Abstract: The present invention resides in a die casting process using a solid lubricant composition. The lubricant composition preferably comprises (a) about 30% to about 70% by weight of a high melting point synthetic wax having a melting point in the range of about 270.degree. F. to about 310.degree. F. (132.degree.-154.degree. C.); (b) about 10 to about 50% by weight of a wax having a lower melting point in the range of about 150.degree. F. to about 250.degree. F. (65.degree.-121.degree. C.).

Abstract: A lubrication system for the plunger of a die cast machine is disclosed that does not require a timing mechanism or an additional pressure source for the lubricant. The forward stroke of a lube piston is used to force lubricant out of a lubrication chamber in the plunger through a passageway to the outer surface of the plunger by decreasing the volume of the lubrication chamber. A spring within the plunger's lubrication chamber is used to retract the piston and thereby increase the volume of the lubrication chamber. The relatively low pressure during this retraction stroke allows lubricant to flow from a lubricant tank into the lubrication chamber for distribution during the next forward stroke of the plunger.

Abstract: This invention provides a die casting method comprising the steps of that a pulverized insulation agent is coated to form a porous insulation layer on the interior surface of die cavity when a casting products are made by utilizing a die casting machine, wherein a molten metal is filled into the cavity with a slow pace thereon, a high pressure is applied upon the molten metal mechanically so as to crush and make thin the porous insulation layer pressed by the high pressurization upon the molten metal, simultaneously the molten metal sinks into and passes through the porous insulation layer to reach at the interior surface of the cavity wherein the molten metal is rapidly solidified to produce a final casting products according to the temperature drop due to the direct contact with the interior surface of the cavity.

Abstract: Molten metal is prevented from cooling too quickly when supplied to an injection sleeve of a casting device by applying a heat insulating powder onto an inner surface of the injection sleeve between each supply of molten metal. The heat insulating powder can be applied to the inner surface of the injection sleeve by way of an electrostatic field created between an electrode which has been inserted into the injection sleeve and the injection sleeve itself.

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 die-casting method in which a lubricant is heated to a temperature higher than a temperature of mold cavity surfaces before molten metal is injected into the mold cavity. The lubricant is heated when the mold cavity is formed by bringing a movable mold into contact with a stationary mold. The heated lubricant is introduced into the mold cavity and applied on the mold cavity surfaces, and the molten metal is then injected into the mold cavity. The molten metal is allowed to solidify in the mold cavity to become a solidified article. A die-casting device for carrying out this method is also provided according to the present invention.

Abstract: A method for manufacturing a fused cast refractory article including the steps of pouring a molten refractory material into a cavity of a mold including a casting sand held by a negative pressure applied through the sand and against a thermoplastic film which surrounds the mold cavity, casting and cooling off the refractory material, wherein the negative pressure is maintained after the casting. The mold includes an upper mold portion including a frame, a casting sand, and a thermoplastic film; a bottom mold portion including a frame, a casting sand and a thermoplastic film; and a cavity defined by the thermoplastic film between the upper and bottom mold portion and having an inlet opening.

Abstract: A method and device for making moulds shaped on two faces by means of model plates (10,11). After depression of the plates, the envelope (17) sealed at (40) containing the granular material (30) is, in its turn, subjected to depression through the tubes (23) and (24) of the armature. The plates are then removed while the internal depression is maintained. The moulds are juxtaposed, and two adjacents moulds will form a print and their free faces will enable the making of two more with two additional moulds. Thus, (n-1) prints will be obtained for n moulds.

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: Metal castings are prepared using rigid closed molds by submerging the mold in a bath of lower temperature molten metal, with removal of the mold from the bath being handled to hold the metal inside the mold, but to allow the excess metal to run off the exterior of the mold without metal freezing thereto which could cause damage or locking-in of the mold.

Abstract: A method for making small lead objects such as bullets. Lead is melted and while in a molten state is pumped through a metering device that regulates the amount fed into a die where it solidifies. Force is immediately applied to the still-soft lead to form the hard bullet.

