Abstract: A casting core adapted to be placed inside a molding cavity for defining a cored-out hollow inside a metal casting, which core comprises a first coated layer formed on an exterior surface of the casting core by coating a slurry containing powdery refractory material, and a second coated layer formed over the first coated layer by applying a solution containing graphite particles. A method of making a metal casting with the use of the casting core is also disclosed.

Abstract: A process for continuous direct chill casting of aluminum alloys, particularly aluminum-lithium alloys. The molten alloy is cast in a mold containing a header comprising delaminated vermiculite or spodumene or lithium aluminate. The header preferably comprises delaminated vermiculite blended with wollastonite, lime, silica, and wood fiber. The mixture is slurried with water, molded into shape, compressed to expel water, steam cured, and dried. The header forms ingots of good quality and has excellent resistance to attack by molten aluminum-lithium alloys.

Abstract: Sand cores containing an acid curable binding agent are used in the production of die castings having undercut regions because of the favorable combination of shakeout properties, resistance to washout, and resistance to surface penetration.

Abstract: Improved small dendrite arm spacings and good technical values, regarding the technical properties of aluminum alloys, particularly tensile strength, yield strength and elongation percent, can be reliably obtained by refining the grain of the casting to provide the smallest possible spacings between the secondary dendrite arms, by casting the aluminum alloys in a ceramic mold provided with numerous micro-sized rough spots and pores and to the inner wall of which mold after it is dried and fired has been applied a thin layer of a salt mixture in which the cations are primarily from the alkalis and/or alkaline earths and the anions are primarily from halogens and which applied salt mixture has a liquidus temperature lower than the casting temperature of the alloy.

Abstract: Time-consuming steps of drying the unhardened and porous refractory dental model, hardening the dried model, and applying multiple coatings of a lacquer spray onto the hardened model are eliminated by spraying the unhardened and porous model with a non-viscous solution of specified cyanoacrylates to thereby produce a final model which yields a mold providing an improved alloy casting dental prosthesis.

Abstract: A casting mold for manufacturing grid plates for lead batteries makes use of easily interchangeable mold inserts for each half of a two-part, external metallic mold holder. The mold inserts are made of a highly porous microfiber nonwoven material, and render unnecessary the conventional cork-flour coating of casting molds due to good thermal insulating properties, high permeability to air and non-wettability by lead. The casting mold inserts are manufactured in a process which involves fixing of the nonwoven material with a curable binder either during or after shaping of the negative for the grid plate, so that the resulting parts assume a cardboard-like consistency.

Abstract: A bottom circular tray, a circular top cap and one or more circular disks are coupled thereto, the disks, the top cap and the bottom tray having a common central sprue or cylinder. The plurality of disks form an ascending spiral path from the bottom tray to the top cap. Liquid metal will flow through the central sprue to the bottom tray and up through the ascending spiral path to the top cap and into the mold cavity to form an inclusion free casting.

Abstract: A mold for continuous casting has indents, grooves, or recesses in the mold wall itself and/or along one or more edges thereof; wear-proof inserts are fitted into these grooves or indents and fastened thereto by means of electron beam welding along exposed joint lines between the inserts as inserted and border edges of the indents or recesses. The inserts are affixed in this manner along edges for engagement with other mold walls, and/or along the lower edge and/or a level which is expected to coincide with the surface level of the molten steel in the mold.

Abstract: Improved casting of titanum or alloy of titanium is obtained by using a crucible and a mold made of high-purity magnesium oxide and/or zirconium oxide. It is also possible for only the interior portion of the crucible to be made of such high-purity material, or for the mold to be made of copper or an alloy of copper. The mold and crucible can be used in a centrifugal-type casting machine or a compression-type casting machine. In either machine, discharge vents must be provided in the mold to connect the casting chamber with the outer atmosphere. An argon electric arc generated between a pivotable, tiltable cathode and an anode may be used for melting the titanium in the crucible. A high-frequency electric current can also be used to melt the titanium. By using the above apparatus, it is possible to obtain castings which are dimensionally accurate and do not have an external layer of fragile metal oxide or rough cavities.

Abstract: A core is formed by molding a mixture of an organic binding material and a fireproof granular substance. The core is impregnated with an aluminum-phosphorus oxide solution. The impregnated core is heated at 400.degree.-1000.degree. C. for about an hour.The disintegrable core for casting can be produced much more quickly than before and with considerably less expenditure of energy.

