Abstract: A sand mold shaping material contains an aggregate comprising inorganic particles, and microcapsules enclosing a binder which causes the aggregate to bind. The binder is a liquid binder that is in a liquid phase at room temperature, and is enclosed in an outer shell comprising a resin that forms the microcapsule. The sand mold shaping material is in a dry state when used to fill a molding die for shaping.

Abstract: A semiconductor device is provided. The semiconductor device includes an electrode pad provided above a semiconductor substrate; and a wire bonded on the electrode pad and including copper. The electrode pad includes an electrode layer including aluminum and a support layer harder than the wire and the electrode layer. The wire is in contact with the electrode layer and the support layer.

Abstract: A foundry mixture for making molds used for molding cast metal parts includes foundry sand, a non-aqueous binder, and a cleaning agent that includes calcium oxide. Residual foundry mixture remaining on the cast part after removal from the mold is removed by electrolytic cleaning of the cast part.

Abstract: A binder composition for making foundry molds, comprising an acid-hardening resin, one or more 5-position-substituted-furfural compounds selected from the group consisting of 5-hydroxymethylfurfural and 5-acetoxymethylfurfural, and one or more compounds selected from the group consisting of urea and derivatives of urea, wherein the content of the 5-position-substituted-furfural compound(s) by percentage is from 1 to 60% by weight of the binder composition. The content of the compound(s) by percentage selected from the group consisting of urea and derivatives of urea is preferably from 0.3 to 10% by weight of the binder composition.

Abstract: A binder for the production of sand cores and/or molds for foundries that includes sand mixed with an alkyl silicate, preferably tetraethyl silicate; an aqueous solution of an alkali metal silicate, preferably sodium silicate, which solution also contains an alkali metal hydroxide, preferably sodium hydroxide, where the ingredients in such mixture are preferably in given percentage ranges and are mixed until the sand shows a homogeneous aspect and constitution. Also method of manufacturing sand molds for foundries that includes mixing foundry sand with the aforementioned binder, blowing the sand mixed with the binder, having still between 0.5% to 2.5% of water, into a cold box by means of air that is at room temperature, and once the cold box mold has been filled with the sand, passing a hot air current through the sand to dry and harden the binder thus obtaining the foundry mold.

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: 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: Described herein, in a preferred embodiment, is a leonardite-based polyurethane resin binder that may be used, among other applications, as a binder in combination with foundry aggregate, e.g., sand, for molding or casting metal parts. The binders described herein comprise a humic substance, preferably leonardite, first mixed with a foundry aggregate and then the humic-aggregate mixture is combined with a polymerizable polyol, an isocyanate, and a polymerization catalyst to make a polyurethane resin binder in situ in a foundry aggregate, such as sand. The lignite is added as a solid to the foundry aggregate, and improves the binder performance of the lignite-containing part of the binder components.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: The present invention provides a binder composition for use in mold manufacturing that is capable of preventing a deterioration in the mold strength in a high-humidity environment, and further restraining the generation of an irritant gas at the time of casting; and a mold manufacturing composition wherein this binder composition is used. In order to provide such the binder composition, the binder composition for use in mold manufacturing, comprises a furan resin, and a metal compound containing one or more metal elements selected from the group consisting of elements in the Groups 2, 4, 7, 10, 11 and 13 of the periodic table, wherein the content by percentage of the metal element(s) in the binder composition is from 0.01 to 0.70% by weight, and the metal compound is one or more metal compounds selected from hydroxides, nitrates, oxides, organic acid salts, alkoxides, and ketone complexes.

Abstract: A method for manufacturing a bolster of a railway car truck includes providing a drag portion and a cope portion of a mold. In a main body section of the mold, a parting line that separates the drag portion from the cope portion is substantially centered between portions of the mold that define brake window openings in sides of the bolster. One or more cores are inserted into the mold and a molten material is poured into the mold to thereby case the bolster.

