Abstract: A method for manufacturing a mold includes providing first information regarding a location of a shrinkage hole generated during hardening of a molten metal in a shell mold. Second information regarding a change in the location of the shrinkage hole in response to adjustment of a heat transfer rate of the shell mold is obtained. The heat transfer rate of the shell mold is adjusted to shift the shrinkage hole to a predetermined location.

Abstract: A foundry core formed from a moulding sand, grains of which are bound together by a binder, and which is provided to form a cooling channel in an engine block for an internal combustion engine. The foundry core has a supporting section, two neck sections, which protrude from a lateral surface of the supporting section and are arranged at a distance from one another, and at least one bridge section which is held by the neck sections at a distance from the supporting section and a minimum thickness of which measured as the distance between its lateral surfaces is no more than 3 mm in an area which lies between the neck sections.

Abstract: A sand casting apparatus, a method of forming a sand casting apparatus, and an automotive component are provided. The sand casting apparatus includes a sand casting base including a sand mold and/or a sand core having a base sand mixture, where the base sand mixture includes a sand material and a binder material. The sand casting apparatus further includes an outer layer disposed on the sand casting base. The outer layer includes silicon, magnesium, calcium, zirconium, manganese, carbon, aluminum, and iron. The automotive component has portions defining an aperture therein. The automotive component is formed of cast iron and has a nodular graphite structure from interior matrix to surface, where the nodular graphite structure on the surface is formed by a sand core having an outer layer that has reacted with the cast iron automotive component to form the nodular graphite structured surface.

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: 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 manufacturing a mold, including steps of (a) expanding a powder mixture containing a water-soluble inorganic salt powder and a water-soluble organic polymer powder in a plane on a table and then selectively spraying a spray liquid containing at least one selected from a water-miscible organic solvent and water through a nozzle on this powder mixture layer to make a bonding strength among particles of the powder mixture in a sprayed region higher than that among particles of the powder mixture in an unsprayed region, (b) further expanding the powder mixture on the powder mixture layer after spraying and then selectively spraying the spray liquid through the nozzle on this powder mixture layer, (c) repeatedly conducting the step (b) over several times to form a mold shaped by the sprayed regions, and (d) taking out the mold.

Abstract: A cost-effective starch/water-based binder composition and related method for forming silica sand cores and molds for foundries, wherein the sand grains are pre-coated with starch having additives making the coated sand effective for blowing said cores and molds. One or more additives are included with the starch; preferably sodium tripolyphosphate and -silicon or Silres BS16. The preferred starch is a tapioca starch. The binder of the invention is highly competitive due to its low cost and effectiveness for forming silica-sand cores and molds, being particularly effective for use in aluminum foundries for the automotive industry.

Abstract: A method to efficiently make flaskless upper and lower molds that are stacked, to efficiently spray a release agent in a closed space, and to promptly place a core. The method includes the steps of holding a match-plate between one pair of cope and drag flasks that are horizontally positioned, each of them having a sand-filling port for supplying molding sand at its side wall, defining upper and lower molding spaces by inserting upper and lower squeeze-plates in respective openings of the pair of cope and drag flasks which openings are opposed to the match-plate, putting the pair of cope and drag flasks and the match-plate in a vertical position, and causing the sand-filling ports to be placed in an upper position, spraying a release agent into the two upper and lower molding spaces, supplying molding sand through the sand-filling ports to the two upper and lower molding spaces, and squeezing the molding sand in the two upper and lower molding spaces.

Abstract: A sand-introducing device that uses air for introducing molding sand in a molding space or spaces is provided. The device is provided with air-permeable partitioning plates that define a double-walled structure together with the wall of the body of the device. The air-permeable partitioning plates are easily produced, they can easily inject pressurized air of a desired pressure, and they will not need regular maintenance. The body of the device, which acts as a pressure tank, defines a double-walled structure together with the air-permeable partitioning plates (10, 11), thereby defining chambers (12, 13). In the sand-introducing device that uses air, while molding sand is fluidized by pressurized air injected from the air-permeable partitioning plates, it is introduced in a molding space. Each air-permeable partitioning plate is made of a porous resin or metal.

