Abstract: A casting method is provided that includes a mold, a mixer, and first and second materials. A first pour and a second pour are dispensed from the mixer. The first pour has different proportions of the first and second materials as compared to the second pour. The first pour forms a first layer of a molded part, and the second pour forms a second layer of the molded part.

Abstract: Described is a phenolic resin composition for use in the polyurethane cold-box and/or no-bake process. The phenolic resin composition comprises an ortho-condensed phenolic resol having etherified and/or free methylol groups in a total amount of 40 to 60% by weight based on the total mass of the phenolic resin composition, free formaldehyde in an amount of less than 0.1% by weight based on the total weight of the phenolic resin composition, one or more reaction products of formaldehyde with one or more C—H-acidic reactant compounds, other constituents in a total amount of at least 38% by weight, wherein the amount of water in the phenolic resin composition is not more than 1.0% by weight in each case based on the total mass of the phenolic resin composition.

Abstract: The invention relates to mold material mixtures for producing molds and cores for metal casting, consisting of at least one refractory material, a binder based on resols and amorphous silicon dioxide. The invention also relates to a multicomponent system and methods for producing molds and cores using the mold material mixtures as well as molds and cores for metal casting produced according to this method.

Abstract: This invention relates to a resin preparable by reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio above 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, and to a particulate material coated with said resin. Said particles can be used e.g. in the shell molding process for the production of shell molds and shell cores; and as proppants for use in the hydraulic fracturing process.

Abstract: A phenol-formaldehyde novolac resin having a low concentration of free phenol prepared by distilling residual phenol from a molten novolac resin and replacing at least a portion of the phenol with a solvent having a volatility equal to or less than phenol. Such modified novolac resins are suitable for the production of resin coated molding sands for shell molding and sand cores, as well as for the production of resin coated proppants for use in oil and gas recovery operations.

Abstract: A “cold box” process for forming a foundry shape by curing a binder in a foundry mix operates by sequentially introducing a first vaporous curing catalyst to a pattern containing the formed foundry mix, followed by introducing at least a second vaporous curing catalyst. By arranging the amounts of the respective vaporous curing catalysts and the contact times, as well as by using the less active vaporous curing catalyst first, the total amount of curing catalyst used to effect the cure is reduced. Carrier gas may be used with the respective vaporous curing catalysts. Typically, the vaporous curing catalysts are tertiary amines having between three and six carbon atoms.

Abstract: The invention relates to a method for producing casting molds and cores, in which a foundry base material comprising at least one refractory material and a binder curable by CO2, preferably based on water glass, is cured by gassing with CO2 and flushing with a second gas. The invention further relates to molds and cores produced according to this method.

Abstract: An alloy casting having a protective layer disposed on a surface of the casting is provided. The protective layer is resistant to liquid metal attack, and wherein the protective layer includes an oxide of an element present in the alloy. A method of forming a protective layer on a surface of the alloy casting is also provided. The method includes disposing the alloy in a mold, and oxidizing an element of the alloy to form a protective layer on the surface of the casting.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: The invention relates to a molding material mixture for production of molded products for the foundry industry, comprising at least one fire-resistant base molding material and a polyurethane-based binder system comprising a polyisocyanate component and a polyol component. According to the invention, the polyurethane-based binder system comprises a portion of a carboxylic acid diester of a branched alkane diol, said portion being at least 3 weight-%, and a portion of aromatic solvent of less than 10 weight-% of the binder system. A preferable carboxylic acid diester is 2,2,4-trimethyl-1,3-pentandiol-diisobutyrate. The molded products produced from the molding material mixture for the foundry industry are characterized by a high strength and a lower generation of fumes and smoke during pouring.

Abstract: A “cold box” process for forming a foundry shape by curing a binder in a foundry mix operates by sequentially introducing a first vaporous curing catalyst to a pattern containing the formed foundry mix, followed by introducing at least a second vaporous curing catalyst. By arranging the amounts of the respective vaporous curing catalysts and the contact times, as well as by using the less active vaporous curing catalyst first, the total amount of curing catalyst used to effect the cure is reduced. Carrier gas may be used with the respective vaporous curing catalysts. Typically, the vaporous curing catalysts are tertiary amines having between three and six carbon atoms.

Abstract: A polyisocyanate component for a moulding material binding agent system is described containing at feast one sulfonic acid in a solution of at least one polyisocyanate, containing at least two NCO-groups in the molecule.

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.

