Abstract: A chill mould for the casting of light metal casting materials is provided. The chill mould is manufactured from an Ni-alloyed and/or Mn-alloyed cast iron material, of which the Ni and/or Mn content is dimensioned in such a way that the thermal coefficient of expansion of the chill mould is adjusted to the thermal coefficient of expansion of the light metal casting material, which is to be cast in each case. A chill mould is provided which can be manufactured in an economical manner which possesses optimized properties of use and at the same time allows for optimized casting results. Such a chill mould can be a constituent part of a sand casting mould for the casting of a cylinder block from a light metal casting material.

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: Techniques for forming cast parts for medical devices suitable for contact with internal regions of patients are described herein. Such parts can be small in scale (e.g., having a major axis less than 0.3 inches, and/or a minor axis less than about 0.08 inches), and can be formed from metals that have a high melting point and high reactivity with environmental components or mold surfaces, such as stainless steel and titanium alloys. Such techniques can include injecting molten metal into the sprue of a mold tree such that the side runners are backfilled after the molten metal impacts a closed end of the sprue. Side runners can be oriented in particular directions and positions to promote backfilling. As well, flask temperatures and the use of surfactants can also promote cast part formation, hindering the formation of surface defects.

Abstract: A method for reducing pollutant emissions from a metal casting case used in foundry practice. The metal casting case includes at least a molding material formed to a metal casting mold. The pollutant emissions are released from material making up the casting cases after pouring molten metal in the metal casting mold. The method includes the steps of adding at least one additional combustible substance to at least one region of the casting mold located outside of a contact region of the casting mold with the casting, and burning the at least one additional combustible substance in one of a gaseous and vaporized state together with the pollutant emissions.

Abstract: A method for producing a core sand and/or molding sand for casting purposes mixes a basic granular mineral molding material such as silica sand with an additive based on an organic or inorganic component, a binding agent being optionally added. The additive is coarsely ground prior to the mixing process, more than 50 percent by weight of the grains having a minimum size of approximately 0.05 mm.

Abstract: A method is for producing a moulding sand that is in particular recirculated, for foundry purposes. A mixture of a granular substance and aggregates, such as a binding agent and water, are added to a material that is not capable of swelling in water. The latter material has cavities with a specific surface area of more than 10 m2/g, in particular more than 50 m2/g and preferably more than 100 m2/g, for improving the characteristics of the moulding sand and/or for reducing the emission of harmful and/or odorous substances.

Abstract: An improved phosphate-type refractory investment material and method for making solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, a water soluble acidic constituent, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or acidic constituent can be combined with the refractory powder at the time of mixing with water.

Abstract: Sand mold for shaping molten metal cast into the mold. The mold includes sand, a thermally oxidizable polymer amongst the grains of the sand, and a catalyst coating on the gains for promoting the thermal oxidation and breakdown of the polymer in the course of removing the sand from the casting and/or reclaiming the sand for reuse. The catalyst coating adheres so tenaciously to the grains of sand that the sand can withstand repeated casting and sand reclamation cycles without the need to replenish the catalyst.

Abstract: The invention relates to a method for reducing pollutant emissions, released particularly in the form of pyrolysis products from metal casting cases, used in foundry practices. The aim of the invention is to reduce said emissions at low cost. This aim is achieved, whereby at least one additional combustible substance is added to the metal casting cases. Said substance changes into gaseous form on heating, provided that it is not gaseous, and burns together with the pollutants when leaving the metal casting cases. The additional combustible substance contains at least one organic substance, preferably a wax or an oil, ideally a ketone, an aldehyde, ether or alcohol. It can also be advantageously formed by a combustible gas (natural gas).

Abstract: A method for treating an unfired, molded ceramic core comprises placing an unfired (green) ceramic core having a thermosetting and/or thermoplastic binder on at least one setter, placing the setter and the green ceramic core thereon on a conveyor, conveying the setter and the green core through the heating oven to heat the setter and the green ceramic core to an elevated superambient temperature at or above a softening temperature of the binder present in the green core. Heating of the green ceramic core in this manner conforms the core to a surface of the setter to reduce distortion of the core and improve yields of cores that are within preselected dimensional tolerances.