Abstract: A sand-introducing device that uses air for introducing molding sand in a molding space or spaces is provided. The device is provided with air-permeable partitioning plates that define a double-walled structure together with the wall of the body of the device. The air-permeable partitioning plates are easily produced, they can easily inject pressurized air of a desired pressure, and they will not need regular maintenance. The body of the device, which acts as a pressure tank, defines a double-walled structure together with the air-permeable partitioning plates (10, 11), thereby defining chambers (12, 13). In the sand-introducing device that uses air, while molding sand is fluidized by pressurized air injected from the air-permeable partitioning plates, it is introduced in a molding space. Each air-permeable partitioning plate is made of a porous resin or metal.

Abstract: A method of producing a sand mold, comprising: after defining a mold space at least by a pattern plate, a flask, and a squeeze means, and after blow-charging molding sand held in a sand blowing device located above the mold space into the mold space by ejecting a first compressed air near sand ejecting ports of the sand blowing device thereby fluidizing the molding sand near the sand ejecting ports, while supplying a second compressed air to a surface of the molding sand held in the sand blowing device, moving the squeeze means toward the pattern plate, where in the pressure of the first compressed air and the period of time for supplying the first compressed air are adjusted to produce a good sand mold.

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: 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 method is disclosed for producing a casting mold for an engine block, the casting mold includes a mold seat for a cast-in-place cylinder bore liner, the seat having a surface disposed at an angle relative to a longitudinal axis of the cylinder bore liner, wherein the cylinder bore liner becomes slightly unseated upon thermal expansion.

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: 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 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 system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the in-flight atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: Before supplying molding sand into the blow head, a blow-in port of the mold-defining device is connected to a blow-off port of the blow head so that molding sand flowing out of the blow-off port is received by the device after the molding sand has been supplied to the blow head. Preferably, after molding sand has been charged into the mold space but before the mold-defining device is moved out of engagement with the blow head, sand remaining in the blow-off port is hardened.

Abstract: A mold sand feeding tank 4 is provided for feeding mold sand S into a hollow core molding portion 2 defined by a pair of molds 1a and 1b mating with each other. A switching valve 7 is disposed within the mold sand feeding tank 4 and has a mold sand feeding opening 5, through which the mold sand S is fed into the mold sand feeding tank 4 from the outside, and a mold sand discharging opening 6, through which non-hardened mold sand Sb within the hollow core molding portion 2 is directly and externally discharged.

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 pattern plate carrier releasably mounts a pattern plate. The pattern plate carrier is rotatable to an inverted position, and a pattern plate changing device is provided for removing a pattern plate from the inverted carrier and replacing the removed pattern plate with a pre-heated substituting pattern plate.

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: In order to prevent casting with an abnormal hollow core having partially thin wall or filled in parts, a new method suitable for forming good hollow core stably and suitable for checking the hollowness of the moulded core before casting is proposed. This method comprises a step of providing a filling hole and an air inlet hole in a mould for core formation, a step of filling the mould with core sand with the air inlet hole in a closed state, a step of heating the mould and a step of sucking out unhardened sand through the filling hole with the air inlet hole in an open state. Unhardened sand is sucked out with the air flow from the air inlet hole to the filling hole, and the hollowness of the core is checked by measuring the pressure at the filling hole.

Abstract: A closed core box is provided with one or more inlets for receiving and passing gas fluidized resin-coated sand to fill the interior of such core box, and with one or more screened outlets for allowing egress of such gas. A closed cylindrical or angular sand-fluidizing chamber is provided for each of the inlets, the chamber having one end connectable to a pressurized gas supply and an opposite end communicating with an inlet. At least part of each chamber is filled with resin-coated sand and a non-porous piston is placed on the sand within each chamber, each piston providing an annular gap (i.e. about 1/16 of an inch) with the interior of such chamber to direct the gas supply along the periphery of the chamber interior.