Abstract: A process for casting ingot molds wherein a smooth, rigidized insulative board is used to form the as cast bottom surface of the ingot mold to produce a smooth flat surface which does not require machining and to permit slow cooling and solidification so that a uniform macrostructure and microstructure is effected.

Abstract: A silicon aluminum oxynitride containing refractory for use in continuous casting is placed between a mold and a tundish and is formed by sintering an admixture of silicon nitride (Si.sub.3 N.sub.4), aluminum nitride (AlN), boron nitride(BN), and a mineral clay. The refractory further includes aluminum oxide(Al.sub.2 O.sub.3).

Abstract: Refractory shapes such as tubular tiles and tubular runners are provided with a novel graphite interior coating penetrating the refractory and forming with the refractory a lining that resists erosion of molten metal flowing therethrough. The coated refractory shapes are particularly useful in forming mold assemblies for bottom pouring.

Abstract: An improved mold, apparatus and method for injection molding is provided. The apparatus is of the type which includes a means for opening and closing a multi-part injection molding mold, means for supplying molten material under high pressure into the mold cavity when the mold is closed and means for removing articles molded in the cavity on cooling. The improvement is provided by a new multi-part mold which is made up of at least two parts. Each part of the mold comprises a mold block portion having a ceramic mold cavity insert. The ceramic mold cavity inserts define the walls of the mold cavity when the mold is closed. Each mold cavity insert comprises a shaped ceramic body having a mounting surface adapted to fit under compressive stress throughout the entire molding operation within a mounting cavity of the mold block portion.

Abstract: A lubricating process is disclosed for continuously casting molten metal through a mold or header including applying a parting lubricant containing alpha-olefin oligomer to the mold or header. In one aspect, the process includes applying a parting lubricant containing alpha-olefin oligomer and fatty ester.

Abstract: A continuous mold for a continuous casting plant comprises inner walls made from copper and/or an alloy of copper and a wear resistant and abrasion resistant layer disposed on the copper and/or copper alloy on the inner exposed side of the mold. The layer covers at most two fifths of the total surface of a side wall and reaches from the output end of the mold up to about one third of the length of the mold at the center of the respect side of the mold. The wear resistant layer reaches in the area of the inner edges of the mold from the output end of the continuous mold to at least about the same level as the layer at the center of the respective side wall and up to the input end of the mold. The wear resistant layer can be provided as an open net like a grid or as a grate on the inner wall of the continuous mold with the surface areas in the open parts in between being formed by copper and/or a copper alloy.

Abstract: A porous layer consisting of sintered material containing metal powder or ceramics powder is provided as the inner surface of a mold for use in continuous metal casting, and a shielding plate is provided on the outside of this porous layer. A gas is supplied in a gap portion formed between the porous layer and the shielding plate and the gas is spouted out from the porous portions in the porous layer into the inside of the mold, thereby forming a gas film between the inner surface of the mold and the molten metal. Electromagnetic coils are interposed between a stiffening plate and sandwiching frames around the mold and hanger frames supporting them. An annular cylindrical partition wall surrounding a nozzle is provided between the mold and a tundish, and a water-cooled reflecting plate having an annular downward reflecting surface is also provided therebetween.

Abstract: A method of continuously or semi-continuously casting an ingot of rectangular cross section in a vertical open-ended direct chill mold having a coolant passageway, wherein a flow of coolant is circulated and discharged from the bottom of the mold, and molten metal poured into the mold is solidified by applying the discharged flow of coolant directly to the peripheral surface of the metal emerging from the bottom of the mold. The method comprises a step of preventing a direct contact of the poured molten metal with an upper part of inner walls of the mold and controlling the cooling of the molten metal by the flow of coolant circulating in the passageway via the inner walls. The above step comprises interposing heat-insulating sheets between the upper part of the inner walls of the mold and the peripheral surface of the poured molten metal within the mold.

Abstract: A method for the manufacture of an investment shell mold is disclosed which comprises applying to the surface of a wax pattern at least one layer of slurry formed by dissolving in an organic solvent a soluble organic cellulose derivative containing a dispersed metallic oxide, subsequenty applying to the first layer at least one layer of slurry formed by mixing a refractory powder with a cellulose binder, and thereafter causing the applied slurry layers to set and removing the pattern by the ordinary method.

