Abstract: Refractory coated gelatin-bonded foundry sand core made by waterproofing the surface of the core and immersing the waterproofed core in an aqueous refractory suspension to deposit the refractory.

Abstract: A plastic forming die for formation of outer surface is set on the inner surface of a cavity of a die. The forming die has a forming die body in a square barrel shape, and there are a lot of through holes provided between mount surfaces and inner side surfaces of the forming die body. Grooves communicating with the through holes are provided in the mount surfaces. When a molten metal is injected into the cavity, the through holes of the forming die body form outwardly projecting portions of a cast product. The forming die is then melted to be removed from the cast product.

Abstract: An apparatus for processing materials which are highly corrosive while in a thixotropic state, for example aluminum. The apparatus includes a barrel which is adapted to receive the material through an inlet. In the barrel, the material is heated and subjected to shearing, forming a highly corrosive, semi-solid slurry which is discharged from the barrel through a nozzle. The barrel is constructed with an outer layer of a first material and an inner layer of an Nb-based alloy which is bonded to the outer layer. Positioned within the passageway of the barrel is a screw, the rotation of which operates to subject the material to shearing and move the material through the barrel. The screw is constructed with an outer layer of the Nb-based alloy that is molecularly bonded to an inner core of a different material. The Nb-based alloy is resistant to the corrosive effects of the material being processed.

Abstract: The present invention is directed to a foundry sand additive composition, and method of casting molten metal against a foundry sand containing the additive composition. The additive composition comprises a humic acid-containing and/or a humic acid salt-containing ore (hereinafter referred to separately or in combination as "humic-containing ore") and carbon or graphite or admixtures of carbon and graphite. The combination of carbon and/or graphite and the humic-containing ore react in-situ when the foundry sand is heated by contact with molten metal, at temperatures of about 450.degree. F. to about 2300.degree. F., particularly in the range of about 600.degree. F. to about 2000.degree. F., to activate the carbon and/or graphite. The carbon and/or graphite, activated in-situ during the molding process, absorb and/or adsorb (sorb) gaseous volatile organic compounds (VOCs) within the mold, so that the VOC gases are held by the in-situ-activated carbon and/or graphite to satisfy VOC emissions requirements.

Abstract: Mold for permanent mold casting having a RPVD ceramic coating atop a mold surface which is textured to provide a specific microtopography suitable for eliminating misruns in the casting.

Abstract: The present invention is directed to an activated carbon and/or activated graphite foundry sand additive, and method of casting molten metal against a foundry sand containing the additive composition. In another embodiment, the activated carbon and/or activated graphite additive (or portion thereof) is formed in-situ by adding to the foundry sand a humic acid-containing and/or a humic acid salt-containing ore (hereinafter referred to separately or in combination as "humic-containing ore") and carbon or graphite or admixtures of carbon and graphite. The combination of carbon and/or graphite and the humic-containing ore react in-situ when the foundry sand is heated by contact with molten metal, at temperatures of about 450.degree. F. to about 2300.degree. F., particularly in the range of about 600.degree. F. to about 2000.degree. F., to activate the carbon and/or graphite.

Abstract: In the production of castings from a melt of a reactive metal selected from the group consisting of titanium, titanium alloys, and titanium-based alloys, a reusable casting mold (20) is used; the mold, at least in the area of the surface which comes in contact with the melt, consists of at least one metal selected from the group consisting of tantalum, niobium, zirconium, and/or their alloys. The casting mold (20) preferably consists, at least in the area of the surface which comes in contact with the melt, of a tantalum based alloy containing at least 50 wt. % of tantalum. The casting molds can be made of a homogeneous metal, but it is also possible to insert shells of the metals in question into a base body to form the boundaries of the mold cavities, whereas the base body itself consists of some other metal or alloy or of a nonmetal such as graphite or silicon nitride.

Abstract: A one-piece steering wheel is formed as a unitary casting from an alloy that includes 11.5% to 14% by weight silicon, and 350 to 450 parts per million strontium. Preferably the steering wheel mold is rotated during casting at relatively high rotational speeds exerting 100 g to 250 g force on the wheel. An optimum rotational speed is disclosed. A one-piece steering wheel formed according to the invention exhibits minimal length ferro-silicon hair-like strands, and thus exhibits reduced brittleness.

