Abstract: A method of making a refractory article is provided. The method includes: a) mixing a binder system, a refractory charge, and a second colloidal binder to form an aqueous slurry; b) casting the aqueous slurry into a mold; c) subjecting the mold containing the aqueous slurry to a temperature that is lower than a slurry casting temperature for a time sufficient to form a green strength article; and d) firing the green strength article at a temperature of at least 450° C. for a time sufficient to achieve thermal homogeneity, thereby forming a refractory article. Refractory articles made in accordance with the method have a unique combination of pore structure and mechanical properties.

Abstract: A method of manufacturing a conductive element is disclosed. The method being executed by an additive manufacturing system and comprises: dispensing a modeling material on a receiving medium to form a layer, and dispensing a conductive ink on the layer of modeling material to form a conductive element. In some embodiments of the invention the modeling material comprises a sintering inducing agent, and in some embodiments of the present invention a sintering inducing composition is dispensed separately from the modeling material and separately from the conductive ink.

Abstract: A method of forming a component having an internal passage defined therein includes forming a precursor core having a shape corresponding to a shape of the internal passage, and forming a hollow structure around the precursor core. The method also includes removing the precursor core from within the hollow structure, and disposing an inner core within the hollow structure to form a jacketed core. The method further includes positioning the jacketed core with respect to a mold, and introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity. Additionally, the method includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: In production of a mold with the reclaimed spherical molding sand having a sphericity of 0.95 or more and mainly composed of Al2O3 together with the binder containing the acid-hardening resin and the hardening agent (I), at least one of the hardening agents (I) and (II) that is used in production of a mold from which the reclaimed molding sand is obtained contains the organic sulfonic acid, and in the hardening agent, a content of sulfuric acid is not more than 5% by weight and a content of phosphoric acid is not more than 5% by weight.

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

Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.

Abstract: A method of forming a porous ceramic body includes providing a moldable material that includes a ceramic material, a binder material and a filler material comprising carbon nanotubes. The moldable material is then formed into a desired shape of a green ceramic body. The green ceramic body is then thermally treated to remove the binder material and the carbon nanotubes. The thermally treated green ceramic body is then sintered to form the porous ceramic body with elongated nanopores.

Abstract: The binder coated refractories comprises the refractory aggregates and the solid-form coating layer which comprises the sugar group as the binder and which is provided to the surface of the refractory aggregates. According to this, the sugar group is used as the binder for bonding the refractory aggregates. Further, even if the sugar group is thermally decomposed, the sugar group emits the carbon dioxide and the water. Therefore, there is little likelihood of emitting the harmful gas. Therefore, it is possible to reduce the environmental pollution. Further, the sugar group is thermally decomposed easily. Therefore, it is possible to manufacture the casting mold having the good breaking property.

Abstract: A metal article containing at least 10% interconnected porosity is produced by using a preform. To make the preform, an organic binder, a wetting agent and a granular material are mixed to obtain a mouldable paste that combines 10 vol. pct. or more of the granular material, this material dissolving easily in a liquid solvent. The paste is shaped into an aerated preform, thus creating an open pore space to be infiltrated by the metal or alloy. The wetting agent is evaporated and the preform is baked to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform. Then, the open pore space is filled with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.

Abstract: Described is a procedure for layered composition of models, whereby at least a first material is applied to an assembly platform, followed by selective application of a second material layer; these two application steps are repeated until the required model is achieved and both materials form a solid structure in an appropriate mixture ratio. The first material comprises a molding sand; the first and/or second material comprises a bonding agent encompassing a salt-crystal binder and/or protein binder.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Abstract: A method for the layered construction of models is disclosed, whereby at least one first material is applied to a building platform and then a second material is selectively applied in layers. Both application steps are then repeated until the desired model is obtained and the both materials form a solid body with a desired mixing ratio. The first material comprises a moulding sand and the first and/or the second material comprises a binder, comprising a crystalline salt binder, or/and a protein binder.

Abstract: A spherical casting sand having an average particle diameter of 0.03 to 1.5 mm, produced by a flame fusion method, usable together with a urethane binder. Casting sands capable of producing a mold having higher strength and excellent surface smoothness without deformation or breakage with fewer gas defects in producing a mold by using a urethane binder in the cold box process or in the urethane self-hardening mold making method. The casting sand has longer bench life in the cold box process. Amount of generated gas that is a problem of the mold making method using a urethane binder can be significantly reduced, and a casting with fewer gas defects can be obtained.

