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: 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: The subject invention relates to a foundry binder system which cures in the presence of a volatile amine curing catalyst comprising (a) an epoxy resin,(b) an organic polyisocyanate, (c) a reactive unsaturated acrylic monomer or polymer, and (d) an oxidizing agent. The foundry binders are used for making foundry mixes. The foundry mixes are used to make foundry shapes which are used to make metal castings.

Abstract: A device for hardening a core mass containing sand contained within a foundry core forming tool includes a mixing device in communication with the foundry core forming tool for introducing a flow of a carrier gas stream enriched by catalyst vapor into the core mass containing sand; a first runnings system including a catalyst receiver tank containing catalyst, a first runnings pipe in communication with the catalyst receiver tank and the mixing device, a pump provided in the first runnings pipe for pumping catalyst from the catalyst receiver tank through the first runnings pipe, valve device provided in the first runnings pipe for dispensing catalyst into the mixing device, and a flow meter provided in the first running pipe between the pump and the valve device; a compressed air source in communication with the mixing device for providing a carrier gas stream comprised of air thereto; and programmed control device for controlling the valve device of the first runnings system and the compressed air source; wh

Abstract: A method of making sand cores to obtain optimum mechanical properties and particularly to obtain accurate adjustment of the gas curing cycle for making optimum resin-coated sand cores.

Abstract: A cope for a core box has a passage for passing sand into a core box cavity and a bore for passing catalyst into the core box cavity to harden a sand core formed therein. The bore may extend from an exterior surface of the cope to the cope passage. The cope may have structure for forming a seal with a sand injection tube following sand injection, such as a blow-up seal or an O-ring. A method of producing cores in a core box includes the step of providing a cope, a drag, and a cavity formed therebetween, the cope having a passage for receiving an injection tube and a bore for passing catalyst. Further steps include using the injection tube to inject sand through the cope passage into the cavity and passing catalyst through the bore in the cope into the cavity. A seal may be formed between the cope and the injection tube after sand injection.

Abstract: A method and apparatus is provided for increasing the packing density and strength of sand for gas-hardening casting molds. The method is characterized by the steps of filling spaces defined by a pattern plate 1 and a mold frame with gas-hardening casting sand 4, depressurizing a closed container 3 after the filled assembly has been conveyed thereinto, introducing air into the container 3, applying a pressure to the upper surface of the casting sand to increase its packing density, and hardening the casting sand by a hardening gas.

Abstract: A resin coated sand is blown into a core box to form an uncured core with a desired packing density. The core box has one or more inlets to permit ingress of gases and one or more outlets to permit egress of only gases. A non-catalyzing gas is passed through the defined sand core in the core box to create a first effluent and the hydrocarbon content in such first effluent that was exposed to the uncured resin of the sand core is measured. A catalyst carrying gas (nitrogen) is injected into the inlets to pass through the defined sand core within the core box for polymerizing the resin and thence exit from the outlets as a second effluent. The hydrocarbon content of the second effluent is continuously measured (i.e. non-dispersive infrared spectroscopy system). When the hydrocarbon content decreases to approximately the hydrocarbon content of the first effluent, the core box is opened to remove the sand core in a consistently cured condition.

Abstract: The injection tube for injecting and gassing of foundry sand in cavities in a core box has a first passage for passing sand and a second passage for passing hardening fluid. Sand may be injected simultaneously to the introduction of hardening fluid into the cavities. Alternatively, sand may be injected prior to introduction of hardening fluid into the cavities.

Abstract: A core box assembly for molding cores includes a first core box and a second core box disposed above the first core box. Each of the core boxes has a cavity. A passage for delivering core material to the cavities in the core boxes extends through the second core box and into the first core box. The second core box is placed above the first core box and core material is injected into the core boxes.