Abstract: A one-body hollow precision cast metal golf club head is fabricated by casting metal about a head core to form a shell, and melting and flowing out the head core. The head core is made of low melting point alloys having a melting point lower than that of the metal used for casting the shell and is coated with an aqueous solution prior to the casting process of the shell. The aqueous solution is a composition including inorganic powders, binders and solvent. The ratio of components should be inorganic powder:binder:solvent=(40-80):(1-10):(10-59) based on weight.

Abstract: A mold for continuous casting comprises a copper or copper alloy mold substrate and a sprayed coating film formed on non-blasted inner surfaces of the substrate with or without a metal plated skin layer provided between the substrate and the film. For the formation of the sprayed coating film, particles of at least one tungsten carbide-based wear-resistant material having a particle size of from 5 .mu.m to 53 .mu.m and having a hardness capable of anchoring in the inner surfaces of the substrate are subjected to high pressure/high velocity oxygen fuel coating under conditions where the particles remain at least partially non-fused on application of heat from a spraying flame. By this, a layer directly anchored in the inner surfaces of the substrate or in the skin layer, if present, is formed at least as one layer of the sprayed coating film formed in a total film thickness of from 0.01 to 6 mm.

Abstract: Steel tooling for die-casting low iron content aluminum alloys is surface treated with a layer of CrN applied to a thickness of at least 4 microns, and preferably 5-10 microns, by physical vapor deposition (PVD), and preferably a steered are evaporation PVD process. The CrN protects the steel tooling from dissolution and erosion by the highly active molten aluminum.

Abstract: A casting apparatus for low-melting metals has a coating layer of two-layered structure which hardly reacts with low-melting metals, adheres firmly to the substrate, and protects the substrate from thermal and mechanical shocks for a long period of time. The layer in contact with the substrate contains glass powder having a melting point below 1000.degree. C. and at least one binder selected from silicates and phosphates. The layer in contact with molten metal contains 5-80 wt. % of at least one fluorine compound (as a corrosion resistant material) having a melting point of above 700.degree. C. Owing to the multiple layers, each having a specialized function, the casting apparatus has improved durability over a long period of time.

Abstract: A grid casting mold for the casting of accumulator lead grids has two plates (11, 12) which can be placed against one another with a casting profile (13) or mold cavity complementary to the lead grid which is to be manufactured being formed in their confronting mold surfaces. The plates (11, 12) moreover have a base body (14, 15) which is provided at the profile side with a thermally insulating layer (16, 17) of high temperature fiber ceramic material which is coated on the side remote from the base body (14, 15) with a high wear resistant metal oxide (18, 19).

Abstract: A core for casting titanium or an alloy thereof consists essentially of a sintered formed substrate of a powder having as its main component either mullite powder alone or a combination of mullite powder and at least one member selected from among quartz glass, alumina, zircon, magnesia, and cristobalite and a surface layer formed of at least one member selected from among yttria, zirconia, hafnia, alumina, neodymium oxide, and samarium oxide and deposited as a coating layer on the surface of the formed substrate.

Abstract: A mold comprising a cavity for defining the shape of a casting and a mold body for forming said cavity, comprising: a mold body formed of an ordinary temperature setting resin or thermosetting resin and casting sand, said mold body having a surface layer portion on the surfaces thereof including depressions, said depressions in the surface layer portion being filled up with at least one porous powdered material selected from the group consisting of hydrous magnesium silicate clay mineral, activated carbon and activated alumina, thereby providing the mold body with smooth surfaces whereby said mold generates less amount of material such as gums which cause defective castings during casting since molten metal is restrained from intruding into the walls of said mold.

Abstract: A melt-out zinc core is coated with insulating mica material and a graphite release agent and supported within a die cavity of a high pressure squeeze casting apparatus. Molten casting metal having a melting temperature above that of the core is injected into the die and then pressurized to about 15,000 psi to squeeze form the article in the die and around the core. The resultant article and core are then heated to above the melting temperature of the core and the core extracted from the article through cast-in outlet openings formed by the core. The insulating material and release agent are also extracted from the cast article by rinsing the cored passages of the cast article with water.

