Abstract: The subject matter of the invention relates to sizing compositions as coating compositions for casting molds. The sizing composition is suitable for cores and molds, in particular those produced using water glass as a binder. The sizing composition contains certain salts.

Abstract: The invention relates to coating compositions, comprising specific clays, an aqueous carrier fluid and refractory materials in powder form, and to the use thereof for casting molds and cores, in particular those that are produced using water glass as a binder. The invention further relates to a method for producing the sizing agents and for applying same to inorganically bound casting molds and cores.

Abstract: A method is provided for repairing defects in a ceramic core adapted for use in a casting process. The ceramic core is formed from a slurry comprising at least one refractory powder material suspended in a liquid vehicle. The method includes forming a repair mixture comprising a liquid diluent and the at least one refractory powder material suspended in the liquid vehicle of the slurry. The repair mixture is applied to a region of the ceramic core that includes at least one defect and then the ceramic core is fired to burn off the liquid vehicle in the repair mixture and form a ceramic composition that closes the defect.

Abstract: The subject matter of the invention relates to coating compositions comprising formic acid esters, an aqueous carrier liquid and pulverulent refractory material, and to the use thereof for casting molds, in particular those produced using water glass as a binder.

Abstract: A method of making an antifouling article includes providing a mold having a mold cavity and a mold surface for defining an article. The method also includes applying a mold release material to the mold surface. The method further includes coating the mold surface with a plurality of metallic powder particles comprising an antifouling agent. Still further, the method includes filling the mold with a curable polymeric material. Yet further, the method includes curing the polymeric material and forming an article having a surface defined by the mold surface, the surface of the article having the plurality of metallic powder particles disposed thereon and comprising an antifouling coating.

Abstract: A method for applying a refractory coating to a sand core, to be used for a metal casting, in a dry state, without the use of a liquid carrier. The coating may be applied by pressing the coating into a mixture of refractory material and impacting media fluidized in a vibratory bed such that the core floats in the mixture, and then rotating the core to coat the surfaces that will be in contact with the molten metal in the casting process.

Abstract: An apparatus, system and method for preparing a surface of a substrate using a proximity head includes applying a non-Newtonian fluid between the surface of the substrate and a head surface of the proximity head. The non-Newtonian fluid defines a containment wall along one or more sides between the head surface and the surface of the substrate. The one or more sides provided with the non-Newtonian fluid define a treatment region on the substrate between the head surface and the surface of the substrate. A Newtonian fluid is applied to the surface of the substrate through the proximity head, such that the applied Newtonian fluid is substantially contained in the treatment region defined by the containment wall. The contained Newtonian fluid aids in the removal of one or more contaminants from the surface of the substrate. In one example, the non-Newtonian fluid can also be used to create ambient controlled isolated regions, which can assist in controlled processing of surfaces within the regions.

Abstract: A method of producing a mold for use in duplicating a light diffusion sheet is provided. The method includes a step of conducting sand blasting for blasting abrasive material from a blast gun to a surface of a mold base material to form unevenness in the surface of the mold base material, wherein the abrasive material is blasted to the surface of the mold base material at a blast angle of less than 90°.

Abstract: A casting system includes a core and a shell positioned relative to the core. A barrier coating is applied on at least one of the core and the shell.

Abstract: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. A pattern coating composition is disclosed wherein the composition is an emulsion including oil, water, graphite, a water dispersible amine, and a clay reactive with the amine to form an organophylic clay.

Abstract: A method and apparatus for the manipulation of colloidal particulates and biomolecules at the interface between an insulating electrode such as silicon oxide and an electrolyte solution. Light-controlled electrokinetic assembly of particles near surfaces relies on the combination of three functional elements: the AC electric field-induced assembly of planar aggregates; the patterning of the electrolyte/silicon oxide/silicon interface to exert spatial control over the assembly process; and the real-time control of the assembly process via external illumination. The present invention provides a set of fundamental operations enabling interactive control over the creation and placement of planar arrays of several types of particles and biomolecules and the manipulation of array shape and size. The present invention enables sample preparation and handling for diagnostic assays and biochemical analysis in an array format, and the functional integration of these operations.

Abstract: A mold-release coating system includes a barrier coating of a substantially liquid wax material. The wax material is deposited onto the mold surface. The wax material includes about 7 to about 10 weight percent solids. The wax material is permitted to substantially dry after deposition onto the mold surface. The mold-release coating system also includes a release powder deposited onto the barrier coating after the wax material has been permitted to substantially dry after deposition onto the mold surface.

Abstract: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. Despite many available pattern coating compounds, mineral seal oil, and a mixture of mineral seal and clay, have been the commercial choices. Hereby the advantages of mineral seal oil-clay pattern coating compositions are retained without its detriments by utilizing a vegetable oil base in a pattern coating composition to replace some or all of the mineral seal oil to provide biodegradable coating compositions with reduced VOC content.