Abstract: To minimize the amount of setting gas to be gasified and to be introduced into a molding sand containing a gas-settable binder, a metered volume of the setting liquid is injected directly into a gassing plate arranged in front of an opening leading to a cavity containing the molding sand. Heat energy is supplied to the gassing plate to effect gasification of the liquid. A superpure gas then is produced and is directed through the molding sand. Consequently, not only is only a small amount of setting liquid required to set the molding sand but only a small amount of compressed air or other non-reactive gas is required for scrubbing to remove the residual superpure gas from the sand. Therefore, cleaning or removal of the gas from the set molding sand can be performed at a low cost.

Abstract: A core forming mold having at least three regions is provided and a molding sand is supplied into the core forming mold. The molding sand is hardened by an amine gas, to obtain a molding core having at least one region which has a diameter smaller than that of other regions. An iron casting mold is provided having a molding cavity therein, such that the molding core is positioned within the molding cavity of the iron casting mold. A molten iron is cast within the iron casting mold to entirely enclose the molding core.

Abstract: A core box has (i) a thermally conductive cope and drag resiliently sealingly mating at essentially a horizontal parting plane, and (ii) core defining walls enclosing an interior and perforated by sand-filtered ports. A sand, resin and liquid catalyst mixture is blown into the interior to form a sand body. At least the outer skin of the sand body is conductively heated to a first temperature (i.e., 300-400.degree. F.); and essentially simultaneously with the conductive heating, the remainder of the sand body is convectively heated by flowing a heated gas therethrough at a second temperature lower than the first temperature (i.e., 250-290.degree. F.). The heated gas enters the sand body from the drag and exits the sand body by way of the cope.

Abstract: The core box vent useful in core making, comprises a porous cylinder of sintered ceramic materials, the pores of such cylinder being less than will allow intrusion of the grain size of sand to be introduced to the core box. A method of making cores using the above vent comprises, first, providing mateable core box sections with blow tubes permitting introduction of an air fluidized sand mixture into the interior of such box sections and providing one or more ceramic core box vents in an exhaust side of the mating core box sections to permit egress of air used to fluidize the sand mixture the vents have a labyrinth of passages or pores smaller in diameter at least than the average grain size of the sand in the mixture sand and resin mixture is blown into the interior of the mated core box sections, with the resin being curable to polyurethane by chemical reaction. Next a catalyst curing gas is blown through the mixture via such blow tubes. Lastly, the mixture is purged with air.

Abstract: A primary gas supply circuit and a secondary gas supply circuit are provided with the primary circuit having a part in common with the secondary circuit. The primary circuit is provided with a source of hardening gas. A sand foundry part containing a binding agent is provided in the part in common with the primary and secondary gas supply circuits. Through the primary gas supply circuit a hardening gas/carrier gas is circulated through the sand foundry part containing the binding agent. The primary gas supply circuit is closed when the quantity of hardening gas present in the part of the primary gas supply circuit common to the secondary gas supply circuit is an amount corresponding to, or slightly exceeding, the theoretical quantity for a complete hardening reaction. The secondary supply circuit is opened and the hardening gas/carrier gas is circulated through the secondary supply circuit until the hardening reaction has been completed.

Abstract: For a production of foundry moulds, dies are stepwise, cyclically conveyed by a continuous conveyor and, synchronously with the dies, shot hoods are conveyed into a shot station which is common to both the dies and shot hoods, with the shot hoods being displaced with respect to the dies. For this purpose, a cyclically revolving die conveyor is provided for the dies, and a further conveyor is provided for the shot hoods, with the further conveyor revolving synchronously with the die conveyor. At least one shot station may be provided which is common to several dies and may be associated with the die conveyor in which dies and the associated shot hoods are conveyed by the die conveyor in a reciprocally displaced manner.

