thus to polymerize the resin. The squeeze head is removed and the now cured, resin sand core or mold part is removed, ready for use in the usual way.

Abstract: The invention concerns the binding of refractory powders into self-supporting `green` shapes which are fired to provide refractory objects. In accordance with the invention the binders are based on zirconium salts and include a separate gell time delaying agent to ensure satisfactory gelling and to achieve control and to allow complex shapes to be made.

Abstract: A method of producing a mould of particulate material comprises admixing the particulate material with a controlled quantity of water, compacting the mixture to the required shape on a pattern or the like, removing the compacted mass from the pattern, and directing at at least the surface of the compacted mould to be contacted by molten metal a stream of coolant, whereby at least that surface is frozen to a depth sufficient to withstand the conditions imposed during the pouring of molten metal into the mould.

Abstract: Disclosed are foundry binder compositions comprising boronated aluminum phosphate and water, cured by contacting them with gaseous ammonia or an amine. Optionally the composition may also include alkaline earth metals and oxides, and solid polyhydric alcohols or solid organic carboxylic acids.

Abstract: Molding composition particularly suited for molding foundry cores and molds is obtained by mixing the components of a polyurethane resin with aggregate (sand), a silane, and iron oxide, molding the mixture to a desired shape and curing it.

Abstract: A shaped mass of particulate material such as foundry sand, admixed with a polymerizable binder, is instantly completely hardened by contact of gas catalyst therewith. The preferred method and apparatus in accordance with the present invention involves first inducing a vacuum within the shaping space of the shaping element and includes employing means for catalyst gassing of the space within the shaping element rather than of the space within the chamber in which the shaping element resides. In addition, a relatively small "aftervoid" chamber is provided and is connected to the shaping cavity at some location therein which is approximately opposite the location of the gas catalyst inlet. The latter eliminates uncured pockets which tended to result from prior methods and apparatus.

Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.