Abstract: The invention relates to modified polymeric aromatic isocyanates having allophanate linkages prepared by (a) reacting a polymeric aromatic isocyanate with a monofunctional aliphatic alcohol to form an intermediate modified polymeric isocyanate; and (b) reacting the intermediate modified polymeric isocyanate at an elevated temperature in the presence of a divalent metal catalyst. The invention also relates to foundry binder systems which use these modified polyisocyanates. These 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 a gaseous amine curing catalyst by the cold-box process.

Abstract: A method for making ceramic, micro-electromechanical tools which can be used for the production of micromagnets with a multi-pole, micro-polarization pattern.

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: An implantable article having on at least a portion of its exterior surface an integral, as-cast macrotextured surface with macropores having undercut edge profiles. A complex macrotextured surface is provided by forming a casting mold so that the mold has complementary macrotextured surface features formed by three-dimensional printing techniques, and casting a molten metal within or in contact with the casting mold to form the implantable article. In a hybrid process, one or more printed surface mold plates are attached by hand, or in a wax molding process, to a simpler wax preform, and an investment is made in which the plates are incorporated into the investment mold. A casting is then made, with each preform yielding one cast article, and the incorporated plate forming the desired surface macrotexture on a region of the east article.

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: A foundry mold is produced from sand by blending, with one another, sand, a binder comprising a ester cured-phenolic resin, a curing agent comprising an organic ester compound and one or more additives containing therein a metal of the groups IB to VIII, and molding and curing the mixture into a foundry mold. The mixture is useful in a self-curing molding method and a vapour curing molding method, and the resulting mold is thereby provided with an unexpected improved mechanical strength. In particular the invention is advantageously effective with used or reclaimed refractory sand.

Abstract: A method is disclosed for making molds for use in injection molding wherein a cement replica is made of a pattern by curing the cement in a silicon rubber negative of the pattern, then pouring molten zinc or zinc alloy into a frame containing the cement replica. The cooling of the mold metal is controlled by the direct application of flame and frequent adjustments of clamps which firmly contact the mold to a solid surface.

Abstract: An apparatus for deburring foundry cores (3) and similar workpieces, comprising a vibration device, a stationary base (10) which carries the vibration device, and a deburring template (4), is designed and constructed for an effective deburring with a reduced risk of damage to the workpiece, and with less wear on tools such that the vibrating movement of the vibration device occurs exclusively in vertical direction, and that a clearance is absent between the contours of the cores (3) to be deburred and the contours of the deburring template (4), so that the burr is cut off as the core (3) passes through the deburring template (4).

Abstract: A metal casting die, and a method for its production, are described. By the method the die has provided over at least a part of its internal cavity forming surfaces, indentations of predetermined depth, area and distribution, by employing a technique selected from the group comprising photoetching, electrochemical etching and grit blasting. The die cavity forming surfaces also have thereon, over at least those surfaces with indentations, a coating of a hard, corrosion and erosion resistant material which extends into and between each indentation as a continuous layer.

Abstract: A method for making slender seamless steel mold is disclosed, wherein the outer surface of a solid slender male mold is first chased with concave and convex stripes. Then, the male mold is hardened and fitted into a hollow female mold which has not been gone through hardening process. Thereafter, a hydraulic pressure is exerted onto the outer surface of the female mold so as to impress the concave and convex of the male mold onto the inner surface of the female mold. Then the male mold is annealed and drilled with a longitudinal through hole. At least three longitudinal slits are cut on the wall of the through hole in an outward direction. Finally, the male and female molds are together heat-treated and put into water with normal temperature in order to create fissures at the slit portions of the male mold and crack the male mold into pieces. Consequently, a slender seamless steel mold having inner surface formed with concave and convex stripes is completely made.

Abstract: Compound concrete composition for the manufacture of moulds, comprising: (1) a binder which comprises an alkaline-earth mineral substance, a constituent made up of fine particles of a compound other than an oxide, 90% of which have a particle size of between 1 and 150 .mu.m with a median diameter of between 3 and 20 .mu.m, these fine particles comprising particles of a substance which has a thermal conductivity higher than approximately 30 W/mK, chosen from silicon carbides, silicon carbonitrides, silicon nitrides, boron carbides, titanium carbides and tungsten carbides and a constituent made up of ultrafine particles at least 70% of which have a particle size smaller than 1 .mu.m with a median diameter of between 0.3 and 0.8 .mu.m, (2) water optionally with the addition of a dispersant, and (3) fillers comprising metal granulates and metal fibres, wherein the water/binder ratio is lower than 0.20 and the concrete composition has a thermal conductivity at 200.degree. C.

