Abstract: A used foundry sand, especially one which has been bonded using sodium silicate binder, is reclaimed by agitating the sand with water in a plenum chamber having a suspended floor comprising a porous membrane, stopping the agitation and allowing the solids to settle on the floor. The water passes through and the sand settles on the floor, and the finer particles may then be removed e.g. by air elutriation. Preferably the water mixed with the sand has a pH below 10 and contains a flocculant, and the water recovered from the vessel has suspended solids content below 500 mg/liter.

Abstract: A method of regenerating old casting sand consists of the steps of introducing essentially dry, used casting sand into a single container, then simultaneously subjecting the sand to rapid heating and extreme turbulence by directing a gas flame against the sand having a temperature of at least 1400.degree. C. (2550.degree. F.) along a first axis, rotating a crushing tool about a second axis parallel to the first axis and positioned such that the crushing tool does not pass through the gas flame and rotating the container about a third axis, parallel to the first and second axes. In a preferred embodiment, the container is cylindrical in shape and the third axis is inclined from the vertical at an angle of between 10.degree. and 60.degree., thereby creating upper and lower zones. The burner flame preferably is directed to the sand in the lower zone and the crushing tool is positioned to operate in the upper zone.

Abstract: The subject matter of the invention mainly relates to the technical areas of foundry, manufacture of parts by casting metal in moulds.The process consists in that after moulding the parts and stripping them from the moulds which were broken, during a first cycle the mixture resulting from the knock-out is recovered. This mixture being stored. This mixture is directed from the storage place to an intermediate container; then the mixture from the intermediate container is fed up to a sieve grading separator unit allowing to separate the grains or particles in several different grading batches; each one of these batches is directed to a separating table designed for separating chromite from silica; the chromite on the one hand and the silica on the other hand are recovered in containers.This invention mainly applies to the recovery of components of different densities, especially chromite and silica.

Abstract: An apparatus for thermally and pneumatically treating granular solids to remove organic and inorganic chemical additives which are bonded to the granular solids or in admixture with them, to provide a purified granular solid product which is suitable for reuse, for example foundry sand for use in high strength molded cores, or for other productive uses, such as landfill. Granular solid feed material is preheated in a dilute phase zone of a fluidized bed, organic chemical additives are thermally oxidized in a dense phase zone of the fluidized bed, and remaining inorganic chemical additives are separated and removed from the granular solids in a contiguous pneumatic impaction zone. The purified granular solids are removed from the pneumatic impaction zone and organic and inorganic materials are elutriated from the fluidized bed and removed from the head space.

Abstract: The present invention relates to a method and apparatus to be used in the reclamation of foundry sand. Mold flasks containing foundry sand shaped by a pattern to form a cavity into which molten metal has been poured are, after the metal has set, subjected to greatly reduced atmospheric pressure whereby to cause the moisture in the foundry sand to evaporate into water vapor, thereby removing moisture and heat from the sand so that the particles can be reused free of lumps or clumping of sand.

Abstract: A process for producing a casting mould with chemically bound moulding material using a pattern is intended to make it possible to forego the use of clay-bound sand, in particular for the mass production of cast members, and to provide a casting mould of adequate gas permeability, which is simple to produce, with a low level of consumption of moulding material, and inexpensive, and which also provides a high level of casting quality wth a low degree of environmental pollution. For that purpose, the moulding material which has become pourable or fluid due to the operation of casting a cast member is removed from a first casting mould comprising a single moulding material, whereas the remaining portion of the moulding material is left, and the hollow space formed when the pattern is re-fitted is filled with moulding material. In addition, the moulding material which has been reduced in strength may be also removed, being for example blown or brushed out.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the disclosed method provides small dendrite arm spacing in a relatively large size ingot.

Abstract: The present invention involves a process for continuously casting a lithium-containing alloy by direct chill with a direct chill coolant and providing a moisture barrier liquid having a flash point higher than about 400.degree. F. to reduce water absorption in the coolant. The process in one aspect includes applying the moisture barrier liquid as a mold parting composition containing less than a varnish-film forming amount of fatty esters, fatty acids, or fatty alcohols. The process is particularly useful in the direct chill casting of aluminum-lithium alloy by direct chill with ethylene glycol coolant.