Abstract: A one-piece water jacket core for an internal combustion engine is formed by providing a first core box portion and a second core box portion adapted for assembly and formation of the one-piece water jacket core. The first core box portion includes a first cavity adapted to form a lower portion of the one-piece water jacket core and the second core box portion includes a second cavity adapted to form an upper portion of the one-piece water jacket core. A plurality of movable members are pivotally carried adjacent to, and preferably by, one of the core box portions. Each of the pivotal movable members includes a portion adapted to form a water jacket port and to be pivoted, after assembly of the first and second core box portions, to a position forming one of the water jacket ports in the one-piece water jacket core. The invention is particularly adapted for the formation of one-piece water jacket cores with a cold-cure process.

Abstract: An improved apparatus for gas curing foundry cores includes an instrument system for attachment to a source of curing gas such as a gas generator. The system includes a signal generating section for providing a plurality of first signals. These signals represent the instantaneous mass flow rate of gas flowing to the core box. A counter/controller section is coupled to the signal generating section and totalizes the first signals. A valve device is coupled to the counter/controller section, opened to initiate the flow of gas to the core box and closed to terminate the flow of gas. The valve is opened upon receipt of a signal initiating the curing process and closed when the total of the first signals reaches a value representing a predetermined total mass of gas which has flowed to the core box. The improved method includes initiating flow of a gas to a core box containing raw cores to be cured. The gas includes a curing constituent, either in substantially pure form or mixed with a carrier gas.

Abstract: Disclosed are water soluble core wherein a particulate refractory material is combined with a binding agent comprising Na.sub.2 CO.sub.3, Na.sub.2 O . NSiO.sub.2 where n is 0.5 to 4, and SiO.sub.2 as ingredients and a process for producing the water soluble core. The process comprises mixing the particulate refractory material with a water glass, casting the mixture of the particulate refractory material and the water glass, hardening the casting by CO.sub.2 gas, and calcining the casting at between 100.degree. C. and a temperature less than that of an endothermic peak of the water glass in differential thermal analysis. Also, a process for die casting a metal is disclosed using the water soluble core which process comprises pre-heating the water soluble core from a temperature of 300.degree. C. below a melting point of the metal to a temperature of the endothermic peak.

Abstract: The invention relates to foundary moulding compositions useful for producing moulds for the manufacture of metal castings wherein the moulds are capable of giving castings with good surface finish without the need for conventional separate blacking applications. A foundary moulding composition of the invention comprises refractory material such as sand, alkali phenol-formaldehyde resole resin solution, carbonifiable material such as styrenated phenol, and an effective amount of an organic ester for hardening the composition. In another embodiment, the invention is a binder composition comprising alkali phenol-formaldehyde resole resin solution and carbonifiable material capable of being hardened by reaction with organic ester. In another embodiment, the invention is a curing additive for a foundry binder comprising carbonifiable material and liquid ester such as gamma-butyrolactone, and the like.

Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.

Abstract: In the process and apparatus for making molds and cores, a casing for producing molds or cores is filled with a mixture of foundry sand and a binder. The mixture is hardened by a reagent which is firstly evaporated and introduced into the casing from a cylindrical container with a carrier gas or air flow supplied from a pressure gas source. The reagent is fed into the container by a dosing pump. A vacuum, or pressure below atmospheric pressure is produced in the container by a vacuum pump. The vacuum leads to the reagent evaporating more quickly than at atmospheric pressure. It is consequently possible to use reagents with a high boiling point, so that the hardening of the molds and cores is obtained less expensively and with reduced odorous annoyance.

Abstract: The subject invention relates to foundry binder systems, which are cured with gaseous sulfur dioxide, comprising as separate components:1. a blend of an acrylated epoxy resin and a monoester solvent and;2. an organic solvent; and a blend of an epoxy resin and an aromatic hydrocarbon solvent which is part of component (a), (b), or both.The invention also relates to the use of the foundry binder systems to prepare foundry mixes, foundry shapes, and metal articles.

Abstract: A binder composition which comprises an aqueous alkaline solution of a phenolic resole resin and an additive wherein the additive is phenoxyethanol or a derivative of phenoxyethanol.