Abstract: A sand core is prepared for use in defining a surface of a cast metal article. The core is formed of sand particles bonded with a polyurethane resin, preferably a polyol moiety-containing polyurethane resin. An alkali metal hydroxide, and optionally a glycol, is mixed with precursors of the polyurethane before they are mixed with sand particles for molding and curing the core. The hydroxide and glycol may be encapsulated to prevent interference with core molding. The hydroxide and glycol is distributed in the polyurethane binder resin and used to reduce the decomposition temperature of the core binder during casting. This practice is particularly useful in removing core sand from castings of light metal, lower casting temperature metal alloys.

Abstract: In production of a mold with the reclaimed spherical molding sand having a sphericity of 0.95 or more and mainly composed of Al2O3 together with the binder containing the acid-hardening resin and the hardening agent (I), at least one of the hardening agents (I) and (II) that is used in production of a mold from which the reclaimed molding sand is obtained contains the organic sulfonic acid, and in the hardening agent, a content of sulfuric acid is not more than 5% by weight and a content of phosphoric acid is not more than 5% by weight.

Abstract: The present invention relates to an improved process for preparing foundry shapes by the cold box process, a process for making cores and moulds and a process for casting metals, carrying out as curing catalyst system a blend comprising at least two tertiary amines.

Abstract: A process for producing a metal article containing at least 10% interconnected porosity, using a preform (11), comprising: mixing an organic binder, a wetting agent and a granular material, to obtain a mouldable paste that combines 10 vol. pct. or more of said granular material, said material dissolving easily in a liquid solvent; shaping the paste into an aerated preform and providing an open pore space to be infiltrated by the metal or alloy; evaporating said wetting agent and baking said preform to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform; filling said open pore space with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.

Abstract: Residual stress is reduced in light metal alloy articles, e.g. aluminum alloy articles, formed as castings against a sand casting mold body by incorporating a wax composition of suitable softening or melting temperature with the sand particles of the mold or core body. The hot cast metal heats adjoining surfaces of the mold body. As the cooling metal forms a solid shell, the surrounding sand particle and wax mixture are heated sufficiently to melt or soften the wax incorporated on or between sand particles. This softens portions of the rigid mold body that could otherwise restrain shrinking surfaces of the casting and produce unwanted stressed regions that are retained in the casting and must be removed by subsequent processing.

Abstract: The present invention relates to spherical casting sand having an average particle diameter of 0.03 to 1.5 mm, produced by a flame fusion method, usable together with a urethane binder.

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 water-dispersible casting mould, particularly a core, for the manufacture of castings is proposed. The mould contains a water-insoluble, particulate material, such as moulding sand, a binder, which has a first binder component based on a condensed phosphate, and optionally a flux. In order to ensure an increased flexural strength and abrasion resistance, there is a second binder component based on polyamines. It is also possible to provide a flux based on alkali metal carbonate, which gives the mould an increased thermal stability. The invention also relates to a method for the manufacture of such a mould, in that the aforementioned components are mixed, accompanied by the addition of water, the mixture is moulded and at least part of the added free water is removed.

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: In a method of making a molded article for use in a casting process, sand particles are mixed with protein and water to effect a coating of protein on the sand particles. Then, the protein coated sand particles are dried and blown into a pattern mold to form a molded article without active cooling of the coated sand particles. Steam is then passed through the molded article to hydrate and melt the protein, thereby forming bonds between contiguous sand particles. Finally, hot, dry air is passed through the molded article to harden the protein bonds between the contiguous sand particles. This forms a protein coated sand core for use in casting molten metals.

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: 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 foundry binder is obtainable by surface modification of a) colloidal inorganic particles with b) one or more silanes of the general formula (I) Rx—Si—A4−x  (I) where the radicals A are identical or different and are hydroxyl groups or groups which can be removed hydrolytically, except methoxy, the radicals R are identical or different and are groups which cannot be removed hydrolytically and x is 0, 1, 2 or 3, where x≧1 in at least 50 mol % of the silanes; under the conditions of the sol-gel process with a below-stoichiometric amount of water, based on the hydrolysable groups which are present, with formation of a nanocomposite sol, and further hydrolysis and condensation of the nanocomposite sol, if desired, before it is brought into contact with the foundry sand.

Abstract: In a method of making a molded article for use in a casting process, sand particles are mixed with protein and water to effect a coating of protein on the sand particles. Then, the protein coated sand particles are dried and blown into a pattern mold to form a molded article without active cooling of the coated sand particles. Steam is then passed through the molded article to hydrate and melt the protein, thereby forming bonds between contiguous sand particles. Finally, hot, dry air is passed through the molded article to harden the protein bonds between the contiguous sand particles. This forms a protein coated sand core for use in casting molten metals.