Abstract: An ultra-light structure is produced by continuously molding a green sand core, forming a material in the mold pattern in the core which solidifies to form a solidified framework, removing the green sand core and wrapping the resultant solidified framework structure in a material.

Abstract: A full automatic die casting machine including a fixed die, a movable die, a melting furnace and an injection cylinder. At least either one of the fixed die and the movable die is provided with a first recess for forming an article and second recess for forming an engageable portion on the article. The die casting machine further includes an article supporting device, a coating device for coating die lubricant on the first recess and the second recess, a finishing device, a packing device and a recycling device.

Abstract: Granular solids are thermally and pneumatically treated to remove organic and inorganic chemical additives which are bonded to the granular solids or in admixture with them, to provide a purified granular solid product which is suitable for reuse, for example foundry sand for use in high strength molded cores, or for other productive uses, such as landfill. Granular solid feed material is preheated in a dilute phase zone of a fluidized bed, organic chemical additives are thermally oxidized in a dense phase zone of the fluidized bed, and remaining inorganic chemical additives are separated and removed from the granular solids in a contiguous pneumatic impaction zone. The purified granular solids are removed from the pneumatic impaction zone and organic and inorganic materials are elutriated from the fluidized bed and removed from the head space.

Abstract: A method and apparatus for reclaiming used foundry sands including organic resin-bonded sands and clay-bonded sands is shown. The method includes passing used sand downward through a series of vertical, fluid sand beds. Hot air is forced upward in countercurrent fashion through the beds in turn so that a boiling action is achieved in the sand masses. The combination of thermal and abrasive action removes both organic resin and clay-bonded materials from the sand in one continuous operation.

Abstract: The invention is a method of reclaiming sand used in a method of casting a metal having a liquidus temperature below 2000.degree. F., the casting method using a vaporizable pattern set within a mold constituted of unbonded sand. The method comprises: (a) blowing, after a predetermined lapse of time after the pouring of the metal into the mold, a combustion supporting gas into and through substantially the entire volume of the mold to levitate at least a region of the sand adjacent to the casting and to combust volatilized byproducts of the pattern entering the mold, and (b) continuing the blowing of the combustion supporting gas to continue combustion and driving of the gas and byproducts of the combustion out of the mold.

Abstract: A continuously cast strand is guided through a cooling chamber and brought into direct contact with a coolant evaporating partially. The coolant vapor is brought into heat exchange with a closed surface condenser arranged within the cooling chamber, and a flow-through medium of the surface condenser is brought into further heat exchange with a heat transformer arranged outside the cooling chamber and connected with the condenser.

Abstract: Used foundry sand is passed downward through a series of vertical, fluid sand beds. Hot air is forced upward in countercurrent fashion through the beds in turn so that a boiling action is achieved in the sand masses. The combination of thermal and abrasive action removes both organic resin and clay-bonded materials from the sand in one continuous operation.

Abstract: A system (10) particularly suited for reclaming used foundry sand by means of thermal reclamation. The subject system (10) includes, arranged in cooperatively associated series relation, thermal reclaimer means (14), post reclaimer means (15), primary cooling means (16), separator means (18), classifying and dust removal means (19), scrubber means (20) and secondary cooling means (22). The used sand, which preferably is first fed through a lump-crusher, shake-out apparatus (12), is made to pass through thermal reclaimer means (14) while being heated to a predetermined temperature for a preestablished period of time in order to accomplish the burning away of the organic materials, i.e., matter, which are present in the used sand. From the thermal reclaimer means (14), the used sand passes to and through the post reclaimer means 15 for further reclaiming and then to and through the primary cooling means (16) wherein the heated sand is cooled to a suitable temperature.