Abstract: A process is described for curing sand moldings, in particular casting cores, by the cold box process. In this process a catalyst containing gas mixture escaping from the mold is passed over a mixture feed side of a semipermeable membrane while a pressure is maintained on the permeate side of the membrane which is less than the pressure on the mixture feed side, whereby the catalyst vapors preferentially permeate through the membrane, and a permeate carrier gas stream which is, in particular, 50 to 300 liters greater than the permeate stream passing through the membrane per m.sup.2 and per hour is passed over the permeate side of the membrane. The catalyst, in particular a tertiary amine, is greatly concentrated in the permeate carrier gas stream and can simply and inexpensively be removed from the latter by condensation. Inexpensive, virtually complete recovery of the expensive catalyst is possible using the process.

Abstract: A process for vaporizing a liquid curing agent includes heating the liquid curing agent while it is stored in a container. Heat is delivered to the container by a heated fluid passed through a jacket which at least partially surrounds the storage container. After vaporization, the gaseous phase curing agent, usually methyl formate, methylal, or other gases, is delivered to one or more work stations where it is used in a curing reaction.

Abstract: The subject invention relates to foundry binder systems, which are cured with gaseous sulfur dioxide, comprising as separate components:1. a blend of an acrylated epoxy resin and a monoester solvent and;2. an organic solvent; and a blend of an epoxy resin and an aromatic hydrocarbon solvent which is part of component (a), (b), or both.The invention also relates to the use of the foundry binder systems to prepare foundry mixes, foundry shapes, and metal articles.

Abstract: In the production of moulds for making moulded articles, e.g. foundry moulds for producing castings, it is known to consolidate resin-coated granular filler in a moulding box containing a pattern to form the mould pieces. A gas such as SO.sub.2 is passed through the filler to cause it to set. However, after repeated use, resin buildings up on the pattern plate. According to the invention, the pattern is provided with a layer of silicone release agent such as siloxane which prevents resin build-up yet can be easily washed away.

Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.

Abstract: Certain carboxylic acids are used in polyurethane-forming binder compositions to extend the bench life of such compositions. The binder compositions are particularly useful for preparing sand castings used for making foundry parts.

Abstract: Foundry molds and cores are prepared by using as a binder a phenolic resin in solution in aqueous sodium hydroxide and using an ester to cure the binder. The ester may be incorporated in the mixture prior to shaping, or the ester in gaseous form may be passed through the shaped mixture.

Abstract: In the mold-immersion type countergravity casting method, a resin-bonded particulate mold is formed in-situ in the vacuum chamber used to draw melt into the mold by: providing the chamber with a porous wall; positioning a gasifiable pattern in the chamber; embedding the pattern in a mass of mold-forming particulate containing a chemically curable precursor of the resin binder; and passing a curing gas through the porous wall and mass to cure the resin and unify the mass about the pattern. Thereafter, the mold is immersed in an underlying pool of molten metal and a vacuum drawn in the chamber to displace the pattern in the mold with metal.

Abstract: An apparatus and method for simultaneously injecting forming material (14) and a curing additive into a form (22). The apparatus (10) includes a container (12) of forming material (14) interconnected by a conduit (20) to a forming cavity (22). Forming material (14) is discharged into cavity (22) through conduit (20). An integrally formed chamber (36) is provided for simultaneously supplying additive to the discharging forming material (14). Forming material (14) is forced into cavity (22) while simultaneously forcing the additive into the path of the discharging forming material (14).

Abstract: A foundry machine for forming molds or cores from a molding material such as sand provides completely automated loading and unloading of tooling elements (24). The tooling elements (24) comprising a sand magazine (36), blow plate (34), combined gassing manifold and top ejector unit (32), upper mold box (30), lower mold box (28) and bottom stool (26) are automatically transferred, in stacked, separable relationship, by tracks (40) to a vertically displaceable, work table. Vertical displacement of the work table (42) sequentially elevates the tooling elements (24) to positions within a mainframe (10) where automatically operated clamping means secure the appropriate tooling elements (24) in respective operating positions. The gassing manifols (32) includes an ejector pin assembly (274, 280) mounted therewithin.

