Abstract: A mold assembly for use in forming a component having an internal passage defined therein includes a mold defining a mold cavity therein, and a jacketed core positioned with respect to the mold. The jacketed core includes a hollow structure, and an inner core disposed within the hollow structure and positioned to define the internal passage within the component when a component material in a molten state is introduced into the mold cavity and cooled to form the component. The jacketed core also includes a first coating layer disposed between the hollow structure and the inner core.

Abstract: A lens includes a plurality of raised portions and recessed portions in an arrangement, and includes an antireflection structure. The antireflection structure includes an area where a height of each of the raised portions is relatively low and a depth of each of the recessed portions is relatively shallow, and an area where a height of each of the raised portions is relatively high and a depth of each of the recessed portions is relatively deep. In the area where the height of each of the raised portions is relatively low and the depth of each of the recessed portions is relatively shallow, first and second flat surfaces are respectively provided at a top portion of the raised portion and a bottom portion of the recessed portion.

Abstract: Disclosed are an inexpensive casting member on which a film with high peel strength is formed, and a method for manufacturing the casting member. A surface-treated mold (1) includes a metal mold (10) having the molding surface including a plurality of protrusions (11) each having an inverse-slope shape, and a carbon film (20) formed on the molding surface of the metal mold (10). The surface-treated mold (1) is manufactured through a step (S1) including a modeling step (S10) for producing the metal mold (10), by means of selective laser sintering, which has the molding surface including the plurality of protrusions (11) each having the inverse-slope shape, and a film-forming step (S20) for forming the carbon film (20) on the molding surface of the metal mold (10) produced in the modeling step (S10).

Abstract: A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

Abstract: Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

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: The invention relates to a stamper in which an oxide film having a fine concave-convex structure made up of a plurality of fine pores having an aspect ratio represented by [the depth of the fine pores/the average interval between the fine pores] of 1 to 4 is formed on the surface of an aluminum base material which is made of aluminum having a content of Ti of 150 ppm to 500 ppm, a content of B or C of 1 ppm to 50 ppm and a purity of 99.9% or more. According to the invention, it is possible to provide a low-cost stamper in which the emergence of a pattern derived from the traces of crystal grains on the surface of the oxide film is suppressed, an article having a favorable appearance, which is manufactured using the above stamper, and a method for manufacturing the above.

Abstract: A metallic, ferriferous permanent mold, especially a permanent steel mold, is provided that can be impinged upon with a liquid or flowable aluminum material, a layer for protecting the permanent form and for obtaining an optimum cast result being producible by means of a mold release agent. The invention also relates to a mold release agent for producing said layer and to a method for producing said layer.

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 relates to a method for manufacturing a stamper for injection molding, and more particularly, to a method for manufacturing a stamper for injection molding which can prevent a scratch from forming thereon and has an excellent durability owing to high hardness even after manufacturing of the metal stamper with micro patterns formed thereon is finished. The method for manufacturing a stamper for injection molding includes a pattern forming step for forming a predetermined micro pattern on a substrate, a metal plating step for making metal plating on the substrate to form a stamper having the micro pattern transcribed thereto, a stamper separating step for separating the stamper of the metal plating from the substrate, and a protective layer coating step for coating a protective layer on the stamper for maintaining a mirror surface.

Abstract: A method for centrifugal casting using a sand core having a refractory coating applied in a dry state, without the use of a liquid carrier, said coating sufficient to withstand the adverse forces of the centrifugal casting environment and yield a finished cast surface with a consistent, smooth surface. The coating may be applied by pressing the coating into a mixture of refractory material and impacting media fluidized in a vibratory bed such that the core floats in the mixture, and then rotating the core to coat the surfaces that will be in contact with the molten metal in the casting process.

Abstract: Described herein a method of manufacturing a metal shape that includes contacting a liquid metal and a surface of a foundry core under conditions wherein vein defects occur, the surface of the foundry core comprising a foundry aggregate, a combustible-organic material and a polyurethane resin, and the surface of the foundry core being free of or essentially free of an anti-veining agent; cooling the liquid metal to a temperature below its melting point thereby forming a metal shape; and then removing the foundry core from the metal shape.

Abstract: The invention relates to a method for producing a casting mould for casting highly reactive melts, in particular for casting titanium, titanium alloys or intermetallic titanium aluminides. Said method consists of the following steps: a contact layer (1) is produced by applying a first slicker containing a first Y2O3-powder as an essentially solid component, to a mould core, the contact layer (1) formed from the first slicker is sanded with a second Y2O3-powder containing Y2O3 as the essential component. With respect to a particular efficient process, a first dry mass for producing the first slicker contains at least 75 wt. % Y2O3 and as additional solid components, at least 1.0-25 wt. % of a hydraulic binder.

