Abstract: In the method for manufacturing conglomerate stone slabs using the Bretonstone technology, in the variant where the starting mixture is enclosed between two paper sheets, the improvement consists in replacing each paper sheet with a containment element consisting of a paper sheet, one surface of which has, applied thereon, a film of plastic material which is impermeable to organic vapours, impermeable to the liquids and in particular to the liquid resin constituting the binder of said mixture, resistant to the catalysis temperatures of the said resin and resistant to hot solvents and chemical vapours. Preferably, said plastic material is water-soluble, in particular polyvinyl alcohol.

Abstract: A mold includes an ingot mold and a top core. The top core is disposed in and/or on the ingot mold. The top core forms, in part, a functional surface of a component formed in the mold and the ingot mold forms at least a sub-region of the functional surface of the component formed in the mold.

Abstract: A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

Abstract: A continuous casting mold according to the present invention has plural separate portions filled with a metal of low thermal conductivity formed by filling a metal having a thermal conductivity of 30% or less of that of copper into circular concave grooves having a diameter of 2 to 20 mm which are formed in the region of the inner wall surface of the copper mold from an arbitrary position higher than a meniscus to a position 20 mm or more lower than the meniscus, in which the filling thickness of the metal in the portions filled with the metal of low thermal conductivity is equal to or less than the depth of the circular concave grooves and satisfies the relationship with the diameter of the portions filled with the metal of low thermal conductivity expressed by expression (1) below: 0.5?H?d??(1).

Abstract: A casting method using combined 3D printed shell mold and the combined shell mold used in the method. The method consists of shell mold making and casting steps. The shell mold is constructed by combination. First, the 3D printer at least prints out a runner part and several pattern die parts for molding products. In the print run, the first interfaces corresponding to the quantity of pattern die parts are printed out integrally on the runner part. The second interfaces corresponding to the first interfaces are formed on the pattern die parts. Afterwards, the first interfaces and the second interfaces are butted, the primary runner in runner part is connected to the die cavities in pattern die parts, the runner part and pattern die parts are combined to form a shell mold for casting multiple products at a time.

Abstract: A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

Abstract: A method of making a refractory metal core includes forming two layers of the core out of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and pulverulent refractory metal material is poured into the flexible mold. The pulverulent refractory metal material is sintered to form the refractory metal core.

Abstract: A mold half, especially for blow molding of thermoplastic articles, has a mold body defined at least in part by a single piece of aluminum or aluminum alloy mold material having a cavity and a pinch-off or other feature area and further having a metal-matrix composite (MMC) layer formed integrally in the mold body at the pinch-off or other feature area. A mold is fabricated from two mated mold halves. A process of producing a mold half involves machining a single piece of mold material to provide a mold body having a cavity and a pinch-off or other feature area, the pinch-off or other feature area being of smaller dimension than required for the mold half, integrally forming a metal-matrix composite layer in the pinch-off or other feature area to build up the pinch-off or other feature area to at least a dimension required for the mold half. The metal-matrix composite comprises an aluminum-nickel alloy matrix (e.g. AI-12Si alloy alloyed with Ni) having WC particles embedded therein or a aluminum matrix (e.g.

Abstract: Provided are a method of manufacturing an aluminum-zinc-based alloy sheet using twin-roll casting and an aluminum-zinc-based alloy sheet manufactured thereby. Specifically, a method of manufacturing an aluminum-zinc-based alloy sheet, including preparing a melt by melting elements corresponding to an aluminum alloy including 0.5 wt % to 10 wt % of zinc, inevitable impurities and aluminum as a balance (step 1); and twin-roll casting by introducing the melt prepared in step 1 between a pair of rotating cooling rolls (step 2), and an aluminum-zinc-based alloy sheet manufactured thereby are provided. The present invention may manufacture an aluminum-zinc-based alloy sheet, in which twin-roll casting is known to be difficult due to a wide solid-liquid coexistence region, by twin-roll casting by using cooling rolls having high thermal conductivity and controlling a reduction force by the rotational speed of the rolls.

Abstract: A water-soluble insert for use in joining pipes, made of a material comprising a salt selected from the group consisting of KCl, Na Cl, and mixtures thereof; and MgO. Upon addition of a small amount of water to the material, the MgO reacts with hygroscopic impurities in the chloride salt to provide a material with superior properties. The insert is cast from the material, in general by being placed on a form and compressed. Also disclosed is the use of the insert in joining the ends of two pipes, especially pipes made from thermoplastic. The insert is placed in the matching pipe ends, which are then welded. After the join is complete, water is flowed through the pipe, dissolving the insert.