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: Improved small dendrite arm spacings and good technical values, regarding the technical properties of aluminum alloys, particularly tensile strength, yield strength and elongation percent, can be reliably obtained by refining the grain of the casting to provide the smallest possible spacings between the secondary dendrite arms, by casting the aluminum alloys in a ceramic mold provided with numerous micro-sized rough spots and pores and to the inner wall of which mold after it is dried and fired has been applied a thin layer of a salt mixture in which the cations are primarily from the alkalis and/or alkaline earths and the anions are primarily from halogens and which applied salt mixture has a liquidus temperature lower than the casting temperature of the alloy.

Abstract: A die-casting arrangement which prevents a lubricant from becoming mixed into a die cast article which might cause it to bulge when later heated. The lubricating agent is sprayed over a high-temperature portion of a sprue interconnecting a mold cavity and an injection sleeve in order to partly carbonize the lubricant. The carbonized lubricating agent even if mixed into a die cast article will not expand even when the article is heated thereby preventing bulging of the article.

Abstract: A mold-release agent injection nozzle is provided in the portion of the die casting machine leading to the mold cavity or in the mold. A mold-release agent is then spray applied to the surfaces of the mold through the nozzle while the mold is closed. The surplus mold-release agent is then discharged through a vent port having a displaceable valve.

Abstract: The subject matter of the invention is a device for supplying spray units for die casting machines each with a fluid containing water and additives for cooling, cleansing and lubricating purposes. The device contains at least one central tank (26,28) storing water comprising additives, whose concentration has been adjusted to a maximum. Said maximum value depends on casting materials, molds (18,20) and die casting methods which are carried out on the die casting machines (10,12). In another central tank (44) water is stored. The tanks (26,28,44) are connected to mixing valves (38,40) provided at each die casting machine (10,12). A pump is connected between the outlet of each mixing valve and the inlet of a respective spray unit at a die casting machine.

Abstract: The present invention discloses an improved rapid solidification casting system which employs one or more metal conditioning brushes. The casting surface is cleaned by the brushes and the pressure on the brushes is adjusted so as to deposit a layer of the brush metal onto the casting surface, the casting surface so conditioned increases the quality of the resulting cast material.

Abstract: A process for production of castings is provided employing patterns combining gasifiable pattern parts, for the creation of nonconforming contours, with reusable pattern parts. After molding, only the reusable pattern parts are removed from the mold, while the gasifiable pattern parts are destroyed during casting.

Abstract: A core is formed by molding a mixture of an organic binding material and a fireproof granular substance. The core is impregnated with an aluminum-phosphorus oxide solution. The impregnated core is heated at 400.degree.-1000.degree. C. for about an hour.The disintegrable core for casting can be produced much more quickly than before and with considerably less expenditure of energy.

Abstract: Metal castings are prepared using thin rigid closed molds by submerging the mold in a bath of high temperature molten metal, with removal of the mold from the bath being handled to hold the metal inside the mold, but to allow the excess metal to run off the exterior of the mold without metal freezing there which could cause damage or locking-in of the mold.

Abstract: A process is disclosed for the continuous casting of a lithium-containing alloy including casting the alloy through a mold and applying alpha-olefin oligomer to the mold. In one aspect, the process includes a lubricant containing alpha-olefin oligomer, preferably having a viscosity in the range of about 1-3 cs at 450.degree. F. In another aspect, the process includes a lubricant containing less than the varnish-film forming amount of fatty ester, fatty acid, or fatty alcohol.

Abstract: Binder, filler, and refractory compositions and methods of using and making these compositions are disclosed. The binder composition comprises colloidal silica, a liquid material containing Si--OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from phosphorus, sulfur, boron and nitrogen and which stabilizes the binder composition against self-gelling. The liquid material and the colloidal silica are present in a ratio by weight of from about 10:1 to about 1:10 respectively. The liquid material has at least about 20% by weight SiO.sub.2. The colloidal silica contains at least about 15% by weight SiO.sub.2.