Abstract: The invention relates to a method for producing a mould for casting metallic melts, in particular for casting titanium, titanium alloys or intermetallic titanium aluminides. Said method consists of the following steps: a contact layer is produced by applying a first slicker containing a first metal oxide powder as an essentially solid component to a moulded core, a first sanding layer is produced on the contact layer formed from the first slicker by sanding with a second metal oxide powder and the layer sequence formed from the contact layer and the first sanding layer is radiated with infrared light for a predetermined period of time. According to the invention, for speeding up the drying process, a first dry mass of the first slicker contains a hydraulic binder.

Abstract: A process of reducing friction, which is encountered in molds utilized in injection molded, solder processing, and wherein glass mold plates have mold pits etched therein. The mold pates are subjected to a heat treatment so as to smooth or round-off sharp edges along the periphery of the mold pits.

Abstract: The invention relates to a casting mould for the casting of metals, wherein a layer consisting of a material which absorbs harmful substances on at least sections of gas outlet surfaces of the casting mould, in particular the top side thereof. The invention also relates to a coating composition, to a process for producing the casting mould and to the use thereof for casting of metals.

Abstract: Provide is a method for manufacturing a glass molding die in which deformation of a molding die in a process after machining is restrained without increased wear of a bit, and a method for manufacturing a molded glass article utilizing the glass molding die. A plated layer made of Ni—P plating is formed on the surface of a substrate, a rough machining is performed on the plated layer to form a shape similar to the desired final shape, the plated layer is then subjected to a thermal treatment, and finally finish machining is performed to form the desired final shape.

Abstract: The present invention relates to wash compositions which comprise a solvent component and a solids component wherein the solvent component comprises as main component water or one or more alcohols, and the solids component comprises as main component a mixture of metakaolinite and pyrophyllite, which can be applied onto casting moulds, casting moulds comprising these wash compositions and the use thereof, in particular in centrifugal casting processes and large-scale casting processes.

Abstract: A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

Abstract: A method and apparatus for alternating pouring into molds, casts or refining hearths from a common hearth in a furnace. The apparatus provides a main hearth, a plurality of optional refining hearths, and a plurality of casting molds or direct molds whereby the refining hearths and molds define at least two separate ingot making lines. The main hearth alternatively pours into a first ingot making line while the other line is prepared, and vice versa allowing for continuous melting.

Abstract: A process of reducing friction, which is encountered in molds utilized in injection molded, solder processing, and wherein glass mold plates have mold pits etched therein. The mold pates are subjected to a heat treatment so as to smooth or round-off sharp edges along the periphery of the mold pits.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: Method and apparatus for compacting support particulates media around ceramic shell molds and around fugitive patterns wherein the mold or pattern is placed in a container and the container is filled with support particulates media. The container is set to rotating and vibrating while it is tilted. The combination of rotation and tilting cause voids at the wall of the mold or pattern to be constantly and methodically reoriented so that the free surface of the support media in the voids is moved past its dynamic angle of repose and is caused to flow into those voids by the combined action of the vibration and the constantly changing orientation of the voids relative to the gravity vector.

Abstract: A sand casting facing composition comprises a dry mixture of about 77% fine sand, 5% binder, 6% green system sand and 12% burned system sand. The fine sand is mulled with 5.8% wt/wt oil per total dry mixture and catalyst at about 0.5% wt/wt. Preferably, fine sand and binder are mulled with oil, catalyst, green system sand and screened burned system. The mulled mixture is rested, mulled again and rested again before use as facing sand for achieving accurate reproduction of the pattern's fine detail. A method of preparing the mold and preserving fine detail comprises riddling the pattern with a thin layer of the facing sand composition, compacting, riddling with dry system sand and riddling with system sand before compacting about the periphery of the pattern. Final layers of system sand are applied and compacted over the entire pattern.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: A method of applying a refractory coating to densified foundry sand cores having micropores between the sand grains having the steps of: (a) mixing a dry powder refractory material (anhydrous MmgOSiO2 talc) with a dry powder impacting media, the refractory material having a particle size in the range of 5-40 microns and the weight ratio between the refractory material and the impacting media; (b) fluidizing the mixture in a contained zone by introducing positive air pressure at one end of the zone and applying a negative pressure at the other end of the zone; and (c) quickly and entirely immersing the sand cores in the zone containing the fluidized mixture and substantially immediately thereafter withdrawing (without reciprocal movement) such sand cores without the need for added motion to be coated with essentially only the refractory material as impacted by the impacting media. The cores will be coated continuously with the refractory material, impacted with the micropores of the sand core.

