Abstract: A mold molding method includes a binder reaction amount calculation step of calculating a reaction amount ?C(?, ti) [wt %] (i=1, 2) of a binder, a specimen room temperature compressive strength calculation step of calculating room temperature compressive strength ?c(?, t) [MPa] of a specimen, a mold room temperature compressive strength prediction step of predicting room temperature compressive strength ?ca(?, t) of the mold in advance, and a mold room temperature compressive strength extraction step of extracting room temperature compressive strength ?ce(?, t) of the mold. When the mold is actually molded, the model is removed just after elapse of the time t1, as one of the molding condition parameters which satisfies the room temperature compressive strength ?ce(?, t).

Abstract: Methods for fabricating an interconnect for a fuel cell system that include forming a metal powder into a preform structure, positioning the preform structure in a die cavity of a press apparatus, and compressing the preform structure in the press apparatus to form the interconnect. Further embodiments include use of thin inserts in the die cavity to provide reduced permeability and/or including filler material in the die cavity.

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: The invention relates to a method for forming a green article for subsequent sintering or infiltration. This method includes providing a mold having an internal cavity that outlines the shape of the article, introducing metal or ceramic particles into the mold in an amount sufficient to provide the article in a desired size, adding a solution comprising an organic fluxing agent onto the particles with the solution carrying the organic fluxing agent into interstices between the particles, and freezing the solution to form a solid green article. The invention also relates to an apparatus and method for manufacturing dimensionally stable articles.

Abstract: A process for making a metal-matrix composite (MMC), includes a mixture of particulate ceramic powder with a liquid carrier, without addition of a binder, to prepare a slip having thixotropic properties. The slip is introduced in a substantially dense consistency into a casting mold which is then subjected to vibrations so as to separate the carrier from the ceramic particles and to allow the carrier to float upon the ceramic particles while at the same time compacting the slip to realize a ceramic preform of porous consistency having pores. After terminating the exposure of the casting mold to vibrations, the liquid carrier is removed and the preform is allowed to solidify in the casting mold, without exposure to any further compaction measures, such as sintering, pressing or the like, and the casting mold is maintained in a position of rest. Subsequently, matrix metal is poured into the casting mold to fill the pores of the preform.

Abstract: A method for compacting molding sand in a molding box in which a model is present, which model is embedded in molding sand. The molding box is vibrated by means of imbalance weights, which are each to be rotated about an axis of rotation during operation. At least four imbalance weights being rotatable about parallel axes of rotation are used, which can be shifted in phase relative to each other.

Abstract: Unique cristobalite-seeded quartz glass crucibles and cores admirably suited for Cz crystal growing and D.S. metal casting are formed by slip casting using a slurry containing a quartz refractory composition comprising silica particles with an average particle size of from 1 to 10 microns and a minute but effective amount of micronized dispersible particles of a unique crystallization aid, such as basic aluminum acetate, which provides the glass with at least 0.005 percent by weight of evenly dispersed metallic ions. The metallic ions provide the quartz glass with nucleation sites so that heating of the glass to a temperature of from 1200.degree. C. to 1250.degree. C. permits formation of a high concentration of evenly dispersed cristobalite nuclei in the glass without causing excessive devitrification prior to cooling of the seeded glass. The desired nucleation sites can also be provided by using micronized particles of alpha quartz or alpha cristobalite.

Abstract: A method of manufacturing a core and a mold for manufacturing a core or a mold using self-hardening molding sand or gas-hardening molding sand, wherein the self-hardening molding sand or the gas-hardening molding sand is charged in a core pattern or a flask while applying three-dimensional jolt, and a method of manufacturing a core and a mold for manufacturing a core or a mold using self-hardening molding sand, wherein air flow is precipitated by sucking the self-hardening molding sand in a core pattern or a flask.