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 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: This invention relates to filters made from a refractory material, preferably an insulating material, and chemical binder. The filters are used in the foundry industry to filter molten metal. The invention also relates to a process for preparing the filters.

Abstract: Described herein, in a preferred embodiment, is a leonardite-based polyurethane resin binder that may be used, among other applications, as a binder in combination with foundry aggregate, e.g., sand, for molding or casting metal parts. The binders described herein comprise a humic substance, preferably leonardite, first mixed with a foundry aggregate and then the humic-aggregate mixture is combined with a polymerizable polyol, an isocyanate, and a polymerization catalyst to make a polyurethane resin binder in situ in a foundry aggregate, such as sand. The lignite is added as a solid to the foundry aggregate, and improves the binder performance of the lignite-containing part of the binder components.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

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: A casting mold which is molded by heating mulled sand including a mixture of refractory molding sand particles, an inorganic water soluble binder and water, wherein the inorganic water soluble binder is made of a combination of a sulfate compound such as magnesium sulfate heptahydrate and a borate compound such as sodium tetraborate decahydrate. The casting mold is formed by baking the mulled sand in such a manner that at least part of the sulfate compound retains water of crystallization therein and the borate compound is once fused and then cured.

Abstract: A foundry sand binder formed by reacting a smectite clay containing exchangeable calcium ions with an acid to enhance the ability of the clay to bind sand in forming a metal casting sand mold. The acid-treated clay is an excellent sand binder for metal casting molds and produces cast metal parts having improved surface finish with the elimination or substantial reduction in carbonaceous, e.g., coal, foundry sand additive, while reducing VOC emissions from the foundry.

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: This invention relates to hydrogenfluorides of aminosilanols and their use. The hydrogenfluorides of aminosilanols are formed by the reaction of an aqueous solution of a fluorinated acid, preferably, hydrofluoric acid, with an aminoalkoxysilane. The hydrogenfluorides of aminosilanols are particularly useful in foundry binders, most particularly no-bake and cold-box phenolic urethane foundry binders.

Abstract: A process for forming a mould or a core for casting molten metal by machining (eg cutting or drilling) to the desired shape a bonded particulate refractory material wherein the shear strength of the refractory particles is less than the shear strength of the bonds between the particles. The preferred particulate is aluminosilicate microspherers (eg “flyash floaters”) and the binder is preferably based on silica (eg fumed silica/sodium hydroxide). The bonded particulate material is easily machined to form accurately dimensioned moulds or parts thereof.

Abstract: A foundry exothermic assembly is formed by mixing hollow glass microspheres and an inorganic or organic binder with matrix forming constituents including an oxidizable metal, an oxidizing agent, a foundry refractory aggregate and, optionally, a pro-oxidant, and shaping and curing the mixture. The hollow glass microspheres are dispersed and embedded in the assembly matrix.

Abstract: This invention relates to insulating sleeve compositions comprising (1) a major amount of hollow aluminosilicate microspheres, and (2) fine silica. The sleeve compositions are used to form sleeve mixes by mixing them with a chemically reactive binder. Sleeves are formed from the sleeve mix and are cured in the presence of a catalyst by the cold-box or no-bake cuing process. The invention also relates to a process for casting metal parts using a casting assembly where the sleeves are a component of the casting assembly. Additionally, the invention relates to the metal parts produced by the casting process.

Abstract: This invention relates to exothermic and insulating sleeve mixes comprising (1) a sleeve composition comprising stabilized hollow aluminosilicate microspheres, and (2) a chemically reactive binder. Sleeves are formed from the sleeve mix and are cured in the presence of a catalyst by the cold-box or no-bake curing process. The invention also relates to a process for casting metal parts using a casting assembly where the sleeves are a component of the casting assembly. Additionally, the invention relates to the metal parts produced by the casting process.