Abstract: A sand-forming apparatus (10) comprising a box (20), a blow tube assembly (50) and a bonnet (90). The box (20) has a cope (30) and a drag (40) which together define a cavity (21) having a shape corresponding to a desired sand-shape. The blow tube assembly (50) comprises a blowplate (55), and at least one tube (50). The bonnet (90) may be fixed to and movable with the blowplate (55). Relative movement between the cope (30), the blowplate (55) and/or the bonnet (90) converts the apparatus (10) between a sand-blowing state and a catalyst-introducing state.

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: A composition comprising (a) an epoxy resin; and (b) a hydroperoxide composition comprising a t-butyl hydroperoxide solution that contains no more than 7 weight percent water, and use of the compositions to prepare foundry shapes, the foundry shapes prepared by the process, the use of the foundry shapes to prepare cast metal articles, and the cast metal articles prepared by the process.

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

Abstract: A foundry binder comprising (a) a polyol component selected from the group consisting of phenolic resins, polyether polyols, polyester polyols, aminopolyols, and mixtures thereof, and (b) a polyisocyanate component, wherein component (a) and/or (b) further comprise, as a solvent, one or more cycloalkanes.

Abstract: An apparatus for the forming of sand cores adapted to convey sand, tamp a sand core, and militate against an undesirable exposure of uncured sand to catalyst gases, while providing a non-tortuous flow path for sand. The apparatus for the forming of sand cores comprises a core box, a gassing manifold, a blow tube, a sand magazine, a connector tube, and a tamping pin.

Abstract: The invention relates to a molding material mixture for production of molded products for the foundry industry, comprising at least one fire-resistant base molding material and a polyurethane-based binder system comprising a polyisocyanate component and a polyol component. According to the invention, the polyurethane-based binder system comprises a portion of a carboxylic acid diester of a branched alkane diol, said portion being at least 3 weight-%, and a portion of aromatic solvent of less than 10 weight-% of the binder system. A preferable carboxylic acid diester is 2,2,4-trimethyl-1,3-pentandiol-diisobutyrate.

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

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.

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

Abstract: The present invention provides an epoxy acrylate foundry binder composition having an epoxy resin component (Part 1) and an acrylate component (Part 2) containing about 1% to less than about 6% by weight of a borate ester. The epoxy acrylate binders of the present invention are useful in making foundry cores and molds in that the addition of the borate ester increases hot strength of the binder system. Also provided is a cold-box process for making sand cores and molds using the epoxy acrylate binders cured by sulfur dioxide vapor.

Abstract: A sand-forming apparatus (10) comprising a sand magazine (12), a manifold (14), a core box (16) defining a cavity (18), a clamp table (20), and a blow tube assembly (22). The apparatus (10) is convertible from a sand-blowing state to a catalyst-introducing state without removal of the blow tube assembly (22) and/or un-clamping of the tool package (e.g., the manifold (14) and the cope/drag halves of the core box (16)). In the sand-blowing state, sand is blown from the magazine (12) into the cavity (18) and, in the catalyst-introducing state, the catalyst is introduced into the blown sand in the cavity (18) to solidify the sand into a sand-shape. Molten metal can be poured into or around the sand-shape formed by the apparatus (10) and, upon completion of casting the metal part, the sand-shape can be removed.

Abstract: Procedure for the production of sleeves for mini-deadheads and an economical method of casting incorporating the use of said sleeves. A fluoride-free mixture, consisting of microspheres of aluminium silicate, an oxidizable metal, such as powdered aluminium, an oxidizable agent, magnesium as initiator element of the exothermic reaction, are introduced by blowing in a mould fitted with two cores to produce a sleeve provided with two openings, one of which is closed with a plug before being used.

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

Abstract: A sand-forming apparatus (10) comprising a sand magazine (12), a manifold (14), a core box (16) defining a cavity (18), a clamp table (20), and a blow tube assembly (22). The apparatus (10) is convertible from a sand-blowing state to a catalyst-introducing state without removal of the blow tube assembly (22) and/or unclamping of the tool package (e.g., the manifold (14) and the cope/drag halves of the core box (16)). In the sand-blowing state, sand is blown from the magazine (12) into the cavity (18) and, in the catalyst-introducing state, the catalyst is introduced into the blown sand in the cavity (18) to solidify the sand into a sand-shape. Molten metal can be poured into or around the sand-shape formed by the apparatus (10) and, upon completion of casting the metal part, the sand-shape can be removed.