Abstract: A hot chamber die casting apparatus for casting aluminum, zinc, magnesium, copper and their alloys as well as other metals which, in the molten state, corrode ferrous materials. The apparatus comprises a crucible, an injection pump in the crucible, and a gooseneck leading from the crucible to an outlet nozzle. The parts of the apparatus have coatings or sleeves of materials which resist corrosion, abrasion, erosion and mechanical or thermal shocks.

Abstract: An improvement in the process for casting metal in sulphur-containing molds is disclosed. The mold is washed before casting with a compound, preferably barium dioxide. The compound reacts with gaseous sulphur compounds produced by the mold, thus lowering the diffusion of sulphur into the casting, and thereby minimizing graphite deterioration at and near the surface of the casting.

Abstract: Continuous casting methods and apparatus are described wherein a defect in the cast surfaces consisting of longitudinal bands of sinkage, sometimes called "sinks", which are spaced relatively far inwardly from the edges of wide, relatively thin slab or strip, usually being spaced inwardly away from the edges by a distance of 3 to 7 times (sometimes up to 9 times) the thickness of the cast slab, is practically eliminated by means of a coating or covering of non-wettable refractory ceramic material of low heat conductivity applied to the inner faces of the edge-dam blocks for reducing heat flow out of the edges of the slab or strip being cast. Numerous such blocks are strung onto a flexible metal band or cable to constitute each of the two edge dams which define the edges of the mold space.

Abstract: Method of forming or shaping a resin-bound mass (e.g., core-making or mold-making pattern or core box, particle board, etc.) in or from shaping means having shaping surfaces and releasing the shaped resin-bond mass from the shaping surfaces, which comprises coating the shaping surfaces of the shaping means with an improved, substantially stable, alcoholic dispersion or solution of a release coating suitable for repeated use, heating the coated shaping surfaces of the shaping means for sufficient time to convert the coating thereon to a stable, cured, abrasive-resistant release coating, placing a curable resin-bound mass of solids to be shaped against the release-coated shaping surfaces, curing the resin-bound mass, and separating the cured resin-bound mass from contact with the release coated shaping surfaces. The coating composition comprises a substantially stable alcoholic dispersion or solution of a substantially pure silanol of the formula RSi(OH).sub.

Abstract: A resin-bonded sand core for high-pressure die casting methods having a first refractory coating, such as of silica, with an inorganic binding agent of colloidal silica and a clay such as kaolin, and a second or top coating of a refractory material containing zircon and an organic binding agent, which combination of these two different coatings enables the bonded sand core to have high pressure and temperature resistance, good washout resistance, freedom from surface penetration, and good shake-out properties.

Abstract: In a method of forming a thin (<2 .mu.m) unbacked metal foil having a desired curviplanar shape, a soluble polymeric film, preferably comprising polyvinyl alcohol, is formed on a supporting structure having a shape that defines the desired shape of the foil product. A layer of metal foil is deposited onto one side of the soluble film, preferably by vacuum vapor deposition. The metallized film is then immersed in a suitable solvent to dissolve the film and thereby leave the metal foil as an unbacked metal foil element mounted on the supporting structure. Aluminum foils less than 0.2 .mu.m (2,000 .ANG.) thick and having an areal density of less than 54 .mu.g/cm.sup.2 have been obtained.

Abstract: A refractory mould core for producing metallic castings of complicated internal shape formed from a water-soluble salt having the following particle size distribution:100% by weight of the particles have a size less than 750 .mu.m;90% by weight of the particles have a size of 8-600 .mu.m;80% by weight of the particles have a size of 5.5-500 .mu.m;70% by weight of the particles have a size of 4-400 .mu.m;60% by weight of the particles have a size of 2.8-350 .mu.m;50% by weight of the particles have a size of 2.0-280 .mu.m;40% by weight of the particles have a size of 1.6-220 .mu.m;30% by weight of the particles have a size of 1.0-180 .mu.m;20% by weight of the particles have a size of 0.3-160 .mu.m;10% by weight of the particles have a size of 0.1-125 .mu.m.