Abstract: An embodiment of the present invention provides a method for improving the tensile strength of foundry cores and molds over what may be conventionally achieved. The use of acidic methylene compounds in binder compositions which include strongly alkaline phenolic resoles results in an ester curable binder that may be used to make foundry cores and molds having significantly greater tensile strengths than are achieved with prior art binders. An embodiment of the present invention provides a composition which includes a phenolic resole having a pH ranging from about 10.5 to about 13.5 and an acidic methylene compound.

Abstract: Insulating sleeve mixes that contain hollow aluminosilicate microspheres, an organic binder, and boric acid and/or a phosphate, and their uses.

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: The invention relates to amine modified polyisocyanates having urea linkages and their use in foundry binder systems. The modified polyisocyanates are prepared by reacting a polyisocyanate with an aliphatic primary or secondary amine. These amine modified polyisocyanates, along with a phenolic resole resin, are added to a foundry aggregate to form a foundry mix which is shaped and cured with an amine curing catalyst.

Abstract: The invention relates to the use of tripotassium citrate monohydrate and other alkali metal salts of polybasic acid as bench life extenders in heat curable hot box foundry mixtures comprising sand, thermosetting binder resin, and a latent acid catalyst composition. In one embodiment, the thermosetting binder resin is a phenolic resole resin modified with urea formaldehyde resin. In another embodiment, the thermosetting binder resin is a furfuryl alcohol resin modified with urea formaldehyde resin.

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: Articles such as molds for thermoplastics, having an insulating layer preferably of resin deposited on the metal core materials, have a second layer of metal suspended in resin deposited on said insulating layer. The second layer may contain metal in platelet form as the inner mold surface, or may contain metal in fiber, whisker or irregular form with a further metal coating deposited thereon to provide resistance to abrasion. In the latter case, the adhesion of the further metal coating to the mold surface is higher than is the case if no metal-containing resin layer is present.

Abstract: A resin composition for investment casting contains a moderate boiling temperature liquid inert diluent, having a boiling point in the range of about 200.degree. to 300.degree. C. The presence of the liquid inert diluent allows the resin to be used as a pattern, or model, in investment casting by preventing breaking of the mold during burnout of the resin. Any of the conventional resins suitable for stereolithography may be employed in the practice of the invention. To the resin is added a moderate boiling point solvent in the amount of about 5 to 30 wt %. Use of the moderate boiling point solvent in conjunction with the resin allows the pattern to shrink and crack at moderate temperature before final burnout. The shrinkage occurs faster and at a lower temperature as compared to the prior art.

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: Dustfree investment materials, for the production of accurately fitting cast parts, are described which contain water-soluble phosphates, magnesium oxide and silicon dioxide. The investment material is made up of two components (a) and (b) and component (a) contains the entire magnesium oxide, optionally a part of the silicon dioxide and, in the presence of silicon dioxide, 0.4 to 6% by weight of a hydrophile, organic solvent, and component (b) contains the phosphate, the remainder of the silicon dioxide and at least 0.5% by weight water.

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: Pre-glued, coil-coated brake shoe stock is manufactured on a continuous coil coating line wherein a heavy gauge steel strip is continuously fed through abrasion and surface cleaning steps, optionally treated with a phosphoric acid/alcohol solution and then followed by application of a phenol-formaldehyde resin, a controlled curing step, and again coiled. The phenol-formaldehyde resin may have incorporated in it solid particles which will improve the dimensional stability, thermal properties and vibration and sound-dampening characteristics of the brake shoes. Brake shoes stamped from the stock made under the particular conditions described have higher shear strength and adhesion to the brake pad or lining materials than those of the prior art and have fewer problems in manufacturing.