Abstract: A unitary-layer partially metallic, suitably adherent, mechanically and thermally durable, non-wetting, fusion-bonded matrix coating on endless, flexible metallic casting belts for continuous casting machines is described. This fusion-bonded matrix coating is also advantageous for coating other molten-metal-contacting surfaces, in continuous casting machines, such as edge-dam blocks that define moving side walls of a mold cavity. The fusion-bonded matrix (or reticulum) coating provides advantageous accessible porosity throughout the coating and comprises a nonmetallic refractory material interspersed substantially uniformly throughout a matrix of heat-resistant metal or metal alloy, for example nickel or nickel alloy, which is fusion-bonded to the grit-blasted surface of the belt and anchors and holds the nonmetallic material. The coating is applied by thermally spraying a powdered mixture directly on the roughened surface.

Abstract: Casting powder is to be fluidized for feeding to a mold for continuous casting. The gas flow providing the fluidization is controlled in response to bath surface temperature, monitored by means of a curved copper sheet, serving as radiation detector. A thermofeeler is attached to the sheet and controls a pneumatic control circuit for the fluidization gas.

Abstract: A die-casting method that eliminates the need to inject insulation. By injecting molten metal sufficiently quickly after injecting tip lubricant, die-cast products may be removed from the mold even without injecting isulation. To this end, a movable die may at least begin moving toward a fixed die before tip lubricant is injected. The tip lubricant may be injected from a molten metal pouring port in a shot sleeve or from the movable die toward the shot sleeve. Tip lubricant which has been introduced into the shot sleeve is conveyed into the die cavity by movement of the molten metal, thus coating the die cavity inner surface.

Abstract: With low-pressure or die-casting methods there frequently occur leaks during the transfer of the molten metal from the metal containing basin or vessel to the mold. These leaks often lead to serious accidents and related operating interruptions. According to the invention these problems are solved by a casting method, wherein all movements of the mold occur in a vertical plane. With a preferred embodiment of apparatus for the performance of the method the mold is placed in a positive or form-locking manner with its casting or pour opening upon the casting hole of the metal containing vessel or basin and pressed against the latter in a fluidtight fashion by means of a pneumatic lifting cylinder. This affords the advantage of a simple connection of the mold with the basin and without requiring a coupling mechanism, and, additionally, the heating of the riser or up tube and/or immersion tube can be omitted, which otherwise conventionally was performed by gas heating.

Abstract: The mold features on its work face a thermally insulating protective layer of sub-micron metal oxide particles.The coating can be applied by spraying an aqueous sol of a metal oxide onto the mold work face which has been heated to at least 60.degree. C.The use of sub-micron sized metal oxide particles enables the formation of a protective coating of very low density and consequently very low thermal conductivity. The coating can furthermore be deposited very economically, and likewise removed again.

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: In welding metal sheets together from only one side, an improved welding backup tape is self-adhesively applied to insure the consistent formation of a smooth, inclusion free, slightly convex underbead which requires little or no dressing, or grinding, and which does not impede in any way the achievement of 100% radiographic weldment testing. This welding backup tape is made in one embodiment by mixing into solution two parts of a colloidal silica solution with one part of a titanium dioxide refractory coating solution. Applying this resulting solution as a refractory coating to the upper portion of an electrical grade, heat treated, braided, natural finish, finely woven, fiberglass material in a sleeving configuration.

Abstract: A mold facing for producing a gas-permeable, non-gassing and, in view of its small thickness and its porosity, heat-conductive cladding of a centrifugal ingot mold for copper and its alloy contains pulverulent material in a dispersing agent, particularly water, evaporating without residue. The pulverulent material has titanium dioxide (TiO.sub.2) as the main constituent or the sole constituent, preferable with an average particle sizes of about 15 .mu.m. A process for cladding a centrifugal ingot mold by using such a mold facing contemplates at first preheating the mold and subsequently applying the mold facing by spraying to the inner wall of the centrifugal ingot mold rotating around its axis in form of a suspension free of binding agents and surface active agents as a thin layer of, as far as possible, uniform thickness of preferably 0.1 to 0.3 mm and subsequently evaporating the dispersing sheet of the mold facing without leaving any residue for obtaining a porous layer.