Abstract: A method of producing an injection molding tool for molding an article includes producing a replica of the article using at least one of an additive manufacturing process, a solid freeform fabrication process, or a computer numerically controlled (CNC) process. A support block is configured to receive at least a portion of the replica and support the replica with at least one of an outer peripheral surface of the replica or an inner peripheral surface of the replica positioned at a spaced distance from a peripheral surface of the support block. The replica is supported inside the support block at the spaced distance, a ceramic resin material is introduced into the spaced distance and cured to form a ceramic shell insert, the insert is removed from the cavity, and the insert is positioned within the support block to form a part of a mold tool adapted for installation in a standard plastic injection molding machine.

Abstract: Disclosed are embodiments of a vessel configured to contain a secondary magnetic induction field therein for melting materials, and methods of use thereof. The vessel can be used in an injection molding apparatus having an induction coil positioned adjacent to the vessel. The vessel can have a tubular body configured to substantially surround and receive a plunger tip. Longitudinal slots or gaps extend through the thickness of the body to allow and/or direct eddy currents into the vessel during application of an RF induction field from the coil. The body also includes temperature regulating lines configured to flow a liquid within. The temperature regulating lines can be provided to run longitudinally within the wall(s) of the body between its inner bore and outer surface(s). A flange may be provided at one end of the body to secure the body within an injection molding apparatus.

Abstract: A method for manufacturing a moth-eye mold of an embodiment of the present invention employs a mold base including a metal base, an organic insulating layer provided on the metal base, and an aluminum alloy layer provided on the organic insulating layer, the aluminum alloy layer containing aluminum and a non-aluminum metal element M, an absolute value of a difference between a standard electrode potential of the metal element M and a standard electrode potential of aluminum being not more than 0.64 V, and a content of the metal element M in the aluminum alloy layer not exceeding 10 mass %.

Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.

Abstract: Devices may be in contact with molten metals such as copper, for example. The devices may include, but are not limited to, a die used for producing articles made from the molten metal, a sensor for determining an amount of a dissolved gas in the molten metal, or an ultrasonic device for reducing gas content (e.g., hydrogen) in the molten metal. Niobium may be used as a protective barrier for the devices when they are exposed to the molten metals.

Abstract: A tubular melt containment member for transient containment of molten metals and alloys, especially reactive metals and alloys, includes a melt-contacting layer or region that comprises an oxygen-deficient rare earth oxide material that is less reactive as compared to the counterpart stoichiometric rare earth oxide. The oxygen-deficient (sub-stoichiometric) rare earth oxide can comprise oxygen-deficient yttria represented by Y2O3-x wherein x is from 0.01 to 0.1. Use of the oxygen-deficient rare earth oxide as the melt-contacting layer or region material reduces reaction with the melt for a given melt temperature and melt contact time.

Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.

Abstract: The present invention provides a structure for casting containing an organic fiber, an inorganic fiber, inorganic particles (A) having an average particle diameter of 50 to 150 ?m, and a binder (a), having a surface layer containing refractory inorganic particles (B) having an average particle diameter of 1 to 100 ?m selected from metal oxides and metal silicates, a clay mineral, and a binder (b), on the surface of the structure.

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 mold includes: a base; and a contact surface which is provided on the base and which comes into contact with a molten material. The contact surface is provided with a first surface portion that includes a first fiber layer in which first carbon fibers are raised, and a second surface portion having different surface characteristics from the first surface portion.

Abstract: This invention teaches an improved apparatus and method to make metal alloy castings, such as freight car yokes. One embodiment of the invention comprises a core mold assembly unit, wherein the mold unit is filled with molten metal. The core mold assembly units may be further formed of the same material, such as phenolic urethane impregnated sand, which is used to accurately replicate the desired shape of a final desired product.

Abstract: A molten metal casting die having a modified surface, a method for making such dies, and a method for making articles of manufacture from such dies is disclosed. The methods are designed to protect die steel surfaces having a protective coating from corrosion by molten metals substantially containing liquid copper.

Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: Tubular metal articles such as pipe and cylinder liners are produced by centrifugal casting on a permanent metal mold coated by refractory glass on the active surface. A coating suspension mix is evenly distributed onto the mold to form a uniform layer of insulation on the surface of the mold. The material for the coating comprises of essentially a waterborne suspension mix of glass particles. The suspension is given time to dry on the surface of the mold. The glass particles dispersed in the suspension are both non-crystalline and nonporous. The glass particles in the suspension and forming the coating are not dissolved and do not chemically attract the polar water molecule or cause it to bond to the surface of glass in the suspension or to the mold active surface. Articles cast as such are smooth surfaced and require only limited machining.

Abstract: A method for the casting of cast parts from an iron melt forming vermicular or spheroidal graphite, includes casting iron melt into a casting mold, which includes at least one casting mold part, which is formed from a mold material, which is mixed from a sand-type basic material and an organic binder, and then gassed with a gas containing sulphur in order to harden the binder, such that a mold part of stable form is obtained. The method provides embodiments in which molds produced in accordance with the SO2 process enable the risk of occurrence of local microstructure degeneration in the cast part to be reduced to a minimum. This is achieved in that, after the hardening of the mold part and before the casting, at least one of the surfaces, which comes into contact with the iron melt, is provided with a coating containing a non-volatile sulphide former.

Abstract: The present invention provides a sealing ring and a preparation method thereof. The sealing ring, based on percent by weight, includes 80%-85% of aluminum, 10%-15% of titanium, 0.1%-1% of scrap iron, and 4%-4.9% of potassium fluoroaluminate. Moreover, the present invention provides a method for preparing sealing ring, which includes the following steps: Step A: melting the aluminum in a medium-frequency induction furnace, adding the potassium fluoroaluminate to the medium-frequency induction furnace after melting the aluminum, melting and stirring the mixture evenly; Step B: adding titanium scrap or sponge titanium, and scrap iron to the mixture successively, melting and mixing the mixture totally at 800° C. to 1200° C., standing the mixture after stirring evenly; Step C: removing scum on the surface; Step D: casting into a mould to obtain a final sealing ring.

Abstract: The invention concerns a metal, iron-containing permanent mold, in particular a permanent mold made of steel, which can be subjected to a liquid or flowable aluminum material, and in which a coating for protecting the permanent mold and for achieving an optimal casting result can be produced using a mold release agent. The invention additionally concerns a mold release agent for producing such a coating, and a method for producing such a coating.

Abstract: The present invention relates to a refractory coating for producing mold coatings by application to inorganically or organically-bound molding materials in lost molds or to cores for iron and steel casting, wherein the ready-to-use refractory coating has proportion by weight of 0.001% or more and less than 1% of inorganic hollow bodies, which partially or fully consist of crystalline material and have a softening point of 1000° C. or higher.

Abstract: The object of the present invention is to provide a casting method capable of simultaneously attaining the shortening of cycle time and the improvement in casting quality. The pressure allowing the molten metal level to go up to the positions of from P0 to P4 is applied to the molten metal within a molten metal reservoir 1. Then, the pressure of P4 is maintained for a predetermined time. During this time, the molten metal which comes into contact with an upper die 4 is cooled earlier than the molten metal being in contact with another die. Through this cooling the molten metal shrinks. However, since the pressure of P4 is maintained, the molten metal is supplied from the lower side to a shrunk portion, so as not to cause shrinkage cavity or underfill.

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: The objective of the present invention is to provide a product that is superior in barrier properties (for example, zinc erosion resistance and anti-adhesive property), abrasion resistant property, surface hardening property, thermal stability and life-time prolonging property. The product, which is made in direct contact with molten metal containing zinc in a molten state, is characterized by including an iron-tungsten alloy coating that is applied to a part or the whole of the surface of the product that comes directly in contact with the molten metal.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: The invention relates to methods of making articles of semiconducting material on a mold comprising semiconducting material and semiconducting material articles formed thereby, such as articles of semiconducting material that may be useful in making photovoltaic cells.

Abstract: There is provided a hard-material-coated member which is suitable as a long-life mold for plastic working of metals and which has a metal as base material and coating layers formed at least on its working plane by physical vapor deposition. At least three layers, i.e., a layer a) as the outermost layer, a layer c) just above the base material and a layer b) between layer a) and the layer c) are formed as coating layers. The hardness values of these layers in terms of hardness symbol HV 0.025 are as follows: 2500>(the hardness of the layer a)>1000, 3500>(the hardness of the layer b)>2300, 2500>(the hardness of the layer c)>1000, (500+the hardness of the layer a)<(the hardness of the layer b), and (500+the hardness of the layer c)<(the hardness of the layer b); the thickness of the layer b) is smaller than that of the layer c); and the total thickness of the coating layers is 5 to 15 ?m.