Abstract: A method for producing a lost mold for titanium casting from a curable embedding compound. The embedding compound contains at least one oxidizable ingredient, such as zirconium. A model of an object to be cast is prepared from a material which can be melted out of the embedding compound. A mold is shaped by embedding the model in the embedding compound. The mold is cured and the embedding compound melted out by heating and holding the mold at a maximum temperature for a period of time. The mold is actively cooled to reduce the cooling time. Preferred embedding compound compositions and time-temperature profiles are disclosed.

Abstract: An improved phosphate-type refractory investment material and method for marking solid investment molds especially useful for casting high melting point metals and alloys, such as platinum and the like. The material consists essentially of one or more phosphate salts, one or more water soluble organic acids, and refractory powder. The material can be prepared as a dry powder blend which is easily shipped to the user and mixed with water at the time of investing the flask. Alternatively, the salt and/or organic acid can be combined with the refractory powder at the time of mixing with water.

Abstract: A sand casting foundry composition reduces thermal defects that cause veining in metal parts cast from sand casting foundry shapes formed from the foundry composition. A plurality of foundry sand grains are mixed substantially uniformly with a plurality of shale particles, and a curable binder coats the sand grains and the shale particles to establish core and mold foundry shapes used to cast the metal part. Anti-veining capability occurs because the shale particles include mineral components which have an inherent characteristic of crystal structural collapse upon exposure to metallurgical temperatures, and the crystal structural collapse yields space which is consumed by thermal expansion of the sand grains in the foundry composition. This compensatory effect avoids the creation of mechanical forces and stresses within the foundry shape that cause cracks and fissures in the foundry shape that lead to veining.

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

Abstract: The present invention includes molding additives and molded materials. This invention also includes machines or electronic apparatus using these aspects of the invention. The present invention also includes methods and processes for making and using these devices and systems. In a preferred embodiment, a dye that fluoresces via ultraviolet absorption is dispersed in an organic additive. The additive is mixed with a molding material that is then formed into a shaped article by compaction. The resultant shaped article is then observed under an ultraviolet lamp to determine fluorescence variation, such variation corresponding to density gradients in the article.

Abstract: A method for producing a cast body having a thin portion is provided, including subjecting a thin member of iron, copper, or nickel alloy to metal-ceramic insertion in a matrix of iron or copper. In the method, the thin member including a ceramic layer on the surface thereof to prevent the thin member from melting upon metal-ceramic insertion. Alternatively, a ceramic layer is formed by using a thin member containing 0.5 wt % or more in total of at least one element selected from the group consisting of Al, Ti, Be and Mg, at least on or near a surface of the thin member, either at the time metal-ceramic insertion or at the time of heating prior to metal-ceramic insertion to prevent the thin portion from melting upon metal-ceramic insertion.

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.

Abstract: An impregnated fired porous alumina-based ceramic core for use in an investment shell mold in the casting of molten metals and alloys wherein the core is impregnated with yttria to improve core creep resistance at elevated casting temperatures and times.

Abstract: Coating foundry sand with a thin layer of an oxidation-promoting catalyst. Preferred catalysts comprise ferric and cupric oxides. The catalysts promote the oxidation of any polymeric binder or residues admixed with the sand. The sand is coated by wetting the grains with a solution of a catalyst precursor, drying the sand and baking the sand in air to convert the precursor to the catalyst.

Abstract: A carbohydrate is added to sand, which has been used to make foundry moulds or cores, and which has been bonded using an alkaline resol phenol-formaldehyde resin, prior to reclamation of the sand by a thermal reclamation. The thermal reclamation may be done in other equipment, for example, a rotary thermal reclamation unit, but is preferably done in a fluidized bed reclamation unit. The carbohydrate is preferably water soluble and is added to the used sand as an aqueous solution. The carbohydrate may be for example a monosaccharide, such as glucose, mannose, galactose or fructose, or a disaccharide such as sucrose, maltose or lactose. The carbohydrate may also be a carbohydrate derivative such as a polyhydric alcohol (e.g., ethylene glycol, glycerol, pentaerythritol, xylitol, mannitol or sorbitol), a sugar acid (e.g., gluconic acid), or a polysaccharide derivative (e.g., a starch hydrolysate, i.e., a glucose syrup or a dextrin).

Abstract: The metal content of a thermoplastic composition containing an undesirably high concentration of metal can be reduced by adding to 100 parts by weight of the composition at least about 0.3 parts by weight of a chelating agent and sufficient water to chelate metal in the composition to form chelated metal in the composition, and then removing at least some of the chelated metal from the composition.