Abstract: A metal casting system including novel process and apparatus wherein the shape of the casting is defined by a thin thermal degrading film supported by a particulate bed. A pattern having the shape of the desired casting is surrounded by the tight fitting film with one end of the pattern exposed. A particulate bed is tightly packed about the film-surrounded pattern. A reduced fluid pressure is established within the particulate bed relative to the pattern so that the surrounding film is tightly held by atmospheric pressure against the particulate bed and slightly released from the pattern. The pattern is removed from the surrounding film and leaves therein a cavity bounded by the film with the shape of the desired casting. The cavity is filled with molten metal for forming the desired casting simultaneously with the vaporization of the film. The present metal casting system is especially useful for the casting of cylindrical shapes using unique molds and a novel flask is provided for such a casting process.

Abstract: An improved method of making internally slitted strip material wherein a metal billet is cast about friable elongated members of weld preventing material and wherein the billet and elongated members are rolled to thin and elongate the billet and to pulverize the weld preventing material into a fine weld preventing powder for distribution along the spaces occupied by the weld preventing material and which spaces upon the pulverized weld preventing powder being removed form the slits, the improvement wherein prior to casting the metal billet about the elongated members of weld preventing material, the friability of the weld preventing member is enhanced to cause the members to pulverize more evenly and to distribute more evenly along the spaces occupied by the pulverized weld preventing material whereby any tendency of the pulverized powder to leave gaps at which welds are formed during rolling is substantially eliminated and wherein such enhancement is provided by coating the elongated members with a predeterm

Abstract: A process relating to the pouring of molten metal into a permanent mould made of iron or other like material, automating the moulds within the system so as to offer diversification of production and while so doing having a finished product that is of a machinable and marketable nature. Slow cooling of the castings through the critical temperature in the system limits the formation of iron carbides and successfully produces a machinable product.

Abstract: The base plates or stools of ingot molds used in the casting and teeming of molten steel can be repaired by spraying onto the ingot mold base plate from 2-5 gallons of a composition comprising:______________________________________ Aluminum silicate refractory grain.sup.1 50-80% Al.sub.2 O.sub.3 4.0-17.0% Bentonite clay 0.2-5.0% Binder 4.0-25% 75% phosphoric acid 72-82% Alumina trihydrate 6.2-16.2% Powdered boric acid 1.0-7.0% H.sub.2 O 4.0-14.

Abstract: Coated sand cores containing a boronated aluminum phosphate 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: The invention relates to metal casting employing a pattern in a sand mold. A thin film of translucent thermoplastic is coated with finely divided graphite and then superimposed on the pattern with the layer of graphite sandwiched in between. Infrared radiation is applied to the film to soften the same with the radiant heat which is absorbed by the graphite serving to speed up the softening process. Then while the film is in soft drawable condition the film is vacuum-formed onto the surface of the pattern with the graphite serving as a lubricant for the plastic film as the film is drawn about irregular or deeply indented surfaces on the pattern to produce a tightly conforming barrier layer. Sand is molded about the pattern and its barrier layer to form a mold, following which the pattern is withdrawn leaving the layer in conforming and supporting contact with the sand.

Abstract: A dispersion composition and a method for coating the surface of steel casting dies for molten metals are described. The dispersion composition comprises boron nitride powder dispersed in a peroxide-modified aqueous dispersion of a water-dispersible film-forming polymer. The coating composition provides thermal insulation to the mold surface, thereby minimizing premature solidification of the cast metal.