Abstract: A high permeability metal casting plaster is used for production of high accuracy simulated castings for prototypes and any other plastermold castings. Methods are provided that create the high permeability metal casting plaster and mold. Also, a high permeability metal casting plaster is disclosed that uses control ground and screened alpha-hemihydrate gypsum, control ground and screened beta-hemihydrate gypsum, sucrose for protection against thermal shock, and a foaming agent.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filler, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: A ceramic core molding composition, which includes alumina fibers, zircon, and fumed silica in an amorphous silica base, reduces shrinkage and shrinkage stresses during the core production process. Cores produced utilizing the disclosed composition and method exhibit an improved resistancce to macrocracking over conventionally produced cores.

Abstract: A mould forming mix of ingredients including sand, a binder, and a catalyst blend is produced. The catalyst blend includes at least two catalysts one of which is slow acting and the other of which is fast acting. The ratio of the fast and slow catalysts used to make up the catalyst blend depends on the time to hardening required, and the temperature of the sand. A data processor is used to combine information concerning the hardening time, the temperature, and the rate at which materials are fed to a mixing unit, and to process the information in order to operate catalyst suppliers which supply the fast and slow catalysts.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filter, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: A method of making a laminated structure for use in an electrical apparatus. A female mold is produced having an upwardly facing cavity of a shape corresponding to the laminated structure. A layer of a ferrous metal is sprayed onto the bottom surface of the mold and subsequently an electrically insulated layer is applied to the layer of metal. Alternate layers of the ferrous metal and the insulating layer are deposited in the cavity of the mold to provide a laminated structure in which the metal and insulating layers are integrally bonded together. Through use of the method of the invention, a ferrous metal with the most desirable electrical characteristics can be employed.

Abstract: A method is described for indexing a polyfoam block in which a metal field shaping block is cast to both the cutting tray of a hot wire cutting system and the treatment tray of a radiation therapy treatment machine. The cast metal field shaping block is automatically correctly oriented for treatment. A cooling tray for cooling the casting is also described.

Abstract: Process for photofabricating master relief patterns from photohardenable layers, e.g., 0.01 to 0.5 inch (0.25 to 12.7 mm in thickness) which comprises: (1) exposing the layer through the back surface to first imagewise modulated actinic radiation for time to render layer insoluble to first preselected depth which when measured from back surface to less than layer thickness, (2) exposing overall to actinic radiation through back to render layer insoluble to second preselected depth which when measured from back surface is less than first preselected depth. (3) exposing imagewise through front surface to actinic radiation for a time sufficient to render exposed areas of layer insoluble to depth extending from front surface to at least second preselected depth, and (4) solvent removing soluble areas of layer.The master relief pattern is useful in making casting molds.

Abstract: Process for the production of casting parts with well-defined reproduction of detail and a great accuracy of measurement using the gypsum-form process. The pattern to be copied is equipped with a drainage apparatus, having at least one channel extending outside the molding box, and the molding material is poured into the mold and solidified. After the pattern is removed from the solidified mold by the introduction of compressed gas, the water of the solidified material is removed from, and after drying the mold is connected to a vacuum line and evacuated. The molten mass is then poured into the mold while the vacuum is maintained and solidified.

Abstract: A method for making a mold employing a flexible pattern and a microwave radiation. A flexible pattern is formed with a material which allows microwave to pass therethrough and which pattern is then coated with a liquid facing agent, including a dielectric material to the microwave, a thermosetting resin, and refractory material powders, by either dipping or spraying. The coated pattern is covered by a molding material, including a thermosetting resin and a dielectric material to the microwave, and then the molding material covered pattern is exposed to a microwave radiation for a time sufficient to harden the molding material, and finally the pattern is separated from the hardened molding material leaving a facing agent covered mold behind.

Abstract: In a method of forming a thin (<2 .mu.m) unbacked metal foil having a desired curviplanar shape, a soluble polymeric film, preferably comprising polyvinyl alcohol, is formed on a supporting structure having a shape that defines the desired shape of the foil product. A layer of metal foil is deposited onto one side of the soluble film, preferably by vacuum vapor deposition. The metallized film is then immersed in a suitable solvent to dissolve the film and thereby leave the metal foil as an unbacked metal foil element mounted on the supporting structure. Aluminum foils less than 0.2 .mu.m (2,000 .ANG.) thick and having an areal density of less than 54 .mu.g/cm.sup.2 have been obtained.

Abstract: To produce frozen casting moulds or core boxes the binder is cooled till freezing at least partly before or during the moulding process. This allows the production rate to be increased to such a level that the working rate of automatic machines for the production of casting moulds and core boxes can be fully obtained.