Abstract: A method for producing high pressure die castings with undercut regions comprises forming an expendable coated core of specific composition, placing it in the die in a die casting machine, injecting molten metal into the die to form the casting and separating the casting from the die and the core from the casting. The composition of the expendable coated core comprises a base sand core held together by a resin binder; a first, bottom, hard refractory coating comprising fused silica and a refractory binder containing at least two of the following additives: a suspension agent, a dispersant, a wetting agent, and an anti-skinning agent; and a second, top, soft, or release coating containing a release material selected from the group consisting of anhydrous powdered aluminum, graphite, talc, titanium dioxide and zircon, and a resinous binder containing at least two different compounds selected from the group of additives consisting of a suspension agent, a dispersant, and an anti-settling agent.

Abstract: A process for preparing an investment casting mold is provided. A kneaded compound composed of an aggregate and an organic binder is cast into a core molding mold to be solidified therein to produce a core matrix which is impregnated with a heat resisting binder to an appropriate depth followed by coating with a wax, whereby a core mold is formed. The core mold is placed in position within a lost model molding mold followed by injection of a lost model forming material. A slurry and stucco particles are alternately coated over the lost model for plural times to form a refractory layer. The lost model is removed to obtain a final mold which is baked to effect simultaneous baking of the core mold and the refractory layer, the former forming the mold core and the latter forming the exterior shell mold.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: The coatings are for an expendable sand core for die casting dies, which sand core has spaces between its contacting sand grains at least partially filled with resin binder. The first, base, hard, or refractory coating for this core is applied from an aqueous suspension comprising a finely ground refractory of fused silica, a refractory binder, and at least two different compounds selected from the groups of compounds or additives consisting of: (1) a suspension agent, (2) a dispersant, (3) a wetting agent, and (4) an anti-skinning agent. The refractory in the first coating may also include a minor amount, i.e. less than 50%, of another refractory oxide. The amount of binder in the first coating is less than about 15% by weight of the total liquid suspension, and the amount of additives is less than about 1.5% and usually less than 1% by weight of the total liquid suspension.

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

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

Abstract: An alkoxy-modified phenolic resole resin providing an improved binder for foundry cores and molds. The resin has predominantly ortho-ortho benzylic ether bridges joining the phenolic nuclei in the resin and at least one alkoxymethylene group for every 20 phenolic nuclei.

Abstract: Pre-glued, coil-coated brake shoe stock is manufactured on a continuous coil coating line wherein a heavy gauge steel strip is continuously fed through abrasion and surface cleaning steps, spray treated with a phosphoric acid/alcohol solution followed by a spray of phenol-formaldehyde resin, a controlled curing step, and again coiled. Brake shoes stamped from the stock made under the particular conditions described have higher shear strength and adhesion to the brake pad or lining materials than those of the prior art and have fewer problems in manufacturing.

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

Abstract: Sand cores containing an acid curable binding agent are used in the production of die castings having undercut regions because of the favorable combination of shakeout properties, resistance to washout, and resistance to surface penetration.

Abstract: A process for preparing an alkoxy-modified phenolic resole resin useful as the polyhydroxy component of a urethane binder composition. A phenol is reacted with a molar excess of an aldehyde in the presence of an alkaline catalyst and the resulting product is further reacted with a monohydric aliphatic alcohol under acidic conditions.

Abstract: This disclosure relates to novel desensitized ketone peroxide compositions containing as desensitizing agent 2,2,4-trimethyl-1,3-pentanediol diisobutyrate. It further relates to the use of these compositions in the manufacture of foundry cores or moulds.

Abstract: A binder is used for binding foundry sand to form a mold and a core for casting, and consists of a condensation-reactive first compound (resin) having at least one methylol group in a molecule, amounting to 100 parts by weight. An additive component is added to the resin to improve the strength and the sand removability of the mold and the core while improving the production yield of the mold and the core. The additive component includes at least one of calcium hydroxide and barium hydroxide in particle form. The particle surface of the at least one of calcium hydroxide and barium hydroxide is coated with a second compound having a melting point not lower than 50.degree. C. and a boiling point ranging from 250.degree. to 400.degree. C., the second compound ranging from 0.5 to 35 parts by weight.