Abstract: The invention relates to plant (1) and to a method for regenerating sand from foundry cores and moulds by calcination in a fluidized-bed furnace (2), the main characteristic of which lies in the fact that the fumes leaving the calcining furnace are used to heat a current of air which is then used, in its turn, to heat the sand to be treated at its inlet to the calcining furnace, and in that the current of air cooled by the sand to be treated is then heated by means of the purified sand leaving the calcining furnace and is then used as combustion air in the calcining furnace.

Abstract: Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low BTU gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollution is reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved.

Abstract: A dry method of conditioning spent foundry sand is disclosed. After having sized the sand and removal of tramp metallic elements, the sand is subjected to a sequence of squeezing under a high-stress low kinetic energy system for a period of 5-30 minutes, and then propelled against a target with high-kenitic energy in the presence of a suction for several minutes. This sequence can be preferably repeated to increase the quality of the resulting product which should have 0.1% or less of fine particles, a pH of 6-9, a clay content and organic combustible content of substantially zero. The reclaimed sand will exhibit a density of at least 100 grams/biscuit when compacted for core making or molding.

Abstract: A method and apparatus for treating granular materials which require to be heated to drive off volatile constituents and which require to be cooled, for example foundry sand containing an organic binder. The method comprises the step of maintaining a mass of the material at a treatment temperature lying in the range 240.degree. C.-400.degree. C. for between four and thirty hours. The mass may be initially heated by virtue of a manufacturing process in which the mass has been previously used. Alternatively, the mass may be initially heated by a preheating step such as heating in a fluidized bed. Alternatively, the mass may be heated by being placed in heat transfer relationship with a second mass of the material which has been previously heated, for example, in a fluidized bed. Apparatus for performing the method is also disclosed.

Abstract: A reclamation apparatus comprising a centrifugal apparatus for removing impurities from sand by abrasion and entrainment. The apparatus is used to reproduce old molding sand so as to be useable again in making molds and, comprises a cylindrical body including an old sand feed hopper and a dust attraction opening in its upper part, an open-top rotary drum in its central part and a reclaimed sand discharge opening in its lower part. The old sand supplied through the feed hopper is distributed uniformly along the peripheral portion of the bottom plate of the rotary drum by means of a distributor, and the rotary drum is rotated at a high speed to cause a shearing phenomenon in the layer of sand and cause the sand to scatter over the peripheral wall of the drum.

Abstract: A method is disclosed for fixing certain dangerous substances into recyclable waste foundry sand so that they are less likely to leach out into the environment. The method uses a roasting process which causes the dangerous substances to form insoluble compounds with the sand. One example is shown where hazardous waste foundry sand which contains acetic acid soluble lead contamination is treated by this method. In this example the lead is believed to react with the sand during the roasting process forming compounds such as lead silicate which are insoluble to acetic acid. The amount of lead which may be leached out into the environment is reduced to a safe level according to the currently accepted test methods promulgated by the U.S. Environmental Protection Agency. The method may be applied to the conversion of waste foundry sand into reusable sand or landfill which are less likely to leach dangerous substances into the environment.

Abstract: An apparatus for reclaiming no-bake foundry sand is provided, in which a fluidized stream of pneumatically conveyed particles of no-bake coated sand grains traveling at velocity sufficient for transport is discharged against a target to fracture the no-bake rigid coatings from the sand grains on impact. Certain of the fractured coatings are removed and the sand grains along with any remaining fractured coating particles are directed through a passageway having a fluidizing air stream induced therein. The air stream entrains and carries off the fractured coatings and the fine sand grains so that only sand grains of desired particle size pass through the air stream for subsequent reuse. Advantageously, the velocity of the air stream is controlled by regulating the cross-sectional area of the passageway at the point at which the air stream is induced.

Abstract: Moulds are made from refractory sand (or other particulate or granular material) obtained from that sand or material. In order to control the temperature of the sand used to form the new moulds, the sand is heat exchanged with a permanent gas in liquid or solid state, or the cold vapour thereof. The temperature of the sand is sensed. The heat exchange is controlled so as to keep the sensed temperature at or below a chosen maximum.