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: An animal collagen or gelatin based crumble, and processes for the preparation of the particulate crumble, are useful in the preparation of collagen or gelatin based compositions. The crumble is prepared by extracting animal collagen from an animal tissue source and combining the collagen with sufficient water to form a composition comprising about 15-45 wt % animal collagen and about 0.01-5 wt % of a stabilizer or preservative. Such a combination of materials can be solidified and then processed into a large particulate format. The large particulate comprises a, regular or amorphous shaped, roughly crumbled or roughly divided, crumble product. The typical particle size of a majority of the crumble is about 0.2-5 cm. The crumble is easily manufactured, packaged, stored, handled and distributed. The crumble can be easily used as is. The material melts easily into a use locus.

Abstract: A water-soluble ceramic core is prepared which can be advantageously used in the die casting, gravity casting, and investment casting of precision aluminum alloy objects. The ceramic core contains: (a) 60 to 70% by weight of alumina (A1.sub.2 O.sub.3) flour; (b) about 15 to 25 by weight of zircon (ZrSiO.sub.4) flour; (c) about 5 to 15 by weight of sodium hydrogen phosphate (Na.sub.2 HPO.sub.4); and (d) about 5 by weight of sugar. In preparing the ceramic core, sodium hydrogen phosphate and sugar are first dissolved in water to form a sodium hydrogen phosphate/sugar solution. Then alumina flour and zircon flour are added into the sodium hydrogen phosphate/sugar solution to form a slurry, which is caused to form a precursory ceramic core using an injection molding or slip casting process. After blow-drying the precursory ceramic core is calcined at temperatures between 70 and 800.degree. C.

Abstract: An animal collagen or gelatin based crumble, and processes for the preparation of the particulate crumble, are useful in the preparation of collagen or gelatin based compositions. The crumble is prepared by extracting animal collagen from an animal tissue source and combining the collagen with sufficient water to form a composition comprising about 15-45 wt % animal collagen and about 0.01-5 wt % of a stabilizer or preservative. Such a combination of materials can be solidified and then processed into a large particulate format. The large particulate comprises a, regular or amorphous shaped, roughly crumbled or roughly divided, crumble product. The typical particle size of a majority of the crumble is about 0.2-5 cm. The crumble is easily manufactured, packaged, stored, handled and distributed. The crumble can be easily used as is. The material melts easily into a use locus.

Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat.

Abstract: A calcia mold facecoat is applied to a mold for casting parts composed of reactive metals such as titanium and titanium aluminide. The facecoat is composed of a calcium carbonate based slurry comprising a dense grain calcium carbonate powder and an aqueous based binder. It is applied to a wax or plastic pattern used in the lost wax process for fabricating a casting shell. The mold is built using multiple dipping of alumina-silicate slurries, and then fired at high temperatures in an oxygen rich environment. The metal part is cast before the fired mold can cool below about 800.degree. C. Organometallic based slurry binders are avoided and significant cost savings are realized owing to the benign nature of the aqueous based suspensions with respect to the environment.

Abstract: A foundry mold member made from a plurality of sand particles bound together with a binder which is concentrated at the contact points between contiguous sand particles and consists essentially of gelatins having a Bloom rating less than about 175 Bloom grams. The sand particles are first coated with a sol of the gelatin, cooled to ambient temperature and conditioned to a prescribed water content necessary to effect migration of the gelatin to the interparticle contact points upon heating of the coated particles in a pattern mold.

Abstract: Molten metal is cast into a mold cavity formed of sand held in a predetermined mold configuration by a binder comprising a plurality of sodium bentonite clays. A blend of two or more sodium bentonite clays obtained from different areas as a foundry sand binder synergistically and unexpectedly improves the foundry sand used as a mold cavity for casting metal objects by unexpectedly improving one or more of the following foundry sand properties beyond the level of either of the blended sodium bentonites alone: green compressive strength; hot compressive strength; dry compressive strength; wet tensile strength; flowability; surface finish; activation speed and shakeout.

Abstract: A method is provided for forming a sand core which is suitable for use in casting processes, and in particular squeeze casting processes, to form internal features and intricate external features of a cast article. The core forming method involves the use of a single-component gelatin binder whose degradation at elevated temperatures is catalyzed by additions of a ferric compound. The gelating binder is a mixture of proteins derived from amino acids such as glycine, alanine, L-glutamic acid, L-aspartic acid, and/or small percentages of others, such that the gelatin binder is water soluble and therefore easily eliminated from the core sand at the end of the casting process. Due in particular to the presence of the ferric compound, the gelatin binder readily degrades at low temperatures, such as those associated with aluminum casting processes, such that the core degrades sufficiently to permit the sand to freely flow from the cast article without the need for core removal operations.