Abstract: A shell mold includes a plurality of sleeve forming portions. Of the sleeve forming portions, at least an endmost sleeve forming portion located adjacent to a subrunner portion has a modified shape for compensating for deformation of cast sleeves caused by solidification and contraction of molten metal. A shell molding apparatus includes an upper die and a lower die which constitute a die set for molding a shell mold. The lower die is composed of shell molding inserts, each having the shape of a halved cylinder, spiny insert receiving recesses formed in the shell molding inserts, and spiny inserts retractably provided in the spiny insert receiving recesses. In a casting method using a shell mold, many protrusions of a spiny insert are reversely copied to the inner surface of a halved shell mold at the undercut portion of the inner surface, thereby forming many depressions at the undercut portion. The halved shell mold is parted from the lower die.

Abstract: A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Abstract: After sand of one layer is loaded into a sand layer elevator (20), a shading mask (38) is positioned above the sand, and a diffused laser beam is irradiated from a diffused laser irradiating source (16). Thereby, a predetermined range of sand under the shading mask (38) is exposed and this exposed portion is cured. This operation is repeated for a predetermined number of sand layers and cured portions are piled up to directly form a 3-D sand mould. Particularly, a diffused laser beam is used to cure a wide range of sand at a time, thereby making sand mould mass-production possible.

Abstract: The core box includes a cavity therein, a vent in fluid communication with the cavity, ejector members, and apparatus coupled to the ejector members for passing a fluid through the vent into the cavity.

Abstract: Ready-to-pour shells or core assemblies produced utilizing at least two in-line core shooting machines (1), each core shooting machine (1) having two, at least slightly differing sets of tools (4), each set comprising an upper tool (2) and a lower tool (3), and identical conveyor plates (5) serving, on the one hand, as the lower tool (3) of the first core shooting machine (1) and, on the other hand, as for transporting the core (6) or the core assembly along a transfer path (7) through the apparatus.

Abstract: A submarine buoyant cable antenna having positive buoyancy comprising a cunications antenna electronics package encased in a polymer composition, the polymer composition comprising from about 80 percent to about 85 percent by weight of a room temperature curable thermosetting polymer having a viscosity, before curing, in the range of from about 700 to about 900 centipoise, and from about 15 percent to about 20 percent by weight of microballoons of a size ranging from about 20 to about 100 microns in diameter, the specific gravity of the composition being in the range of from about 0.51 to about 0.65 grams per cubic centimeter to provide the positive buoyancy.

Abstract: An apparatus for cleaning shot hoods during the manufacture of casting molds or core packets that are ready for casting, by means of core shooters or shooting stations, preferably in a linear arrangement, the core shooters in each instance incorporating a shot hood (3) that comprises a shot plate (1) and shot nozzles (2), it being possible to uncouple the shot hood (3) from the core shooter and lay it on a pallet (4) or the like with the shot nozzles (2) pointing downward, characterized by a delivery system (5), a transfer station (6), an emptying station (7), a flushing system (8), a drying system (9), an exit station (10), optionally an inspection station, and a removal system (11), the shot hood (3) that has been laid upon the pallet (4) being moveable from the core shooter to the transfer station (6) by means of the delivery system (5), it then being possible to raise it from the pallet (4) by means of a first manipulator (12) and pivot it through approximately 180.degree.

Abstract: A storage hopper retains the mold core material and an outlet member is connected below the hopper for discharging the mold core material into the core shooting head. The outlet member is inserted into the core shooting head and is mounted on a vertically adjustable machine frame such that it may be inserted to various depths within the core shooting head and may also be removed. A shutoff device in the form of a rotating shutter closes the outlet member. A frame supports the outlet member and the storage hopper and vertically adjusts both for immersion within the core shooting head. A displacement measuring sensor detects the vertical position of the vertical adjustment members in relation to the machine frame. In the method the storage hopper is filled with mold core material, the outlet member is positioned over the core shooting head, and the outlet member is immersed within the core shooting head.