Abstract: An aluminum-diffusion coated steel pipe having an aluminum-coated layer on at least the inner surface of the steel pipe to be in contact with molten metal is used as a gating pipe system in a casting mold comprising a mold body and a gating system for pouring molten metal into the mold body. This aluminum-diffusion coated steel pipe can be further subjected to a secondary heat treatment in a high-temperature oxidizing atmosphere.

Abstract: Sand cores containing an acid curable binding agent are used in the production of die castings having undercut regions because of the favorable combination of shakeout properties, resistance to washout, and resistance to surface penetration.

Abstract: A binder composition which contains certain fulvenes and/or prepolymers thereof, and a metal salt catalyst.

Abstract: In welding metal sheets together from only one side, an improved welding backup tape is self-adhesively applied to insure the consistent formation of a smooth, inclusion free, slightly convex underbead which requires little or no dressing, or grinding, and which does not impede in any way the achievement of 100% radiographic weldment testing. This welding backup tape is made in one embodiment by mixing into solution two parts of a colloidal silica solution with one part of a titanium dioxide refractory coating solution. Applying this resulting solution as a refractory coating to the upper portion of an electrical grade, heat treated, braided, natural finish, finely woven, fiberglass material in a sleeving configuration.

Abstract: A mold facing for producing a gas-permeable, non-gassing and, in view of its small thickness and its porosity, heat-conductive cladding of a centrifugal ingot mold for copper and its alloy contains pulverulent material in a dispersing agent, particularly water, evaporating without residue. The pulverulent material has titanium dioxide (TiO.sub.2) as the main constituent or the sole constituent, preferable with an average particle sizes of about 15 .mu.m. A process for cladding a centrifugal ingot mold by using such a mold facing contemplates at first preheating the mold and subsequently applying the mold facing by spraying to the inner wall of the centrifugal ingot mold rotating around its axis in form of a suspension free of binding agents and surface active agents as a thin layer of, as far as possible, uniform thickness of preferably 0.1 to 0.3 mm and subsequently evaporating the dispersing sheet of the mold facing without leaving any residue for obtaining a porous layer.

Abstract: A binder composition which contains certain fulvenes and/or prepolymers thereof, and a metal salt catalyst.

Abstract: Coated sand cores containing a boronated aluminum phosphate binding agent are used in the production of die castings having undercut regions because of the favorable combination of shakeout properties, resistance to washout, and resistance to surface penetration.

Abstract: Cast iron ingot mold stools having exceptionally smooth flat surfaces and a longer average life are produced by casting such stools in a mold, the inside of which is formed by rigid thermal insulative boards.

Abstract: A method and an apparatus is provided for casting molten metallic materials through runners in the form of casting gates, flow-through tubes, feeders, rising gates and the like. The method basically comprises casting the molten metals through runners defined by bodies of porous calcium hydro-silicate such as gas concrete. A filler, such as quartz, may be used. The runner bodies are formed of gas concrete and provided with a moisture ratio of 3 to 30% so as to afford progressive evaporation of the moisture during casting to thereby produce a cooling effect on the runner walls. The runner bodies can be reinforced.

Abstract: The invention provides shaped, refractory, heat-insulating articles, for use in a metallurgical vessel, comprising particulate refractory material, binder and particulate de-fibred bagasse or the like. The articles may be made by mixing the ingredients, pressing them in a former and causing or allowing the binder to set. The articles may be slabs for lining the head of a mould for steel ingots.

Abstract: A method for minimizing the formation of a reaction layer at the metal-ceramic interface comprises doping a superalloy material with the rare earth metal whose metal cation is in the ceramic material comprising the mold and/or core used in casting and directionally solidifying the superalloy material.

Abstract: A method of making a shell mold (6) includes alternately applying a ceramic coating composition (8) and a stucco composition (10) to an expendable pattern, the presence of graphite being substantially avoided therein, and applying a barrier coating (16) thereto including a ceramic powder, a binder, and a preselected amount of graphite. A preferred range of graphite of about 13 to 17 Wt. % in the barrier coating (16) minimizes decarburization of a ferrous article formed in the cavity of the shell mold (6).

Abstract: A metal mold employed for the casting of metals, preferably steel, has a wear resistant layer on the casting surface thereof formed of a different metal having solid particles dispersed therein. A preferred mold is formed of copper or alloy thereof having an electrolytically deposited nickel layer with silicon carbide particles dispersed therein.