Abstract: The invention concerns a device and method for continuous fabricating of foundry molds from granular material.The device consists of a frame (10) with lights (11) supporting through swivels (31) caissons (30, 40) with large partitions (42) provided with grooves (421) into which pattern-plates (60) are inserted, and with small partitions (43) provided with suction holes (431); the caissons being connected to a vacuum source through flexible hoses controlled by solenoid valves; the whole assembly being placed after heat-forming of a polymer film (92) around a grid (70) with a hollow rib (74) and filter (741) connected to a vacuum source through a connector (75).

Abstract: A cope flask is precisely centered relative to a cope pattern by a flask displacement mechanism affixed to a cope stool which lineraly shifts the flask relative to the pattern while taking up clearance between the locator pins of the cope flask and the locator bushing in the stool. This precision centering is maintained while mold sand is poured into the flask and compacted. The cope mold comprising the flask and the hardened sand is stripped from the stool for subsequent mating with a drag mold made in a similar manner but with the drag stool having locator pins secured in its top surface and the locator bushings provided in the drag flask. As with the cope mold making procedure, the drag flask is precisely centered relative to the drag pattern by linearly moving the drag flask to take up clearance between the centering pins and the centering bushings in the drag with the displacement mechanism.

Abstract: A flask adapted to contain a pattern and sand is resiliently supported in a controlled orientation and vibrational forces are imparted to the flask including a horizontal force component causing generally horizontal oscillating movement of the flask and alternative oppositely directed vertical force components maintaining the flask in a controlled orientation during the generally horizontal oscillating movement thereof. The vertical force components are adapted to counteract rotational inertia of the flask, pattern and sand.

Abstract: A high-density silica glass article with excellent thermal shock characteristics is formed from a high purity vitreous silica containing an aluminum compound as a crystallization aid and having a dense concentration of cristobalite muclei. The aluminum compound is aluminum oxide, aluminum hydroxide, an aluminum salt, or other aluminum-oxide precursor.A refractory silica glass crucible made according to the invention has remarkable advantages in a Czochralski crystal-growing process. The entire crucible can be crystallized during the initial melt down in the Cz furnace to provide a cristobalite inner surface which effectively resists attack by the molten silicon to minimize contamination problems during crystal growing.Another embodiment of the invention relates to a unique drawn silica glass with good flexural strength having fibrous oriented veins of cristobalite embedded in a matrix of vitreous silica and having remarkable resistance to deformation at temperatures of 1500.degree. C.

Abstract: The method and apparatus are based on the use of a casting process in which expendable patterns are made of a low density material, then evaporated by molten metal as the metal advances into the cavity created by the evaporation of the pattern material. The outer supporting material of the cavity is an unbonded granular material of sufficient grain size distribution. This unbonded material is vibrated in defined partial volumes of the whole volume of a holding vessel called a pouring container and compacted to a predetermined density around the expendable pattern so that it fills all cavities of the expendable pattern prior to the introduction of molten metal into the container to displace the pattern. The compacting vibration is performed in several independent zones to achieve uniform compaction and to prevent pattern deformation. The pouring container follows a loop via a conveyor system preferably through four operation stations.

Abstract: A compaction unit (12) having a frame (14) resiliently mounted to a rigid support (10), the frame rigidly supporting a molding flask (24) therein, and having at least one pair of synchronized motors (A) with eccentric rotors coupled to the frame for vibratory motion therewith. The motor pairs are synchronized in counter rotation so that a given pair produces a net force vector perpendicular to a line joining the motor pair. Preferably, three motor pairs (A, B, C) for driving the frame in three different axis, are controlled by a program which permits sequential specification of the duration and net vector acceleration, over a wide range of values. The motors are maintained in synchronized phase relationship during the changeout of flasks, so that the compaction vectors experienced by each flask begin from the same initial idle condition.