Abstract: A ceramic core that includes, prior to core sintering, erbia filler material alone or admixed with a second ceramic filler material, such as alumina, and a binder to provide a core that is relatively non-reactive with superalloys used in the manufacture of turbine blades, dimensionally stable during directional solidification (DS) for extended times, removable by chemcial leaching techniques, and having enhanced X-ray detectable during post-cast inspection operations. After core sintering, the ceramic core has a microstructure comprising an erbia-alumina garnet phase and an unreacted ceramic filler phase (e.g. alumina).

Abstract: In a casting process using a resin core, sometimes molten resin remains in a cast product after the steps of withdrawal of the resin core from the cast product. In order to solve the problem, as a material of the resin core, a resin which is hard and not deformed against high temperature and high pressure of molten metal until the molten metal is solidified and is softened with an increase of temperature beyond the temperature at which the metal is solidified is used. The resin core is withdrawn from the cast product after it is softened but before it is melted. The softened core is pulled out from the cast product without being broken apart.

Abstract: This invention provides a method of molding which can feed the high-viscosity material quickly and accurately as well as with good operability. For achieving quick heating and cooling cycles in a mold, the mold is constructed from a mold material having superior heat-conductivity in such a way that the high-viscosity material can be heated and cooled from outside of the mold.Thereby, this invention comprises:a step for preparing a mold fabricated with high orientation graphite material,a step for feeding high-viscosity material into the recess portion for molding inside said mold in the non-molten state,a step for heating and melting the high-viscosity material in the recess portion via said mold from the outside, anda step for cooling the molten high-viscosity material via said mold and molding it into a desired shape.

Abstract: A lost foam casting method for the manufacture of scrolls.

Abstract: A method of making a ceramic core for use in a casting process comprises the steps of forming a core in a mould by hot injection of a thermoplastic paste consisting of a refractory ceramic composition and an organic fraction, eliminating the organic fraction from the core by heat treatment, heat treating the core to achieve the minimum consolidation necessary to enable the core to be handled, impregnating the porous structure of the core with a solution comprising a silica or alumina based elementary oxide colloid, and eliminating the liquid from the impregnated product.

Abstract: A sand molding medium for the use in founding of iron. The medium includes wettable uintaite as a carbon source supplemental to sea coal. The wettable uintaite is included in a carbon additive that is combined with sea coal to formulate the carbon component of an a pre-mix. The pre-mix also includes a clay component. The pre-mix is combined with sand to formulate the sand molding medium.

Abstract: A metal matrix composite is produced by closely aligning together a sheet of hydrided or hydrogenated alloy with a filament preform at a relatively low temperature. The resulting metal matrix will have a minimum of excessive chemical reactions at the alloy-filament interface thereby allowing the composite to achieve theoretical mechanical property values.

Abstract: The present invention provides methods for treating reclaimed sand obtained from dismantled foundry molds and cores which contain a cured binder derived from an ester cured alkaline phenolic resin. Treatment of the reclaimed sand with a silane solution, particularly an aqueous solution, enhances the tensile strengths of foundry molds and cores produced therefrom beyond those obtained with untreated reclaimed sand. Methods for producing foundry cores and molds which incorporate such a treatment process are also provided by this invention as are raw batch formulations.

Abstract: In a method and apparatus for casting an engine block, a core holding portion located below an open upper mold located above a lower mold fixed on a stationary platen is caused to hold a water jacket formation destructive core surrounding a cylinder bore formation portion. Slide molds divided in a circumferential direction, located between the upper mold and the lower mold, and supported by the upper mold to be opened/closed in a horizontal direction is closed. Mold clamping is performed upon downward movement of the upper mold. A molten metal is injected at a high casting pressure of not less than 300 kg/cm.sup.2 from a molten metal injection sleeve open to a portion at which the lower mold is brought into direct contact with the upper mold.

Abstract: A molding medium and process for making it, preferably for use in the evaporative pattern casting process, is disclosed. The molding medium comprises, in one embodiment, a base granular molding material having spherically shaped grains wherein the individual grains of the material are coated with a refractory material. Preferably the grains are coated first with a binding agent and then mixed with a refractory material, which may be zirconium oxide. After coating, the material is fired at a high temperature, crushed and screened to size, according to one method. Alternatively, the base molding material may itself be a refractory material, in which case the refractory material is mixed with a binding agent to agglomerate the base material into substantially spherical particles and a refractory coating need not be applied. In either embodiment, substantially spherical free-flowing particles are produced having a low angle of repose.