Abstract: A metallic mold for casting a vehicle wheel having openings in a periphery of a disk portion of the wheel comprises a first mold for forming that external side of the wheel which faces an outside of a vehicle when mounted thereon and a second mold for forming an internal side of the wheel. The first mold has those projections for forming the openings which abut the second mold. A high-hardness coating material is coated by electric discharge coating on at least those base portions of the projections which extend diametrically inwards of the wheel, among outer surfaces of the projections. A coating of a mold coating agent is formed on portions of sharp draft in the projections. The coating has a three-layer construction comprising an under coat coated with a mold coating agent consisting essentially of ceramics, a middle coat coated with a mold coating agent consisting essentially of a mixture of boron nitride with ceramics, and a top coat coated with a mold coating agent consisting essentially of titania.

Abstract: Titanium based and nickel based castings are made by casting a suitable melt having a relatively low melt superheat into a mold cavity defined by one or more low carbon steel or titanium mold members where the melt solidifies to form the desired casting. The melt super-heat is limited so as not to exceed about 150.degree. F. above the liquidus temperature of the particular melt being cast. For a steel mold, one or more titanium melt inlet-forming members are provided for cooperating with the steel mold members to form an melt ingate that communicates to the mold cavity for supplying the melt thereto in a manner to avoid harmful iron contamination of the melt during casting. The mold body-to-mold cavity volume ratio is controlled between 10:1 to 0.5:1 to minimize casting surface defects and mold wear/damage.

Abstract: A foundry sand binder composition and method of manufacturing cast metal objects by casting molten metal into a mold cavity formed of sand held in a predetermined mold configuration by a binder comprising a plurality of sodium bentonite clays. A blend of two or more sodium bentonite clays obtained from different areas as a foundry sand binder synergistically and unexpectedly improves the foundry sand used as a mold cavity for casting metal objects by unexpectedly improving one or more of the following foundry sand properties beyond the level of either of the blended sodium bentonites alone: green compressive strength; hot compressive strength; dry compressive strength; wet tensile strength; flowability; surface finish; activation speed and shakeout.

Abstract: Methods are known for producing a body from a material susceptible to thermal cracking, in particular from an alloy, by casting a melt of the material in a mold with thermally insulated side walls and a bottom of material with good thermal conducting properties and cooling the melt in the casting mold, where the solid-liquid interface forming as the border between the melt and the already solidified material essentially extends parallel to the bottom and, in the course of the solidification of the melt, moves from the bottom in the direction of the exposed surface of the melt.

Abstract: This invention provides a copper or copper alloy mold for continuous casting of steel characterized in that a nickel-boron alloy plating layer containing 0.06 to 0.3 wt. % of boron is formed on its interior surface.

Abstract: In forming an aluminothermic weld between adjoining rail ends, a sand mold is arranged around the rail ends disposed in spaced relation. The sand mold is formed at least in part of silica sand. The surface of the mold in contact with the rail ends and enclosing the space between the rail ends is formed of one of a combination of silica sand and zircon sand, a layer of zircon sand inwardly from a layer of silica sand, or a thin layer of a zircon mold wash on a surface formed of silica sand.

Abstract: A mold for lead casting comprising a porous metal material which does not form an alloy with molten lead and which has a thermal conductivity of from 3-15 kcal/(m.multidot.hr.multidot..degree.C.) and having a percentage of pores having a radius larger than or equal to 40 microns being 7% or less of the total pore volume. The porous metal material has a permeability of at least 0.2 ml/sec.multidot.cm.sup.2 at a material thickness of 10 mm and ambient pressure of 0.02 kg/cm.sup.2. A casting mold enabling casting of a lead grid without using a lubricant due to the lubricity of the mold material itself is realized.

Abstract: A continuous steel casting mold includes walls with base members of copper alloy which are provided with cooling ducts. In order to improve the wear resistance and to prevent cracks, a working coating of pure copper is provided on the base members. It is also possible to provide an intermediate layer of pure copper on the base member and a working coating on the intermediate layer. The layer of pure copper has a thickness of at least 0.2 mm.