Abstract: This invention relates to a process for making foundry shapes (e.g. cores and molds) using epoxy-acrylate cold-box binders containing an oxidizing agent and elevated levels of an organofunctional silane, which are cured in the presence of sulfur dioxide, and to a process for casting metals using the foundry shapes. The metal parts have fewer casting defects because the foundry shapes made with the binder are more resistant to erosion.

Abstract: A powder product for the protection of centrifugal casting molds for cast iron pipes includes an inoculating metal alloy and possibly mineral powders, and a strongly reducing metal that is volatile at the temperature of the liquid cast iron. The use of products according to the invention prevents accumulation of dirt on molds and improves the surface condition of the cast iron pipes.

Abstract: A method of the surface treatment of a mold for casting, which comprises subjecting a cavity surface of a fixed mold made by the use of a SCM420 material to first shot peening, a sulfurizing-nitriding treatment and second shot peening. The resulting cavity surface of the fixed mold exhibits a high hardness of 700 or higher in terms of Vickers hardness due to the presence of a sulfurized and nitrided layer, and further has a compression residual stress of more than 1200 Mpa and a largest height, which is a surface roughness value defined by JIS standard, of 8 ?m or less.

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: In a method of making a subframe of a motor vehicle profile elements made of hollow sections of steel are placed in a casting tool. Subsequently, aluminum material is filled into the casting tool to casting around the profile elements so as to form plural cast nodes on the profile elements in spaced-apart relationship.

Abstract: In order to increase the endurance and lifetime of highly loaded components (6, 8, 12, 14, 24, 26, 34) of a steelworks, an electrolytically applied coating (38) is provided, having a ductile metallic base material (39), in particular nickel or a nickel alloy, with hard material particles (40), in particular boron carbide particles, incorporated in it. This measure achieves high resistance to corrosion, good thermal conductivity and at the same time high mechanical loadability.

Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends. The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of +/?0.060 inches.

Abstract: Disclosed herein are methods for forming casting molds. In one embodiment, a method for forming a mold comprises casting a mold having a cavity surface, forming surface features on the cavity surface, wherein the surface features comprise a mixture, and heat treating the mixture. In another embodiment an article is disclosed.

Abstract: A method of forming at least one concavity of a selected size and shape within a surface of an internal passageway of a metallic component comprises: depositing a ceramic-based material by a direct-write technique onto a ceramic core which is suitable for forming the internal passageway during a casting process to form the metallic component, wherein the ceramic-based material is deposited as a positive feature; heat-treating the deposited ceramic-based material; forming the metallic component by a casting process in which the ceramic core is incorporated into the casting, in a position selected as a desired position for the internal passageway; and then removing the ceramic core from the metal component after the casting process is complete, thereby forming the internal passageway, with the concavity contained within the surface of the passageway, said concavity formed by removal of the positive feature of the ceramic-based material.

Abstract: A green product for use in fabricating a ceramic article comprises a ceramic powder immobilized within a silicone matrix, wherein the silicone matrix comprises one or more cross linked or polymerized silicone monomers and/or oligomers, wherein the one or more cross linked or polymerized silicone monomers and/or oligomers have a alkenyl reactive functional group and a hydride reactive functional group. Processes for forming a green product and a ceramic core with the silicone monomers and/or oligomers are also disclosed.

Abstract: A die coating for use on the surface of a metal mold or die component contacted by molten metal in low pressure or gravity die casting, and a method for its production. The die coating includes a porous layer of ceramic material produced by co-deposition, using a thermal spraying procedure, of a powder of said ceramic material and a powder of an organic polymer material. After the co-deposition, the co-deposited layer is heated to remove the polymer material, and provide the porous layer of ceramic material.

Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of +/?0.060 inches.

Abstract: A metal object is formed by die-casting with the use of a specially treated mold. The mold has cavity-defining surfaces covered by a heat-insulating layer made of a material that includes ceramic powder and heat-resistant resin. Molten metal is injected into the cavity coated with the heat-insulating layer.

Abstract: A simple, cost-effective stamping or molding in the nanometer range is enabled using a stamping surface or molding face with a surface layer having hollow chambers that have been formed by anodic oxidation.