Abstract: Arrays of protein-capture agents useful for the simultaneous detection of a plurality of proteins which are the expression products, or fragments thereof, of a cell or population of cells in an organism are provided. A variety of antibody arrays, in particular, are described. Methods of both making and using the arrays of protein-capture agents are also disclosed. The invention arrays are particularly useful for various proteomics applications including assessing patterns of protein expression and modification in cells.

Abstract: A method of applying surface-modifying auxiliary substances to the working area interior surfaces of die molds for the production of molded products, in particular made of rubber or plastics. The auxiliary substance is supplied in the form of a gas or vapor to the interior surfaces of the die mold, which is integrated into the processing machine, and the gas or vapor is condensed there.

Abstract: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. Despite many available pattern coating compounds, mineral seal oil, and a mixture of mineral seal and clay, have been the commercial choices. Hereby the advantages of mineral seal oil-clay pattern coating compositions are retained without its detriments by utilizing a vegetable oil base in a pattern coating composition to replace some or all of the mineral seal oil to provide biodegradable coating compositions with reduced VOC content.

Abstract: Protein arrays for the parallel, in vitro screening of biomolecular activity are provided. Methods of using the protein arrays are also disclosed. On the arrays, a plurality of different proteins, such as different members of a single protein family, are immobilized on one or more organic thinfilms on the substrate surface. The protein arrays are particularly useful in drug development, proteomics, and clinical diagnostics.

Abstract: Protein arrays and protein-coated substrates for the parallel, in vitro screening of biomolecular activity are provided. Methods of using the protein-coated substrates and protein arrays are also disclosed. A plurality of different members of a single protein family may be immobilized on the protein-coated substrate or array. The protein-coated substrates and protein arrays are particularly useful in high-throughput drug screening and clinical diagnostics.

Abstract: Arrays of protein-capture agents useful for the simultaneous detection of a plurality of proteins which are the expression products, or fragments thereof, of a cell or population of cells in an organism are provided. A variety of antibody arrays, in particular, are described. Methods of both making and using the arrays of protein-capture agents are also disclosed. The invention arrays are particularly useful for various proteomics applications including assessing patterns of protein expression and modification in cells.

Abstract: A method of applying a refractory coating to densified foundry sand cores having micropores between the sand grains having the steps of: (a) mixing a dry powder refractory material (anhydrous MmgOSiO2 talc) with a dry powder impacting media, the refractory material having a particle size in the range of 5-40 microns and the weight ratio between the refractory material and the impacting media; (b) fluidizing the mixture in a contained zone by introducing positive air pressure at one end of the zone and applying a negative pressure at the other end of the zone; and (c) quickly and entirely immersing the sand cores in the zone containing the fluidized mixture and substantially immediately thereafter withdrawing (without reciprocal movement) such sand cores without the need for added motion to be coated with essentially only the refractory material as impacted by the impacting media. The cores will be coated continuously with the refractory material, impacted with the micropores of the sand core.

Abstract: A method for precison polishing non-planar, aspherical surfaces in substrates, particularly surfaces of molding tool substrates for molding optical surfaces therewith, which is accomplished by coating the non-planar, aspherical surface with a layer of material having a melt temperature which is less than a temperature at which the substrate will distort, heating the layer of material coated on the non-planar, aspherical surface to at least the melt temperature thereby flowing the layer of material to yield a surface tension smooth surface superimposed over the non-planar, aspherical surface, and etching the surface tension smooth surface down into the substrate to completely remove the layer.

Abstract: Refractory coated gelatin-bonded foundry sand core made by waterproofing the surface of the core and immersing the waterproofed core in an aqueous refractory suspension to deposit the refractory.

Abstract: A core material for making cores to be used in molds for the casting of metals and comprising a mixture of hollow ceramic particles uniformly distributed throughout a resin binder of organic material. The hollow ceramic particles are individually in intimate surface contact with adjacent individual hollow ceramic particles throughout the core materials to allow the heat of the casting to be conducted efficiently through the core material. The amount of resin binder being maintained at a minimum to reduce the amount of gas generated by the resin binder as it is exposed to the heat of the metal being cast. The hollow ceramic particles comprising about 99.0 to about 96.5% by weight of the core material and the resin binder comprising about 1.0 to 3.5% by weight, respectively, of the core material prior to the core material being cured, and the hollow ceramic particles preferably ranging in diameter from about 200 microns to about 450 microns, with a preferred mean diameter of about 325 microns.

Abstract: A composition for the preparation of articles of calcium oxide, comprising calcined calcium oxide and an organic phase consisting of at least one polyol in an anhydrous medium. The composition may be used to form linings for molds and crucibles intended to come into contact with molten metals of groups IV and V of the periodic table.