Abstract: The disadvantages of the prior art are substantially overcome by a twist lock junction and method having the mating joints of refractory tubular shapes formed in a polygonal configuration. Each junction includes a polygonal female recess and a complementary interfitting polygonal male projection. The female recess is dimensionally larger than that of the adjoining male projection. When either the female or male joint is rotated clockwise or counterclockwise relative to the other, a multi-point wedging or "twist lock" effect occurs. This wedging condition offers a tighter fit than the conventional gravity or circular fit. In addition, this "twist lock" effect squeezes the mortar applied to the joints and forces a thin seal near the sites of the point loading. This decreases the chance of metal leakage or fracture of the mortar seal due to mechanical abuse.

Abstract: In a Cu-alloy mold for use in centrifugal casting of Ti or Ti-alloys, the mold body is made of a Cu alloy satisfying the following relationship:Ts+0.3.rho..gtoreq.70where Ts is the tensile strength (kg/mm.sup.2), and .rho. is the electrical conductance (% IACS). A cavity disposed in the mold body has a volume which is at most 30% of the volume of the mold body. Also disclosed is a method for centrifugally casting Ti or Ti-alloy by the use of the above-described mold.

Abstract: Continuous casting is improved by providing a continuous casting mold of copper alloy, said copper alloy including from 1.6 to 2.4% nickel, from 0.5 to 0.8% silicon, from 0.01 to 0.2% zirconium possibly including up to 0.4% chromium and/or up to 0.2% iron, the remainder copper as well as inevitable manufacturing impurities and usual working additives preferably the zirconium amount is smaller than the upper stated limit and the alloy includes in addition up to 0.1% of at least one of the following cerium, hafnium, niobium, titanium and vanadium.

Abstract: This invention provides a die casting method comprising the steps of that a pulverized insulation agent is coated to form a porous insulation layer on the interior surface of die cavity when a casting products are made by utilizing a die casting machine, wherein a molten metal is filled into the cavity with a slow pace thereon, a high pressure is applied upon the molten metal mechanically so as to crush and make thin the porous insulation layer pressed by the high pressurization upon the molten metal, simultaneously the molten metal sinks into and passes through the porous insulation layer to reach at the interior surface of the cavity wherein the molten metal is rapidly solidified to produce a final casting products according to the temperature drop due to the direct contact with the interior surface of the cavity.

Abstract: A method for manufacturing a sculpture having simulated hair includes forming a rigid body of an animal figure having a plurality of small holes, cutting a plurality of lengths of metallic link chain to the desired length of hair strands for the body, soldering at least some of the chain links together with a metallic matrix having a lower melting temperature than the metal of the chain links, orienting the bonded chain links to style the chain into a preferred hair pattern, finishing the styled hair pattern chain with decorative metal plating or patina, and bonding the styled and plated chain hair pattern into the holes of the animal body.

Abstract: A chill plate for continuous casting of high melting temperature metals. The chill plate is made from a copper substrate and subsequently coated by plasma spraying. The copper mold coating composition consists of a copper alloy, 10 to 20% by volume refractory powder having a mean particle size between about 5 to 250 microns, and 3 to 7% by volume of a flammable metal powder.

Abstract: A method for producing high pressure die castings with undercut regions comprises forming an expendable coated core of specific composition, placing it in the die in a die casting machine, injecting molten metal into the die to form the casting and separating the casting from the die and the core from the casting. The composition of the expendable coated core comprises a base sand core held together by a resin binder; a first, bottom, hard refractory coating comprising fused silica and a refractory binder containing at least two of the following additives: a suspension agent, a dispersant, a wetting agent, and an anti-skinning agent; and a second, top, soft, or release coating containing a release material selected from the group consisting of anhydrous powdered aluminum, graphite, talc, titanium dioxide and zircon, and a resinous binder containing at least two different compounds selected from the group of additives consisting of a suspension agent, a dispersant, and an anti-settling agent.