Abstract: Casting side dam apparatus for use in a twin-belt continuous casting machine. The side dams each comprise a multiplicity of slotted dam blocks strung on a flexible metal band. The dam blocks are each formed of a beryllium-copper alloy and are resistant to intergranular cracking and chipping over a prolonged discontinuous, cumulative period of thermal cycling between temperatures ranging between about 800.degree. F. and about 300.degree. F.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of fiber-reinforced composites. A model of the body to be cast is prepared and coated with a one-piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: Casting side dam apparatus for use in a twin-belt continuous casting machine. The side dams each comprise a multiplicity of slotted dam blocks strung on a flexible metal band. The dam blocks are each formed of a beryllium-nickel-copper alloy and are resistant to intergranular cracking over a prolonged period of exposure to elevated temperatures ranging from about 300.degree. F. to about 800.degree. F.

Abstract: An improved method of assembling molds enables the size of successive molds to be adjusted to provide cast articles having a desired size. In practicing the method, a first or initial mold is assembled in a fixture. This initial mold is used to form a cast article. The cast article formed in the initial mold is measured to determine the extent to which the dimensions of the article deviate from predetermined design dimensions. The fixture is then adjusted to compensate for the deviations in the dimensions of the cast article from the intended or design dimensions. A second mold is then assembled in the fixture. Since the fixture has been adjusted to compensate for the inaccuracies in the first mold, a product cast with the second mold will have dimensions closer to the desired dimensions.

Abstract: A method for making a tapered-bore optical waveguide coating die comprising the steps of forming a mold core consisting of a tapered pin and molding a die around the pin to form the tapered bore, is described.

Abstract: A method for forming at least one air vent or hole in a casting mold made of molding said and having a top flask with at least one blind hole originating at its parting plane with a bottom flask comprises the steps of pressurizing the mold cavity and drilling the air vent or hole into communication with the blind hole while drawing off the materials produced by drilling directly at the drilling point. An apparatus for performing the above-noted method includes, according to a preferred embodiment, a source of compressed gas having a pressure hood mountable over the inlet of the mold, and a drilling tool disposed within a suction hood which is placed in a sealing engagement with the top flask after the drilling tool has been properly aligned with the blind hole that is to form part of the air vent or hole.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of ber-reinforced composites. A model of the body to be cast is prepared and coated with a one piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: A method of fabricating a funnel-shaped miniature electrode with thin walls and very sharp edges for use in a field ionization source for ionizing components of a fluid sample is disclosed, which method includes the use of a female mold, or matrix, formed with a stepped, generally frustoconical-shaped aperture therethrough. The aperture wall includes a plurality of different diameter generally tapered wall sections of decreasing size in going along the aperture axis, with the smallest diameter section at the one end being of short length and small diameter. It is convenient, but not necessary, to coat the aperture wall with a parting layer which aids in the separation of the subsequently-formed miniature funnel-shaped electrode from the female mold and facilitates cleaning of the mold for reuse.

Abstract: Molding composition particularly suited for molding foundry cores and molds is obtained by mixing the components of a polyurethane resin with aggregate (sand), a silane, and iron oxide, molding the mixture to a desired shape and curing it.

Abstract: A method for producing multilayered contacts for medium-voltage vacuum power circuit breakers is provided comprising impregnating under vacuum with oxygen-free, liquid copper, a composite body of metal powders consisting of at least 35% by volume of a metal selected from the group consisting of chromium and vanadium and at least one metal selected from the group consisting of chromium, vanadium, cobalt, nickel and iron, in a crucible comprised of a metal selected from the group consisting of iron, steel, and chromium-nickel steel; and removing at least part of the crucible to expose a contact surface.

Abstract: The invention relates to a method of fixing a shaped body of a refractory material to an interior face (e.g. of a wall) of an ingot mould in which an adhesive composition is applied to either the body or the face or both and the body and the face are urged together, the thus fixed body serving to identify an ingot when cast in the mould. In the method of the invention the adhesive composition is a mixture consisting essentially of aqueous alkali metal silicate such as sodium silicate and a particulate refractory material such as china clay, silica or zircon, the mixture having a viscosity of at least 2000 poises measured on a Brookfield Viscometer model RVT at 20.degree. C.

Abstract: Metal casting components, e.g. molds and cores, are produced from a compacted mass of plaster by a two-stage drying treatment in a microwave oven with an intermediate cooling step whereby the plaster is completely calcined, and the resulting component will promote cast reproduction of its surface pattern with maximum fidelity of detail.

Abstract: A method for producing a pattern for making a cast part is described which comprises the steps of defining the structure of the part in terms of computer aided design system data, selecting a parting surface for the part to be cast; defining core requirements for the part by sweeping each positive feature of the part to the parting surface, subtracting the part from the projection, adding any remaining volume to the core, sweeping negative features away from the parting surface to the top or bottom of the mold and subtracting the negative features from the projection and intersecting the remainder of the part and adding any remaining volume to the core; repetitively generating alternative parting surfaces for the part and defining the corresponding core requirements whereby an optimum parting surface is defined for which the quantity and complexity of the corresponding core requirements are minimized, constructing core prints for each core requirement; constructing a pattern by adding the core prints to the p