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: A novel method of making a ceramic core for use in casting a metal component includes freezing a ceramic slurry comprising a ceramic powder filler, a freezable liquid and a gelling agent in a mold to form a frozen core shaped body. The frozen core shaped body is removed from the mold and thawed to room temperature. A high viscosity gel is provided in the core shaped body at room temperature that is strong enough to retain the core shape until the body can be fired to form a porous, sintered ceramic core. The gel present at room temperature may be formed as the ceramic slurry is cooled in the mold cavity to form the frozen article shaped body and/or as the frozen core shaped body is thawed to room temperature.

Abstract: An additive for green moulding sands for use in foundry industry comprising a "stabilized" and polyhydroxylated carbohydrate, in particular as aqueous solution, and preferably consisting of a monosaccharidic and/or oligosaccharidic derivatives where any of the aldehydic and ketonic functions have been selectively reduced or oxidated. The additive improves the flowability and plasticity of the moulding said with a reduced moisture demand and a better surface finishing of the castings.

Abstract: For the fabrication of a disintegratable sand core, refractory particles such as silica sand are mixed with two binders, one consisting of an inorganic substance such as a silicate and the other consisting of a starch, and, preferably, with water. The two binders function to cancel the disadvantages arising from the use of only either. The mixture is introduced into a core box molded essentially of materials pervious to microwave energy. Exposed to microwave energy through the core box, the mixture hardens in the shape of the core box cavity. For the production of cores having greater surface stability at room temperature, the starch and water are first mixed together into a paste, and this paste is added to the refractory particles together with the inorganic binder, thereby assuring uniform dispersion of the starch throughout the mixture.

Abstract: An yttria-based slurry comprising a dense grain yttria powder and a non-aqueous-based binder is used as a mold facecoat and corecoat for investment casting of reactive metals such as titanium and titanium alloys.

Abstract: There is disclosed a mould for lost pattern casting. The shell of the mould comprises a graphite coating and a hydrocarbon binder. The binder comprises a polyol with at least three alcohol functions such as pentaerithritol.

Abstract: Esters of alkoxy acids, particularly those of 3-alkoxypropionic acids are used as part or all of the polar solvent in solvent systems for binder compositions containing phenolic resins and polyisocyanates.

Abstract: The present invention provides a binder for foundry sand which comprises a hydrolyzate of a butadiene/maleic anhydride copolymer, a neutralized or a partially neutralized substance of the hydrolyzate, a modified substance prepared by modifying the hydrolyzate with a basic organic compound, or a mixture thereof.

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: 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 is formed by polymerizing or hardening a binding material or composition, an unsaturated polymer or unsaturated monomer or mixtures thereof (polymer solution), wherein at least part of the unsaturation is ethylenic, preferably of vinyl or acrylic type, by free radical polymerization. The free radical polymerization is caused by contacting the unsaturated binding material with a free radical initiator comprising a peroxide and catalytic agent. In the preferred embodiment the binding material is a solution of an ethylenically unsaturated polymer in a solvent of unsaturated monomeric compound or compounds, in which vinyl or acrylic unsaturation is present. The binder is formed upon polymerization which occurs when the unsaturated monomer, polymer or polymer solution is exposed to the free radical initiator. Subjection of the unsaturated monomer, polymer or polymer solution to the initiator begins the formation of free radicals and subsequently the binding composition is polymerized to form the binder.

Abstract: A foundry mould binder is manufactured by mixing at least one monobasic acid selected from the group consisting of formic acid, acetic acid, propiolic acid, propionic acid, and acrylic acid, with a precipitant for the acid, and water, the water being present in an amount no greater than 1.5 times the weight of the total acid content, calculated on that acid content being in a water free state.

Abstract: A polyisocyanate component useful in polyurethane binder compositions is provided. The polyisocyanate component incorporates organic phosphorous compounds that impart longer bench life to the binders making them more useful for prepraring moldable compositions such as foundry cores and molds.

Abstract: A foundry mold member made from a plurality of sand practice bound together with a binder which is concentrated at the contact points between contiguous particles and consists essentially of gelatins having a Bloom rating less than about 175 Bloom grams. The sand particles are first coated with a sol of the gelatin, cooled to ambient temperature and conditioned to prescribed water content necessary to effect migration of the gelatin to the interparticle contact points upon heating of the coated particles in a pattern mold.