Abstract: An aqueous reaction mixture having a pH of 4.5 to 5.5 of a multi-functional polydimethyl siloxane emulsified polymer, a methyl triethoxy silane, a mixture of substituted nonyl and octyl phenol derivative surfactants, non-ionic fluorinated alkyl ester surfactant and synthetic ethoxylated amine surfactants, a silanol terminated polydimethyl siloxane and ethanol. The reaction mixture is coated on a mold core surface and cured with heat to form a mold release surface that can be used in excess of twenty times prior to recoating.

Abstract: Finely pulverized facing sand particles are provided for the production of casting molds in metal foundries. A feed device passes a bed of molding sand containing lumps to a refining device. The refining device includes a plurality of refining elements on a carrier. The refining elements are movable along an orbital path to remove lump-free facing sand particles from the bed of sand and deliver these in a free falling stream of finely pulverized facing sand particles. The refining elements are spaced on the carrier and the carrier is moved at a speed to maintain the spaces free of lumps.

Abstract: An aqueous reaction mixture of a multi-functional polydimethyl siloxane emulsified polymer, a methyl triethoxy silane, a mixture of substituted nonyl or octyl phenol derivative surfactants and synthetic ethoxylated amine surfactants, and ethanol. The reaction mixture is coated on a mold core surface and cured with heat to form a mold release surface that can be used in excess of twenty times prior to recoating.

Abstract: A new and improved, non-porous carbon foundry sand and a method of treating a fluid coke, having a spherical or ovoid particle shape and a size suitable for a coating surface, or a core or mold surface in the foundry industry, wherein the carbon sand is processed by heating the carbon particles at a controlled rate to a temperature in the range of about 1900.degree. F. to about 2300.degree. F. during a period of time preferably of more than about 30 minutes, and preferably for a period of about 1 to 2 hours, particularly to about 2000.degree. F. to about 2200.degree. F., and a method of casting molten metal against the heat treated carbon particles wherein the non-porous carbon foundry sand is combined with a suitable binder with which mixture a mold is formed to cast metal parts. The non-porous carbon sand also is useful in forming molds, cores, shell molds and shell cores and otherwise in using the carbon sand to replace other molding an core-making sands used in the foundry industry.

Abstract: A small amount of tall oil uniformly dispersed in a vegetable oil is a superior concrete from release coating composition.

Abstract: The release of a moulded concrete body from the mould can be improved by applying, to the mould, an effective amount of a concrete release composition in the form of an oil-in-water emulsion in which the oily phase is at least one of the following: a mineral oil with a content of aromatics of at most 9%, a vegetable oil and one or more oily esters of aliphatic carboxylic acids with mono- or dihydric alcohols and having a melting point of at the most 35.degree. C., the total number of carbon atoms in the esters being 8-46, and comprising one or more non-ionic surfactants in an amount of 0.5-20% by weight and one or more anionic surfactants in an amount of 1-100%, based on the non-ionic surfactant. The emulsion may also comprise cationic surfactants, anti-freeze, stabilizers, corrosion inhibitors, etc. The oily esters of aliphatic carboxylic acids with mono- or dihydric alcohols may also be used in non-emulsified form.

Abstract: A new and improved carbon sand and a method of treating a petroleum fluid coke, having a spherical or ovoid particle shape and a size suitable for a core or mold surface in the foundry industry, by heating or roasting the carbon particles at a temperature in the range of about 1000.degree. F. to about 1500.degree. F., particularly about 1200.degree. F. to about 1400.degree. F., for a time sufficient to volatilize from the carbon particles substantially all of the organic contaminants volatilizable at the roasting temperature, and a method of casting molten metal against the heat treated carbon particles, combined with a suitable binder, to form cast metal parts. The carbon sand also is useful in forming shell molds and shell cores and otherwise using the carbon sand to replace other molding and coremaking sands used in any of the various molding and coremaking processes with any of the various binder systems practiced by the foundry industry.

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 mold surface treatment process comprises: providing a fluidized bed of a treating powder; holding the mold in the fluidized bed to fill up the depressions of the mold surfaces with the treating powder by employing a surface treating member for pushing the treating powder into the depressions; and taking the mold out of the fluidized bed. The mold surface treatment allows to make molten metal less likely penetrate into the walls of mold, and to manufacture a mold which generates less amount of gum causing defects during casting.

Abstract: An expendable substrate which in use contacts molten metal, for example a foundry mould or core or ladle lining, is coated with a coherent layer of refractory particles by tribo-electrically charging refractory particles coated with an organic binder, the coated particles having an electrical resistivity of at least 10.sup.10 ohm. cm. at 10kv, earthing the substate and bringing the charged particles into contact with the earthed substrate. Suitable binders are thermoplastic resins, thermosetting resins and waxes and the quantity of binder in the binder coated particles is usually less than 10% by weight.