Abstract: In blowing gas-curing casting sand, which is accommodated in a receiver of a blow head, into a cavity in molding dies and thereby packing it into the cavity, prior to the blowing and packing of the casting sand into the cavity, the casting sand in the receiver is stirred by a stirrer until the stirring resistance of the stirrer enters a predetermined range (a range corresponding to an optimum bulk density range of casting sand within which casting sand can efficiently blow out through blow nozzles).

Abstract: A sand-forming apparatus (10) comprising a sand magazine (12), a manifold (14), a core box (16) defining a cavity (18), a clamp table (20), and a blow tube assembly (22). The apparatus (10) is convertible from a sand-blowing state to a catalyst-introducing state without removal of the blow tube assembly (22) and/or un-clamping of the tool package (e.g., the manifold (14) and the cope/drag halves of the core box (16)). In the sand-blowing state, sand is blown from the magazine (12) into the cavity (18) and, in the catalyst-introducing state, the catalyst is introduced into the blown sand in the cavity (18) to solidify the sand into a sand-shape. Molten metal can be poured into or around the sand-shape formed by the apparatus (10) and, upon completion of casting the metal part, the sand-shape can be removed.

Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) a fluorinated acid, preferably hydrofluoric acid; (d) an effective amount of a oxidizing agent; and (e) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) an effective amount of a oxidizing agent, and (d) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Abstract: The invention relates to a method for hardening foundry cores from sand-containing molding materials. The core, for the purpose of hardening it, is subjected to a catalyst vapor/gas mixture in a core molding tool (20). and then to a pressurized air flow, at a predetermined pressure and predetermined temperature, via a gassing plate (30) that can be coupled to the core molding tool in a gas-tight manner. The amine is, preferably during core injection, supplied to a heating and mixing stage (17) in liquid form and in a dosed manner and converted to its gaseous state. Once the gassing plate has been coupled to the core molding tool in a gas-tight manner, heated pressurized air is guided through the heating and mixing stage (17) charged with the amine gas within a predetermined time interval and with proportional pressure increase for gassing the tool in a time-controlled manner. From there, the gas is guided as a catalyst vapor/gas mixture through the sand-containing molding material in the core molding tool.

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

Abstract: A sand-forming apparatus (10) comprising a sand magazine (12), a manifold (14), a core box (16) defining a cavity (18), a clamp table (20), and a blow tube assembly (22). The apparatus (10) is convertible from a sand-blowing state to a catalyst-introducing state without removal of the blow tube assembly (22) and/or unclamping of the tool package (e.g., the manifold (14) and the cope/drag halves of the core box (16)). In the sand-blowing state, sand is blown from the magazine (12) into the cavity (18) and, in the catalyst-introducing state, the catalyst is introduced into the blown sand in the cavity (18) to solidify the sand into a sand-shape.

Abstract: A cold-box process for preparing a foundry shape, e.g. mold or core, that uses a binder comprising a phenolic resin component and an isocyanate component, wherein the phenolic resin component comprises (a) an alkoxy-modified phenolic resole resin and (b) an oxygen-rich polar, organic solvent component, which contains a fatty acid ester.

Abstract: This invention relates to erosion resistant foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) a multifunctonal acrylate; (c) a phenolic resin that is soluble in (a) and (b); and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy novolac resin; (b) preferably a bisphenol F; (c) an acrylate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an aliphatic epoxy resin; (b) a multifunctional acrylate; and (c) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly aluminum castings.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl silicate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Abstract: The molding sand comprises hollow microspheres of aluminum silicate, preferably with an aluminum content between 15 and 45% by weight, a wall thickness between 3 and 10% of the particle diameter and a particle size between 10 and 350 &mgr;m. These sands are useful to manufacture low density cores with good “veining” and penetration characteristics, moreover maintaining the mechanical properties of the core obtained. These cores are useful in the manufacture of iron casting.

Abstract: This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.

Abstract: A method of preparing foundry shapes, e.g. molds and cores, by mixing a foundry aggregate with a foundry binder, shaping the mixture in a pattern, curing the mixture, and removing the mixture from the pattern. The foundry binder is a phenolic urethane binder that utilizes a phenolic resin prepared by reacting a phenol, an aldehyde, bisphenol-A-tar, and a divalent metal catalyst.

Abstract: An apparatus for curing foundry cores 100 is provided, including a first curing agent supply 110 passing through foundry core 145 primarily through first directional plane 130 and a secondary curing agent supply 160 passing through the foundry core 145 primarily through a secondary directional plane 170.

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