Abstract: The casting wheel of a continuous casting machine is cooled by a conventional external spray cooling system, but the continuous band looped around the casting wheel to close a predetermined segment of it and thereby form a continuous moving mold cavity is not directly cooled. Rather, the band incorporates a layer of heat-insulative sheet material to deter heat transfer from molten metal introduced into the mold cavity through the band. The result is that the metal solidifies in a direction generally radially outward from the casting wheel toward the insulated band. Shrinkage of the metal occurs primarily adjacent to the band so as to eliminate or reduce internal shrinkage cracks and voids.

Abstract: Improved technology for the melting and casting of a particular class of true beta-type titanium alloys is described. A typical alloy is titanium--35% vanadium--15% chromium. By providing carbon surfaces for contacting molten beta titanium alloys of this type improved melting and casting procedures are effectuated.

Abstract: A cooling roll for producing quenched thin metal tape from molten metal by the twin-roll method. The roll is made of copper or copper alloy, and the roll surface is covered with a first layer of nickel plating 0.2 to 0.6 mm thick and a second layer of chromium plating 0.02 to 0.05 mm thick. The roll has the surface which does not suffer from deformation, seizure, winding, roughening, wear, and cracking. Thus the roll can produce quenched thin metal tape with a smooth surface in a stable manner for a long time.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of semi-solid metal particles and producing a flow of the particles along with the gas flow in a generally downward direction. The apparatus also has a substrate disposed below the atomizer for impingement on the substrate of the gas flow at a steady state temperature resulting from heat transfer by the metal particles to the gas flow and for receiving a deposit of the particles in the spray pattern to form a product thereon.

Abstract: A mold surface treatment process comprises: providing a fluidized bed of a treating powder; holding the mold in the fluidized bed to fill up the depressions of the mold surfaces with the treating powder by employing a surface treating member for pushing the treating powder into the depressions; and taking the mold out of the fluidized bed. The mold surface treatment allows to make molten metal less likely penetrate into the walls of mold, and to manufacture a mold which generates less amount of gum causing defects during casting.

Abstract: A three-layer shot sleeve assembly for transferring molten metals to a die and method of making same. A copper layer is welded onto a steel inner barrel leaving a region at each end of the inner sleeve upcoppered. A high yield strength outer shell is shrink fitted onto the coppered inner barrel. The two steel layers are welded together at the two ends. The steel outer shell is more massive and stronger than the inner barrel and serves to hold the inner barrel straight until excessive heat build up in the region opposite the well area is dissipated by the copper layer and transferred to the outer shell.

Abstract: A core mold to be assembled with a shell mold for use in an investment casting process is provided. The core mold comprises a core matrix essentially consisting of an aggregate and an inorganic binder, a binder layer impregnated from the surface of said core matrix, a coating layer formed by coating a slurry over said binder layer, and a paraffin wax layer covering the exterior periphery of said coating layer. Also provided are a process for preparing the core mold and a process for preparing an investment casting mold in which the core mold is assembled.

Abstract: A mould for the continuous casting of billets of steel or other metal with a high melting point is manufactured by electroforming and is reinforced throughout its thickness by a reinforcing material, such as carbon, boric, or glass fibers.

Abstract: An asbestos-free insulating material suitable for use as a header in molten metal casting. The material is made from a dry mixture comprising lime, siliceous component, delaminated vermiculite or spodumene or lithium aluminate or mixtures thereof, and optionally, wollastonite and organic fiber. The dry mixture is mixed with water to form a slurry, shaped, heated in the presence of steam, and dried to remove free water.

Abstract: A light metal alloy such as an aluminum alloy is cast into a casting such as an automobile engine cylinder head under low pressure. A fluid pressure is applied to the surface of a light metal alloy stored in a closed container to introduce the light metal alloy from the closed container through a transfer tube and a sprue into a mold cavity defined in a mold assembly. The introduced molten metal alloy is brought into contact with molds of the mold assembly which have different thermal conductivities, respectively. The time in which the molten metal alloy is solidified is controlled by the molds of different thermal conductivities. The molds may forcibly be cooled by a cooling medium passing therethrough or cooling blocks mounted thereon.