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: A method of providing a mould 1 (FIG. 1) with a release layer, in which a hydrophilic, inorganic surface 2, 4 of the mould is treated with a silane compound of the formula (R).sub.m --Si--(X).sub.4-m under anhydrous conditions.

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 method is disclosed of dehydrating a thin water based ceramic slurry coating on a foam pattern assembly having hidden internal surfaces. The method comprises sequentially subjecting the coated assembly to a first warm air flow at a sufficient temperature and time to dehydrate and remove 60-80% of the water of the coating, and secondly subjecting the dehydrated coating assembly to low level microwave energy to substantially remove the remainder of the water in all of the coating, the dehydrated coating being devoid of bubbles or cracking.The coating is made by use of a slurry comprising a thixotropic silica water suspension with the silica comprising only 40-50% of the slurry; the slurry also may include a small portion of clay and in some cases an acrylic or epoxy glue additive. The pattern assembly or cluster is comprised of a plurality of molding patterns integrally carried by a gating system and common sprue, the patterns being at least four in number and radiating from the common sprue.

Abstract: A foundry shell core and mold composition comprises particulate matter coated with a curable phenolic-furan resin. The process for making the resin coated particulate matter substantially eliminates the sue of hexamethylene tetramine.

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: Sand casting is an old art. In this molding process sand is compacted around a pattern and the pattern is removed, leaving a mold cavity the shape of the pattern. Molten metal can then be poured into the cavity to form the object. To increase the life of the mold, and to make removal of the pattern easier, the pattern must be coated with a protective material. Despite many available pattern coating compounds, mineral seal oil, and a mixture of mineral seal and clay, have been the commercial choices. But they are not without their disadvantages. The properties of mineral seal oil are not entirely desirable, particularly its low flash point and toxicity. Hereby the advantages of mineral seal oil-clay pattern coating compositions are retained without its detriments.

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 P, S, B and N 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. The solvent and the organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.

Abstract: A process for the deburring of bonded moldings of granular material, for example, casting sand cores, by coating them in the same operation with a surface layer. The moldings are circulated within an annular vibrator together with an abrasive body medium which contains a powdered coating agent, the medium being preferably deflocculated by an approximately 50% proportion of hard-foam bodies.

Abstract: A resin-bonded sand core for high-pressure die casting methods having a first refractory coating, such as of silica, with an inorganic binding agent of colloidal silica and a clay such as kaolin, and a second or top coating of a refractory material containing zircon and an organic binding agent, which combination of these two different coatings enables the bonded sand core to have high pressure and temperature resistance, good washout resistance, freedom from surface penetration, and good shake-out properties.

Abstract: The process for preparing a resin-coated casting sand by coating sand grains with a binder comprising a liquid phenolic resin component and a polyisocyanate component, the improvement of which comprises coating sand grains with an organic solvent prior to coating of the sand grains with the binder, thereby prolonging the bench life of the resulting resin-coated casting sand and enhancing the strength of a casting mold prepared from this resin-coated casting sand. Furthermore, this process enables the utilization of sand of a low grade or reclaimed sand having a high alkaline component content, that has not been used in the conventional process, and the supply of an excellent resin-coated casting sand which is capable of providing a casting mold having a high strength and has a long bench life.

Abstract: A coating for foundry cores and molds comprising an aqueous suspension of clay, olivine, and sodium tripolyphosphate.

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 composition for coating the molding surfaces of molds for casting metal parts comprising an aqueous dispersion containing finely divided zirconia, a colloidal silica composition, finely divided mica, finely divided zircon, finely divided bentonite and, optionally, an inert coloring agent. While capable of protecting the molding surfaces against high temperature molten metal and producing castings having substantially defect-free surfaces, the coating composition provides cleaner castings by partially attaching to the casting and spalling off as the casting cools.

Abstract: Phosphosilicate compositions are disclosed for treating foundry molds and like products to enhance mold strength and refractoriness. The phosphosilicates, characterized more specifically as silicyl metaphosphates, may be used in combination with select refractory aggregates and other additives to form mold surface treating compositions, or may be combined directly with foundry sand or other comminuted refractory material for compacting into a mold form.

Abstract: Flammable foundry coatings are disclosed in which the carrier liquid is safer to handle than previously used types e.g. isopropanol, and which also burns off more satisfactorily. The carrier liquid is a mixture of an essentially aliphatic hydrocarbon liquid of flash point greater than 32.degree. C., e.g. an aliphatic petroleum distillate, and a mono alkyl ether of a polyhydric alcohol, e.g. ethylene glycol monoethyl ether (oxitol).