Abstract: A machine and method for making molds and mold cores (126) includes a pair of mold boxes (42a, 42b) removably mounted on a frame (60) for rotation between an upright, molding position in which molding material is introduced into the mold cavity of the mold boxes (42a, 42b) by a carrier (26) and an inverted discharge position in which the mold (126) is removed from the boxes by a mold receiving assembly (76). A pressure head assembly (46) both compresses molding material within the mold cavity and introduces a catalyst gas into the cavity for curing the molding material. A system for removing the spent gas from the mold cavity includes a pair of gas receiving chambers (122a, 122b) integral with the frame (60) which receives gas through the bottom of the mold boxes (42a, 42b) and an exhaust assembly (68, 70) which is selectively coupled with exhaust ports (124a, 124b) in the chambers (122a, 122b).

Abstract: Curable epoxy resin compositions are described which comprise a mixture of an acid curable epoxy resin and a minor amount of an oxidizing agent capable of reacting with sulfur dioxide to form a catalyst for curing said epoxy resin. The curable epoxy resin composition may contain solid particulate materials. The procedures for curing such epoxy resins as well as methods for forming sand cores and molds also are described. Sand cores and molds produced in accordance with the method of the invention have sufficient strength and hardness after a few seconds of curing for normal foundry applications.

Abstract: The subject invention relates to modifiers for aqueous basic solutions of phenolic resins. The modifiers are open-chain ether alcohols or ketone alcohols. They assist in stabilizing the aqueous basic solutions of phenolic resole resins and improve the tensile strength of foundry shapes prepared from foundry mixes made with the aqueous basic solutions.

Abstract: A plurality of identical green sand molds are sequentially formed by horizontal compaction on automatic mold making machinery. Each mold has a front and back vertical face with a recess formed in the front face and a plurality of down runners formed in the back face. A mold piece insert is formed of a mixture of green sand and a chemical bonding agent, preferably a resin binder and cold set in a pattern box to form the cavities for the cast articles. The mold piece insert is received flush in the mold front face recess with the cavities opening to the front face. A plurality of molds, with inserts, are adjoined in front-to-back relationship with the down runners overlapping the cavities for feeding the molten pour thereto.

Abstract: A machine for making molds and molding cores (126) includes a pair of mold boxes (42a, 42b) removably mounted on a frame (60) for rotation between an upright, molding position in which molding mateiral is introduced into the molding cavity of the molding boxes (42a, 42b) by a carrier (26) and an inverted discharge position in which the mold (126) is removed from the boxes by a mold receiving assembly (76). A pressure head assembly (46) both compresses molding material within the molding cavity and introduces a catalyst gas into the cavity for curing the molding material. A system for removing the spent gas from the molding cavity includes a pair of gas receiving chambers (122a, 122b) integral with the frame (60) which receives gas through the bottom of the mold boxes (42a, 42b) and an exhaust assembly (68, 70) which is selectively coupled with exhaust ports (124a, 124b) in the chambers (122a, 122b ).

Abstract: A machine for making molds and molding cores (126) includes a pair of mold boxes (42a, 42b) removably mounted on a frame (60) for rotation between an upright, molding position in which molding material is introduced into the molding cavity of the molding boxes (42a, 42b) by a carrier (26) and an inverted discharge position in which the mold (126) is removed from the boxes by a mold receiving assembly (76). A pressure head assembly (46) both compresses molding material within the molding cavity and introduces a catalyst gas into the cavity for curing the molding material. A system for removing the spent gas from the molding cavity includes a pair of gas receiving chambers (122a, 122b) integral with the frame (60) which receives gas through the bottom of the mold boxes (42a, 42b) and an exhaust assembly (68, 70) which is selectively coupled with exhaust ports (124a, 124b) in the chambers (122a, 122b ).