Abstract: An adhesive paste for adhering two or more objects, a composite assembly comprising two or more elements bonded by such paste, and a process for preparing cast metal articles using such paste are provided. The adhesive paste comprises an aqueous solution of a specific alkali phenol-formaldehyde resin and a hardener for that resin, wherein the paste prepared by mixing the resin and hardener has a viscosity, as mixed, in the range of about 1,000 cps to about 15,000 cps. The composite assembly comprises at least two separate elements bonded by the adhesive paste of the invention. The process uses a mold or core assembly having at least two separate elements.

Abstract: A method of preparing a template for a product from a sample of the product. The ultimate template is either larger or smaller in size than the sample. Initially, a mixture of liquid rubber and a curing agent is prepared. The sample is then covered with the mixture and the mixture is permitted to harden to form a temporary mold. The sample is then removed from the mold to form a cavity, and the size of the cavity in the mold is altered to either increase or decrease its dimensions. Finally, a hardenable material, such as an epoxy resin, is poured into the mold to form the template. If an enlarged template is to be formed, the size of the cavity of the mold is increased by immersing the mold in an organic solvent bath. If the size of the mold is to be decreased, an organic solvent is added to the mixture before formation of the mold, and after the mold has been formed, it is heated to shrink the size of the mold.

Abstract: A molding medium and process for making it, preferably for use in the evaporative pattern casting process, is disclosed. The molding medium comprises, in one embodiment, a base granular molding material having spherically shaped grains wherein the individual grains of the material are coated with a refractory material. Preferably the grains are coated first with a binding agent and then mixed with a refractory material, which may be zirconium oxide. After coating, the material is fired at a high temperature, crushed and screened to size, according to one method. Alternatively, the base molding material may itself be a refractory material, in which case the refractory material is mixed with a binding agent to agglomerate the base material into substantially spherical particles and a refractory coating need not be applied. In either embodiment, substantially spherical free-flowing particles are produced having a low angle of repose.

Abstract: A mold for casting particularly a core, is produced by mixing refractory particles with colloidal alumina to give a slurry, filling said slurry in a pattern having water absorption properties, solidifying the slurry, followed by drying and firing. The resulting mold, particularly core, has high dimensional accuracy with no cracks.

Abstract: An investment material for dental casting comprises 100 parts by weight of a mixture of hemihydrate gypsum, quartz and/or cristobalite and 2 to 5 parts by weight of natural starch optionally with 0.1 to 1.0 part by weight of soluble starch.

Abstract: A squeeze formed aluminum alloy article, such as a piston, is formed with a re-entrant cavity (14) by locating an isostatically compacted salt core (10) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (14) is subsequently dissolved from the squeeze formed article to provide a corresponding shape to the article which does not require subsequent machining.

Abstract: An improved process for preparing foundry cores and molds using a foundry aggregate and a binder therefor wherein the aggregate is mixed with an aqueous suspension of cereal flour and then with a core oil, the improvement comprising mixing the aggregate with phosphoric acid or sulfuric acid before mixing with the aqueous suspension of the cereal flour.

Abstract: An improved binder for a foundry aggregate comprising aluminum dihydrogen phosphate in combination with ammonium polyphosphate, potassium polyphosphate, potassium olivine phosphate, volcanic ash, sodium silicate, phosphoric acid or mixtures thereof.

Abstract: An inorganic cement binder for a foundry aggregate comprising, in combination, potassium olivine phosphate and as a hardener therefor, water, aqueous sodium silicate, or aqueous phosphoric acid.

Abstract: A method for making foundry moulds and cores where after preparation of the moulds and cores having a sand composition of a low strength up to 0.03 MPa, a cooling medium is introduced into the mould cavity, preferably liquid nitrogen, in an amount to provide hardening of only the surface layer of a required sufficient to reproduce the shape of the mould cavity.

Abstract: Ceramic cores suitable for use in investment casting operations are molded from a mixture containing comminuted refractory which includes partially dehydrated gypsum and a sublimable binder. When the sublimable binder has been sublimated from the molded core, it is soaked in water in order to hydrate the gypsum and cause it to set.