Abstract: A low vacuum is applied to selected surface areas of a resin bonded sand mold to draw ambient air into selected portions of the mold. The air entering the mold burns out a significant portion of the resin binder to form a low BTU gas fuel and to recover casting heat for use in a waste heat boiler or other heat abstractions device. Therefore, foundry air pollution is reduced, the burned out portion of the molding sand is recovered for immediate reuse, and a savings in fuel and energy.

Abstract: This relates to a device for crushing sand lumps. The device includes a tub which is resiliently mounted and is provided with means for vibrating the same in a generally vertical direction parallel to a rear wall of the tub. The tub rear wall is hollow and is provided on the inner face with perforated crusher plates. Sand flow through the crusher plates is down through the hollow rear wall and there is an upwardly directed airwash for the falling sand. The lower portion of the rear wall is in the form of a door mounted for swinging movement about a horizontal axis. The door is operated by a cylinder having an axis parallel to the direction of vibration and the door is opened during the vibration of the tub so as to direct scrap and uncrushed lumps out through the lower portion of the rear wall in the same direction of salvaged sand flow.

Abstract: A sand moisture control system for a sand casting foundry system incorporates non contact sensing techniques for controlling the moisture content of foundry sand by the addition of water at the muller or mixing operation of a sand casting system. The temperature of the foundry return sand is measured by an infrared detector while moisture content is measured by a microwave detector along the conveyor feed input to the muller or at the return sand holding tank. Electrical outputs from each detector corresponding to temperature and moisture are integrated to provide a signal corresponding to the % of moisture deviation from a predetermined value and this signal is utilized to control the amount of water added to the Muller.

Abstract: In a hydro-jet housing the form block, possibly with core, is stripped of mold sand by means of a high-pressure water jet. The sand is fed in the form of a muddy pulp to a first hydrocyclone, where the water is largely separated and is supplied for the formation of new muddy pulp. The sand flows into a scrubbing mechanism for knocking off its binding material, which has settled as a coat around the sand grains. After being scrubbed, the sand is fed to a second hydrocyclone for hydro-extracting water and dislodged binding material from the sand. The sand is then dried and cooled and is available for further use. The contaminated water is neutralized with flue gas, after which a flocculation agent is added to it and the water is then purified for reuse in a settling tank and possibly in a filter.

Abstract: A method of manufacturing a casting mold includes the steps of forming a casting mold body of a flowable binder-free backfilling material, stabilizing the casting mold body by negative pressure, and providing in the body a lost form of synthetic plastic material, particularly foamed synthetic plastic material.

Abstract: Centrifugal casting apparatus for casting cylinder liners and other tubular articles, characterized by recovery of at least a major portion of the particulate refractory material used to line the mold, with the recovered refractory material being suitable for re-use. The apparatus provides a chamber having aligned openings through which the cast article moves as the article is withdrawn from the mold by a puller. Particulate refractory material from within the mold and from the surface of the cast article is collected in the chamber and conveyed from the chamber to separator means for removal of debris.

Abstract: Method for purifying foundry sand which involves the passage of sand through layers of steel wool supported on perforated discs mounted on a vertical shaft in a standpipe. Perforations in the sides of the standpipe permit air to be blown through the sand as it drops down through the steel wool. The vertical shaft supporting the discs and steel wool is vibrated to cause the sand to move through and past the packs of steel wool.

Abstract: Liquid amorphous metal alloy is manufactured into shaped laminations ready for assembly in an inductive component in one process. The rotating chill surface to which the melt is delivered has high thermal conductivity metal in a pattern corresponding to the shaped lamination and is surrounded by thermally insulating material. Melt coming in contact with the high thermal conductivity metal becomes amorphous and that contacting the thermally insulating areas cools more slowly and becomes crystalline. The brittle crystalline scrap is broken away from the strip of laminations and is collected and recycled to the melt.

Abstract: A foundry apparatus and a method of operating a foundry in which molding material is prepared by mixing sand and water in a muller, formed into molds for sand casting of metals, and later recycled. In accordance with the present invention, fine particles of molding material are removed as a wet waste, which is subsequently delivered to the muller for mixing with sand and water in preparing molding material.