Abstract: Foundry moulds and, more especially, cores are made by the use of a binder comprising ammonium polyacrylate and zinc oxide or a metal salt to form a complex ammonium metal polyacrylate which is mixed with the sand and after the core or mould has been formed in a warm box warm air is passed through it to drive off the ammonia and form a water-insoluble metal polyacrylate which bonds the grains of sand together. The resulting core or mould has a good shelf life combined with excellent knock-out behavior.

Abstract: Mold parts are produced in accordance with a cold box procedure with passing a gaseous catalyst during curing, wherein for improvement of the application characteristics before/during curing, a gradient of properties within the mold part is caused such that the resistance of the surface layer of the mold part is increased relative to the resistance of the interior of the mold part.

Abstract: A process for making a foundry mold for use in metal casting, which comprises the steps of heating and drying mold sand composed of refractory particles and a water-soluble binding agent, charging a cavity formed in a mold pattern with the mold sand under dried condition, during the charging step, moisture being kept on the peripheral surface of the mold to be made, and heating the whole pattern of which the cavity has been filled completely with the mold sand to thereby cure mainly the peripheral surface of the mold.

Abstract: An apparatus and method for making hollow shell cores wherein a core box assembly is provided including a vented pattern. Baffles are provided in the core box in the space between the pattern and the core box walls whereby a catalyst gas flowing into the core box through an entry port will be caused to enter the pattern and to flow along the outer layer of a sand and binder change in the pattern. The gas will then be caused to flow out of the pattern into a trapped gas vent and out of an outlet port of the core box. The continuous flow of catalyst gas through only the outside layer of the sand and binder charge in the pattern will only cause the outer layer of the charge to be cured and to form a hardened shell. After formation of the shell, the uncured sand and binder mixture in the shell will be discharged and reused. The shell is then transferred from the core box assembly.

Abstract: The addition of the metal drier to the phenolic urethane binder enhances the breakdown of the binder when the system is subjected to the elevated temperatures caused by pouring the molten metal into the mold and enhances the subsequent shake out of the sand from the cores and molds.

Abstract: A foundry binder of the water-soluble alkali metal polyacrylate type having additives that include lime is cured by the use of the vapour of a low-boiling point organic ester having not more than three carbon atoms, primarily methyl formate, entrained in a carrier gas, e.g. carbon dioxide or nitrogen.

Abstract: A binder composition containing a phenolic resin, a polyisocyanate, a phosphorus based acid and optionally an acid halide and/or a base, and methods of making and using the same.

Abstract: A binder for a foundry core or mould consists of an alkali metal salt of a polybasic organic acid or of a polymerized monobasic organic acid, for example sodium polyacrylate, an alkaline earth metal hydroxide such as calcium hydroxide, one or more polyvalent metal oxides, preferably magnesium oxide, and calcium citrate, together with water. The mixture may also include another polyvalent metal oxide, for example zinc oxide. The inclusion of calcium citrate in the binder composition, particularly in the presence of magnesium oxide, has been found to reduce the problem of `softening back` in which the strength of the core or mould interior deteriorates over storage periods of a few days due to the continued absorption of carbon dioxide from the atmosphere in damp conditions.

Abstract: A process for casting metals is disclosed wherein a thin refractory lining is formed between a pattern half and a permanent backup plate. For each desired casting, two mating backup plates are provided; each having portions corresponding roughly to the desired configuration of the casting. A pattern half is aligned against each backup plate so that a thin space along the plate - pattern interface is formed. A bondable refractory material is blown into this space and caused to set by heating or the addition of reactants or catalysts thereto. Each pattern half is then removed from the backup plate assembly and the lined, mating backup plates are assembled together so as to form a lined mold cavity therebetween. The desired molten metal is then poured into the cavity. After the casting is cooled, the refractory is stripped from the backup plates and the backup plates are recycled for further use.

Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.