Abstract: A method of removing a coating material from a substrate surface portion comprises providing a substrate having a coating material adhered to a surface thereof. The coating material comprises a CO2-soluble material. The coating material is contacted to a fluid comprising carbon dioxide to dissolve the coating material therein. The carbon dioxide fluid is then separated from the substrate to remove the coating material from the substrate surface.

Abstract: A rotating gate feeder (1) for feeding substantially particulate material comprises a housing (2) and a rotor (3) and also an end cap (8) at each end of the housing. The invention is characterized in that a wear-resistant coating (6) is cast directly on to the inner wall (14) of the housing which faces towards the rotor (3). The inner wall (14) of the housing functions as an outer mold and a purpose-adapted core (15) is used as an inner mold. The housing (2) may be provided at certain points with release zones on the inner walls (14) which face towards the cast wear-resistant coating (6). One or more wear members (12) having greater wear resistance than the molding compound may be embedded therein.

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 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 and apparatus are shown for improving the collapsibility characteristics of foundry cores and molds after being contacted with a heated, cast product. The foundry cores/molds are contacted with an oxidant impregnating liquid after being formed and prior to contact with the heated, cast product. The heat of the cast product is sufficient to sustain combustion of the chemical coating of the sand particles making up the cores/molds to facilitate removal with a minimum of force after casting.

Abstract: The disclosure concerns a process of producing expendable coated cores for castings comprising mixing sand with a resinous binder, polymerizing the binder, and then washing the resulting bound sand core with an organic solvent to remove unpolymerized residuals from the surface of the core before applying a coating to the core.

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: 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: 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: 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 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: 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 P, S, B and N 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. The solvent and the organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.

Abstract: Process for the production of precision castings with well-defined reproduction of detail and a great accuracy of measurement, by which the pattern to be reproduced is equipped with a drainage apparatus, having at least one duct extending outside the molding box, and the molding material containing phosphate as the bonding agent is poured in the molding box and solidified. After the pattern is removed from the solidified mold, by the introduction of compressed gas, the water of the solidified material is pressed out, and after calcining at a temperature of at least 250.degree. C., the mold is connected to a vacuum line and evacuated. The molten metal mass is then poured into the mold while the vacuum is maintained and solidified.

Abstract: A fibrous composite material useful in contact with fused aluminum or aluminum alloys is disclosed. The composite material is comprised of alumino silicate-based ceramic fibers, at least one micaceous mineral, an inorganic binder, a dispersant and a plasticizer.

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: 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: A coating for foundry cores and molds comprising an aqueous suspension of clay, olivine, and sodium tripolyphosphate.

Abstract: An improved method of making internally slitted strip material wherein a metal billet is cast about friable elongated members of weld preventing material and wherein the billet and elongated members are rolled to thin and elongate the billet and to pulverize the weld preventing material into a fine weld preventing powder for distribution along the spaces occupied by the weld preventing material and which spaces upon the pulverized weld preventing powder being removed form the slits, the improvement wherein prior to casting the metal billet about the elongated members of weld preventing material, the friability of the weld preventing member is enhanced to cause the members to pulverize more evenly and to distribute more evenly along the spaces occupied by the pulverized weld preventing material whereby any tendency of the pulverized powder to leave gaps at which welds are formed during rolling is substantially eliminated and wherein such enhancement is provided by coating the elongated members with a predeterm

Abstract: A method for fabricating superplastically formed/diffusion bonded structures wherein metal blanks of a titanium alloy are joined at selected areas by diffusion bonding and expanded superplastically to form a desired sandwich or integrally stiffened structure. In such method, the metal blanks are treated in selected areas with a "stopoff" material to prevent bonding at those areas during diffusion bonding and to permit forming or shaping at the same areas during superplastic forming. An improved stopoff compound is provided for this purpose, in the form of yttria of relatively coarse particle size, coarser than 5 microns, in a suitable volatilizable vehicle. Such stopoff compound is inert to reactive metals such as titanium at the high diffusion bonding temperatures, and permits relatively low breakthrough pressure-time product during superplastic forming, thereby preventing excessive strain or rupture of the metal through non-superplastic deformation.

Abstract: In a method for casting metal alloys, a molten metal alloy is introduced into a mold of a desired configuration containing a core material fabricated to a desired shape from titanium nitride while maintaining the mold under a vacuum. After allowing the mold to cool slowly to room temperature, the casted metal alloy with the core material exposed at one end is removed from the mold and immersed in a boiling caustic solution, thereby causing the titanium nitride core material to decompose. The casting so obtained has a smooth inner surface, an indication that no chemical reactions have occurred between the alloy and the core material.

Abstract: In a glass container making machine using a split face mold, means are provided for controllably diverting the parisons from the mouth of the mold to a waste glass collector when the mold is closed so that at the same time swabbing means lubricate the inner faces of the mold cavity.