Abstract: A method of casting a metal article in a mould box comprises locating an expendable pattern in the box, the pattern having a gas permeable refractory coating thereon, placing and compacting unbonded particulate material about the pattern and supplying molten metal into the box so as to vaporize or burn away the pattern and form the article of defined shaped while applying a vacuum during casting. According to this invention, the method is improved by compacting the particulate material to a maximum bulk density where it contacts the coated pattern and applying a vacuum to the compacted particulate material so as to create sufficient pressure gradient in the height of the compacted material to maintain the integrity of the gas permeable refractory coating. In this way, the risk of mould collapse, metal breakout, and pollution are reduced.

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 phosphorus, sulfur, boron and nitrogen 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.

Abstract: A molding apparatus comprising a rigid mold flask adapted to contain a mold pattern and sand, and when containing sand, having a combined center of gravity, a support for resiliently supporting the mold flask for horizontal movement only of the mold flask as a whole body, and a vibrator for shaking the mold flask to provide horizontal vibrational forces directed in a horizontal plane extending approximately through the combined center of gravity.

Abstract: A mold pattern is held in position in a mold flask in an unconnected relation to the mold flask. Sand is supplied to the mold flask to surround the mold pattern while the mold flask is vibrated to compact the sand around the mold pattern.

Abstract: The invention relates to the casting of molten metal where a pattern embedded in sand is used to determine the shape into which the molten metal is formed. To ensure that the foundry sand fully penetrates all cavities and recesses of the pattern, the mold flask containing the pattern and sand is first vibrated at a frequency and stroke to produce accelerations in excess of the acceleration due to gravity to cause the sand to penetrate and completely fill all cavities, etc. in the pattern and then the accelerations are reduced to produce an acceleration less than the acceleration due to gravity to compact the sand in place.

Abstract: A machine for producing sand molds by a single operator, wherein the flask assembly, including the cope, drag and matchplate remain in the machine at all times, and the method utilized therein.

Abstract: A method of making sand molds, cores or the like for use in casting foundry pieces. First and second continuous conveyors are utilized, the first conveyor having a number of pattern pieces and flasks attached to it, and the second conveyor for transporting the sand molds, cores or the like from the flasks after deposition thereon by inverting the flasks over the second conveyor. Each flask is filled in turn with sand and binder mixture when in an upright position, the sand-binder mixture is compacted and partial curing thereof is allowed, the flasks are inverted in turn to bring the sand mold into contact with the second conveyor, and the sand mold is released from each flask while it is inverted. Each flask is then brought back into an upright position for receipt of further sand-binder mixture to repeat the process, the process being substantially continuous.

Abstract: A method of making a more economical and reliable treating agent for use in late metal treatment when pouring metal castings. The treating agent is defined as an essentially homogeneous solid cast block preferably containing alloying ingredients to nodulize or inoculant ferrous metal. Each block is designed to present a generally uniform reaction surface to molten metal to be treated. This is obtained by casting the block to a shape which snugly fits a prepared basin in the mold gating system over which the molten metal to be treated must flow, or to cast the block in an annular configuration through which the molten metal must flow. The latter block has contoured inner surfaces which maintain a generally constant reactive surface as the block is consumed. These blocks are preferably prepared by simultaneously casting a large number in closely nested relation.

Abstract: A contact adhesive that is a polymeric material with a major proportion of a tackifier is applied to sand in making a foundry mold. No curing step for the adhesive is required but instead pressure is applied to get the desired bonding together of the sand granules.

Abstract: The method envisages calcining ceramic casting moulds, their cooling to between 30.degree. and 60.degree.C, applying particulate material preheated to a temperature between 600.degree. and 850.degree.C to the outside of the moulds followed by the compacting of the material and keeping the moulds in said preheated particulate material for a period lasting between 10 and 40 minutes.

Abstract: Apparatus for forming a refractory lining is disclosed which comprises a molding box for forming a refractory lining of an inner wall of a container for molten metal made up of an irregularly shaped mass of refractory material which has been vibrated and given thixotropic fluidity. The molding box is positioned within the container having at least one hole pierced in its bottom and means are provided for opening and closing the hole and vibrating the molding box, with the hole being connected with a vessel for vibrating the refractory material.