Abstract: Used foundry sand is reclaimed by crushing the sand and separating both metallic material and at least a portion of the unwanted non-metallic portion of the sand, then heating the sand to a temperature of about 1400.degree. F. for burning off the foreign material and causing the sand particles to pass through a strong expansion phase somewhere above 1000.degree. F. and passing through a contractual phase at a higher temperature to thereby cause the foreign material to be cracked or otherwise parted from the particles and the sand particles become increasingly thermally stable from subsequent reuse as clean sand. The heated sand is then cooled to about 400.degree.-500.degree. F. The process includes the utilization of some of the heat of the thermal furnace for a shell coating operation.

Abstract: A sand cooler control system for a sand casting foundry system incorporates a cooling system positioned downstream of the shakeout station where castings are separated from the hot sand. The amount of cooling fluid utilized in the cooling process is controlled by a digital system responsive to the total heat (BTU) content of the sand as determined by a combined function of sand temperature and volume. The temperature and volume parameters are determined by non-contact sensors which take the form of an infrared sensor and sonic sensor, respectively.

Abstract: A process for treating waste foundry core and/or molding sand in a manner which upgrades these scrap streams to new sand quality for entry at the core making point. The process consists of incrementally heating the sand as required up to temperatures in the 1800.degree. to 2500.degree. F range, followed by cooling. The degree of heating is chosen to achieve a desired lowering of acid demand value (ADV) from that which would result from heating only to conventional high temperatures, about 1500.degree. F. Lowering of ADV reduces the variability which would otherwise be introduced into a mixture of new and recycled sand for cores.Heating waste molding sand to the temperatures contemplated by the method of this invention also causes clay additives to fuse, become non-absorptive and thus eliminating the need for mechanical attrition which would otherwise be needed to remove the clay so that it would not absorb high quantities of resin in the core making process.

Abstract: A foundry casting machine comprising an endless conveyor supported on a frame within an overall casing for movement in a vertical plane through a sinuous path, the casing having a first opening therein so that trays supported by the conveyor, as they move past said first opening can have moulds assembled thereon, a second opening in the casing at a pouring station to enable molten metal to be poured into the moulds and a third opening in the casing through which the contents of the trays may be removed, air extraction means for withdrawing undesirable gases and air-borne particles from the interior of the casing and means to hold together the parts of the mould prior to the pouring of the molten metal, said means comprising either one or more weights which are automatically placed upon the moulds prior to a pouring operation and are removed from the moulds subsequent to the pouring operation or clamping devices supported on the trays, the clamping devices being suitable either for clamping together mould part

Abstract: Foundry sand particles are regenerated by contact with a liquid containing ither a peroxide oxidant or an oxidizing salt to remove resinous binder material accumulated around each of the particles.

Abstract: A sand cooler control system for a sand casting foundry system incorporates a cooling system positioned downstream of the shakeout station where castings are separated from the hot sand. The amount of cooling fluid utilized in the cooling process is controlled by a digital system responsive to the total heat (BTU) content of the sand as determined by a combined function of sand temperature and volume. The temperature and volume parameters are determined by non-contact sensors which take the form of an infrared sensor and sonic sensor, respectively.

Abstract: Apparatus for purifying foundry sand which involves the passage of sand through layers of steel wool supported on perforated discs mounted on a vertical shaft in a standpipe. Perforations in the sides of the standpipe permit air to be blown through the sand as it drops down through the steel wool. The vertical shaft supporting the discs and steel wool is vibrated to cause the sand to move through and past the packs of steel wool.

Abstract: Apparatus is disclosed which functions to adjust the moisture content of casting sand as it is being recovered, so that the sand may be re-used without significant or further adjustment of its water content. The apparatus includes a cooler-drier which receives hot castings and sand and discharges the sand and castings separately. A water spray impinges upon the sand and castings as they are moved through the cooler-drier and a temperature sensor which senses the temperature of the sand/castings mixture at the inlet controls the water spray so that the discharged sand possesses a uniform and selected moisture content.