Abstract: This invention relates to a process for the preparation of foundry cores and molds by mixing a filler and a casting resin mixture and then curing the resultant mixture. The casting resin mixture is made from (a) 25 to 99.9% of at least one organic polyisocyanate, (b) 0.1 to 50% of at least one organic compound containing at least two epoxide groups, and (c) up to 50% of a polyhydroxyl compound, the quantities being based on the total quantity of resin.

Abstract: A heat curable organic sand binder based upon epoxide or epoxide novolac resin and a latent dicyandiamide or imidazole curing agent, with or without an imidazole accelerator, which may be used as a direct replacement for other "Hot Box" and "Warm Box" foundry resin binders and as a direct replacement for other "Shell Sand" foundry resin binders.

Abstract: Compound concrete composition for the manufacture of moulds, comprising: (1) a binder which comprises an alkaline-earth mineral substance, a constituent made up of fine particles of a compound other than an oxide, 90% of which have a particle size of between 1 and 150 .mu.m with a median diameter of between 3 and 20 .mu.m, these fine particles comprising particles of a substance which has a thermal conductivity higher than approximately 30 W/mK, chosen from silicon carbides, silicon carbonitrides, silicon nitrides, boron carbides, titanium carbides and tungsten carbides and a constituent made up of ultrafine particles at least 70% of which have a particle size smaller than 1 .mu.m with a median diameter of between 0.3 and 0.8 .mu.m, (2) water optionally with the addition of a dispersant, and (3) fillers comprising metal granulates and metal fibres, wherein the water/binder ratio is lower than 0.20 and the concrete composition has a thermal conductivity at 200.degree. C.

Abstract: A blow tube arrangement and method for controlling the flow of granular mold material to the cavity of a mold or core making machine, in which one or more transverse openings are formed in the tip of the blow tube, which allow flow into the cavity when the tip is inserted into the cavity but which are covered as the tip is withdrawn. A spring urged covering sleeve receives the tip as it is withdrawn from the mold pattern structure to maintain closure of the tip openings.

Abstract: An expendable substrate which in use contacts molten metal, for example a foundry mould or core or ladle lining, is coated with a coherent layer of refractory particles by tribo-electrically charging refractory particles coated with an organic binder, the coated particles having an electrical resistivity of at least 10.sup.10 ohm. cm. at 10kv, earthing the substate and bringing the charged particles into contact with the earthed substrate. Suitable binders are thermoplastic resins, thermosetting resins and waxes and the quantity of binder in the binder coated particles is usually less than 10% by weight.

Abstract: Molding material composed of casting sand coated with a thermosetting resin and hydrous magnesium silicate clay mineral which may be impregnated with an acid and/or coated with a thermosetting resin, and a shell mold produced from the molding material. This material and mold minimize generation of smoke and irritating gases at the time of mold making and casting.

Abstract: A special stucco for use in the construction of shell molds for investment casting is disclosed. The stucco particles comprise refractory powder held together by a binder which volatilizes or otherwise disintegrates at firing temperatures. Since the particles lose their structural integrity in the firing process, the shell mold may be more easily broken away from the finished casting.

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 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: A process for making an investment mold wherein a paste composition is used as the separating layer between the investment mould of refractory material and the surface of the metal container in which the investment mould itself is located. The composition is constituted by an organic component which can be eliminated by thermal degradation at temperatures above 200.degree. C. and a refractory mineral component which is stable at the casting temperature of the alloy used in the casting process. In a preferred embodiment, the composition comprises vaseline, talc and kaolin.

Abstract: A binder containing a phenolic resin; a polyisocyanate; a curing component, and a phosphorus halide and use thereof.