Abstract: The coatings are for an expendable sand core for die casting dies, which sand core has spaces between its contacting sand grains at least partially filled with resin binder. The first, base, hard, or refractory coating for this core is applied from an aqueous suspension comprising a finely ground refractory of fused silica, a refractory binder, and at least two different compounds selected from the groups of compounds or additives consisting of: (1) a suspension agent, (2) a dispersant, (3) a wetting agent, and (4) an anti-skinning agent. The refractory in the first coating may also include a minor amount, i.e. less than 50%, of another refractory oxide. The amount of binder in the first coating is less than about 15% by weight of the total liquid suspension, and the amount of additives is less than about 1.5% and usually less than 1% by weight of the total liquid suspension.

Abstract: A paint or coating composition which contains only pure Ziroconium containing compounds, and a small amount of NH.sub.4 (OH).sub.2 and acid is applied to the vertical walls of a vacuum arc furnace Copper crucible to form a stable, substantially uniform, coating thereon. The Zirconium coating composition of the present invention is free of Aluminum and Aluminum compounds and consists essentially of Zirconium Oxide suspended in a water-based Zirconyl Nitrate gel, to which small amounts of base and acid have been sequentially added. This coating eliminates the introduction of spurious impurities into the surface of the zirconium ingot formed during vacuum are melting of a zirconium compact.

Abstract: An improved expendable pattern casting process and an improved refractory composition for coating expendable patterns used in the process comprising substantially spherical refractory material and an inorganic binder selected from the group consisting of aluminum phosphate, sodium silicate and potassium silicate.

Abstract: Polymeric cyclopentadiene derivatives, method for preparing polymeric cyclopentadiene derivatives, and use of polymeric cyclopentadiene derivatives in curable binder compositions.

Abstract: Casting cores are fabricated from a mixture comprising a molten salt having dispersed therein a particulate material which includes a first refractory material having a mesh size of 60-120 and a second refractory material having a mesh size of at least 200. The salts are preferably halides, carbonates, sulfates, sulfites, nitrates or nitrites of Group Ia and Group IIa metals and the refractory material may be selected so as to be non-reactive with the molten salt. Some preferred refractory materials include alumina and magnesium silicate.

Abstract: Disclosed is a collapsible core for use in a casting and a method for producing the collapsible core. The collapsible core comprises a main core body, a first layer formed over the core body, a second layer formed over the first layer, and a third layer formed over the second layer. The second layers includes a thermosetting resin such as low temperature decomposable resin. The low temperature decomposable resin comprises one of urea resin and phenol resin. The thermosetting resin is applied to the first layer by dipping, spraying or brush-painting. This thermosetting resin provides tight bonding to the neighbouring layers.

Abstract: An extrusion-forming jig for extruding a ceramic batch to regulate a sectional shape and external dimensions of a honeycomb structure is formed by the extrusion. The jig includes electric discharge coating layers on surfaces of the jig contacting the ceramic batch. The electric discharge coating layers are made of a cemented carbide such as tungsten carbide. The jig is able to be used for many hours without necessitating replacement.

Abstract: A method of carrying out gravity mold casting, i.e., pouring of molten metal into a mold cavity under the force of gravity. This particular method features the application of a heating insulating coating or an equivalent coating on the surfaces of an area the cross-sectional area of which is larger than that of other sections of the cavity and where the metal flowing speed is slower than in other areas of the mold. The coating is effected before pouring metal into the cavity.

Abstract: A continuous casting furnace (10) of modular design. The furnace is made of a crucible section (16) a feed section (18) and a die section (12). Each of these various sections are separable from the other parts, and each of these parts is in turn made up of various individual components. Thus, the crucible section includes a refractory liner (24) made of a non carbon containing material which may be disposed within a monolithic graphite crucible (22). The graphite crucible is provided with a cylindrical aperture at its bottom which receives a feed tube (30), there being a soft seal (32) between the bottom of the liner (24) and the top of the feed tube (30). The feed section and the die section are generally formed in the same manner in that there is a non carbon containing refractory tubular member (48, 64) disposed within a graphite member (50, 62). Between the feed section (18) and the die section (12) is a soft seal (66).