Abstract: A composition and method for coating the surface of steel casting dies for molten metals are described. The composition comprises a dispersion of boron nitride powder, an elastomeric polymer and an organic solvent or diluent. The elastomeric polymer consists of two fractions, a high-polymer fraction and a low-polymer fraction. The treatment provides thermal insulation to the mold surface, thereby minimizing premature solidification of the cast metal.

Abstract: A process relating to the pouring of ferrous metal into a permanent mould made of iron or other like material, automating said moulds within the system so as to offer diversification of production and while so doing having a finished product that is of a machinable and marketable nature. Slow cooling of the castings through the critical temperature in the system limits the formation of iron carbides and successfully produce a machinable product.

Abstract: A metal mold employed for the casting of metals, preferably steel, has a wear resistant layer on the casting surface thereof formed of a different metal having solid particles dispersed therein. A preferred mold is formed of copper or alloy thereof having an electrolytically deposited nickel layer with silicon carbide particles dispersed therein.

Abstract: The base plates or stools of ingot molds used in the casting and teeming of molten steel can be repaired by spraying onto the ingot mold base plate from 2-5 gallons of a composition comprising:______________________________________ Less than 20 mesh alumina-silicate refractory grain.sup.1 49.5% Less than 200 mesh alumina silicate refractory grain.sup.1 11.56% Less than 325 mesh Al.sub.2 O.sub.3 13.21% Less than 325 mesh bentonite clay 1.75% Binder - 75% phosphoric acid 77.0% Alumina/trihydrate 11.2% Powdered boric acid 2.35% H.sub.2 O 9.45% 11.99% Water 11.99% ______________________________________ +HU 1Contains approximately 47% as Al.sub.2 O.sub.

Abstract: A fired alumina article having a core of material having from 20 to 65 percent continuous porosity by volume and desired crushability characteristics and an integral outer barrier layer consisting of porous alumina having a density gradient.

Abstract: A copper mold release material comprising titanium dioxide slurried in a liquid medium. The titanium dioxide is easily removed from a casting, if any adhers thereto, by washing with, for example, water and does not contaminate electrolytes utilized in electrolytic refining processes.

Abstract: Less than 3 weight percent of a rare earth metal is employed in doping a directionally solidified eutectic alloy or a superalloy material to minimize the formation of a metal-ceramic reaction layer during casting and solidification thereof.

Abstract: An improved apparatus and method for making solid filamentary elements from a pendant drop of a high melting point material (e.g. hafnium, zirconium). The improvement constitutes providing a protective layer in the form of a thin film on the circumferential edge of the casting wheel prior to engagement of the drop and release of the elements. The layer material serves to reduce heat flow from the drop material to the wheel as well as prohibit bonding of the drop material thereto. The preferred layer materials are aluminum, carbon (e.g. graphite), boron nitride, and borosilicate glass.

Abstract: A process for applying a coating to a centrifugal casting mold for casting copper or alloys thereof in which prior to introducing the molten metal into the mold, an aqueous suspension of powdery material is introduced into the mold and applied on the internal surface thereof in the form of a thin layer. The constituent components of the suspension are zirconium oxide (ZrO.sub.2) and an inorganic binder material, preferably non-sintered alumina (Al.sub.2 O.sub.3), so that a heat-conductive and gas-permeable layer is formed on the surface of the mold.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.

Abstract: An applicator nozzle for applying a coating solution onto the molding surface of a metal mold for use in centrifugal casting. The applicator nozzle mounted on an applicator lance is provided, at its one end facing the molding surface, with a plurality of small nozzle openings which are arranged at a predetermined pitch to each other in the direction of movement of the lance into the metal mold, through which nozzle openings, a solution of coating material is emitted in solid rod-like form in such an amount as to be sufficient to complete mold coating in one way of the nozzle into the metal mold, thus producing mold coating free from an undesirable spiral pattern.

Abstract: An improved ingot mold for producing steel ingots is disclosed. The primary feature of this improved mold is an interior sidewall coating which is composed of an aqueous slurry of finely divided iron oxide and a lignosulfonate.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.