Abstract: Method for making a novel shell mold for use in directional solidification and for casting alloys containing reactive components, wherein a binder comprising a fibrous colloidal alumina in aqueous dispersion and being essentially free of silica, is employed. The resultant shell mold is particularly suitable for the casting of nickel and cobalt based alloys containing relatively reactive constituents such as zirconium, alumina and titanium.

Abstract: The invention relates to a method of producing a graphite die for use in continuous casting of non-ferrous metals. The die has wearing surfaces which, in accordance with the invention, are coated, using either plasma-combustion flame or liquid-spraying techniques, with a first layer consisting of a metal or a metal plus a ceramic material and then with a second layer of ceramic material. The coating materials are applied as a suspension in a liquid medium by painting or spraying techniques or they must be applied by plasma or combustion flame spraying techniques.The first layer may comprise one or more of the following substances: silicon, iron, nickel, chromium, molybdenum, tungsten or their alloys or any other metal which can be subsequently carburized by heating with graphite in an inert or reducing atmosphere.Alternatively the first layer may be either aluminium, an aluminium alloy, an aluminium-metal composite or a mixture of the metal(s) and alumina and the second layer is preferably alumina.

Abstract: A process for applying a coating to a centrifugal casting mold for casting copper or alloys thereof in which prior to introducing the molten metal into the mold, an aqueous suspension of powdery material is introduced into the mold and applied on the internal surface thereof in the form of a thin layer. The constituent components of the suspension are zirconium oxide (ZrO.sub.2) and an inorganic binder material, preferably non-sintered alumina (Al.sub.2 O.sub.3), so that a heat-conductive and gas-permeable layer is formed on the surface of the mold.

Abstract: In a continuous casting mold of a copper alloy havng a nickel layer plated on the mold cavity surface, wherein an alloy layer of nickel containing one of Co, Fe and Mn and 3-5 mm thickness replaces the Ni layer.

Abstract: A method of producing cast articles having internal cavities is disclosed. The method is particularly suitable for casting gas turbine components from nickel base and cobalt base superalloys. The method comprises: forming a core to the desired cavity configuration, the core consisting essentially of densified silicon nitride; securing the core within a mold; casting the alloy within the mold and around the core; removing the solidified cast article from the mold; and leaching the silicon nitride core from the casting in molten sodium hydroxide.

Abstract: An improved alumina or alumino-silicate refractory for lining aluminum-melting furnaces and other containers for molten aluminum including 0.5 to 30% by weight of BaSO.sub.4. The addition of BaSO.sub.4 to a phosphate-bonded or phosphate-free plastic, ramming mix, brick, mortar, or castables eliminates metal penetration and reduces dross and metal adherence.

Abstract: The present invention relates to a refractory materials used in processing molten metals comprising combining at least one of the refractory materials selected from the group consisting of SiO.sub.2, Al.sub.2 O.sub.3, MgO, ZrO.sub.2 with an activatable element for labeling which has an activation cross section of over 1 barnand apparatus made from a plurality of differently labeled refractory components.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.

Abstract: A chill preventing arrangement is used in a metal mold employed in centrifugal casting. The metal mold is provided, at its spigot portion, with an end plate which has a central opening smaller in diameter than the internal diameter of the metal mold main body and which includes a metallic base plate, an intermediate layer of metallic alloy formed by flame or plasma spraying on a surface of the metallic base plate contacting the molten metal for casting, and a coating of ceramic material more than 0.7 mm thick formed on the intermediate layer by flame or plasma spraying for preventing chill formation at the corresponding end portions of tubular castings.

Abstract: Method and apparatus for casting a metal article in a mold at least as long as the article, utilizing a cooled mold of elongated form having top and bottom portions. The method includes the steps of introducing molten metal from a source through the bottom portion of the mold, flowing molten metal into the mold so as to form a solidifying casting shell which .Iadd.a .Iaddend.during casting occupies at least 40% of the cross-sectional mold area and .Iadd.a .Iaddend.has a molten core, and flowing molten metal from the source through the core towards the mold top .Iadd.at a filling rate, dependent on the mold cross sectional area, such that the product produced will have a relatively fine grained structure throughout the cross-section thereof.Iaddend..

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.