Abstract: A heat exchanger heat-utilization device is obtained that can efficiently store heat and dissipate heat in or from a chemical thermal storage medium, and a manufacturing method of the heat exchanger heat-utilization device. A heat exchanger heat-utilization device includes: chemical thermal storage medium composite molded formed by organizing chemical thermal storage medium particles into a porous structural body having flow channels; and a heat exchanger body. The heat exchanger body has thermal storage medium containing portions in which the chemical thermal storage medium composite molded bodies are accommodated, and fluid flow channels that are partitioned from the thermal storage medium containing portions by partition walls and through which a heat exchange medium flows for heat exchange with the chemical thermal storage medium composite molded bodies.

Abstract: A disk roll base material includes 20 to 38 wt % of alumina silicate wool that include 40 to 60 wt % of alumina and 40 to 60 wt % of silica, and have a content of shots having a dimension of 45 ?m or more of 5 wt % or less, 10 to 30 wt % of kibushi clay, 2 to 20 wt % of bentonite, and 20 to 40 wt % of mica.

Abstract: To provide a long-life refractory capable of maintaining durability under severe conditions. The castable refractory comprises a mixture containing at least one of 2 to 10 mass % of silicon carbide and 3 to 10 mass % of chamotte, as an auxiliary raw material, and a binder material, with the remaining balance being one or more main raw materials selected from corundum, mullite, bauxite, chamotte, talc and silica, and is used in an environment exposed to an alkali component-containing hot gas atmosphere. In an alkali component-containing gas atmosphere at a high temperature (750° C. or more), silicon carbide and/or chamotte are vitrified to a thickness of 1 mm or less in the surface layer of the refractory to prevent the alkali component-containing gas from intruding inside of the refractory.

Abstract: The present invention relates to a ceramic material structure (100) at least partly produced with a ceramic material comprising an effective quantity of Li—Al nesosilicates (euryptite) (110). In a further aspect thereof, the present invention relates to a process for producing the aforesaid ceramic material structure. The ceramic has a low thermal expansion and may be used for cooking plates, cooking utensils and similar applications requiring thermal shock resistance.

Abstract: Sintered, spherical composite pellets or particles comprising alumina fines, at least one of clay and bauxite and optionally a sintering aid, are described, along with a process for their manufacture. The use of such pellets in hydraulic fracturing of subterranean formations and in grinding is also described.

Abstract: Sintered, spherical composite pellets or particles comprising alumina fines, at least one of clay and bauxite and optionally a sintering aid, are described, along with a process for their manufacture. The use of such pellets in hydraulic fracturing of subterranean formations and in grinding is also described.

Abstract: The present invention relates to a method of producing a ceramic material comprising the steps of; a) mixing a first clay composition silica and a silicate mineral with a second clay composition; and b) firing the mixed clay composition from step a)to form a ceramic product. The present invention also relates to an engobe clay composition, sanitary ware and methods of productions thereof.

Abstract: The present invention provides refractory materials for the kilns in the cement industry. The refractory material comprises andalusite, silicon carbide, and clay, or kaolinite, silicon carbide, and clay. The refractory materials can be configured as bricks such as fired refractory firebricks or formless configurations such as mortar. The material can be applied to the inside of the kilns to counteract thermal and physical/chemical deformation that occurs inside the kilns.

Abstract: The present invention relates to a decorative refractory tile and it's method of use. This decorative tile utilizes a specially formulated clay body that undergoes dehydration and vitrification by firing in a specific manner with respect to temperature, time and rate of temperature increase. This thin, refractory tile has a high thermal conductivity, high structural strength able to maintain a minimal of cracking, distortion and spalling under rapid temperature changes and possesses a high resistance to erosion from ash-laden gases encountered in a conventional fireplace. This tile can be colored with heat resistant glazes, stains and oxides and sized or shaped within certain dimensional ranges, so as allow it to present patterns, designs or even pictures on the sides, floor and back of the firebox. When this tile is crafted by one with an artistic flair, and affixed to the walls, floor or sides of a firebox, aesthetically favorable fireplaces can be created.

Abstract: This invention concerns a non-basic refractory batch as well as its use.

Abstract: This invention provides a silicon composition comprising at least 15 wt % of hydrolysed silicon compounds and at least 3 wt % of a binder material. The silicon composition is used in the manufacture of ceramics. The hydrolysed silicon compounds can for example be the gel produced by hydrolysing higher boiling point organohalosilanes produced in the manufacture of organohalosilanes or halosilanes by the direct process.

Abstract: The use of a three-component water-soluble polymer comprising 5–90% by weight of a component a), preferably of the maleic acid, fumaric acid or itaconic acid type, 5–90% by weight of a component b) essentially from the group consisting of 2-acrylamido-2-methylpropanesulfonic acid, vinylsulfonic acid and vinylphosphonic acid, and 5–90% by weight of a component c) comprising acrylic acid, methacrylic acid, acrylamide or methacrylamide, as fluidizer for refractory compositions comprising alumina cement is described. The copolymer, which has a preferred molecular weight Mw of <50,000, can also be combined with further quality-improving additives such as silica, lime or soda and further customary additives for refractory compositions.

Abstract: A batch, in particular for the production of refractory shaped bodies, includes a mixture of a refractory, metal oxide main component containing 40 to 60% by weight of Al2O3, a phosphate bond and finely particulate SiC having a grain size of <0.2 mm, and a process using the mixture for forming the batch to produce the refractory shaped bodies.

Abstract: An improved lightweight and highly permeable proppant composition for use in increasing the productivity of a gas or oil well. The proppant composition includes equal amounts by weight of uncalcined bauxite, uncalcined shale and quartz, held together with a binder formed of wollastonite and talc in an amount of less than 10% by weight of the composition. The proppant composition has an alumina content of less than 25% by weight of the composition and a silica content of over 45% by weight of the composition.

Abstract: An article is fabricated with a ceramic surface having a controllable surface finish. In one form, the ceramic is applied as a coating to a substrate article. Preferably, an aqueous coating mixture of phosphoric acid, alumina powder, and cordierite powder is prepared. The mixture is contacted to the surface of the article, and a mechanical overpressure is applied to the external surface of the mixture using a pressing tool. The surface character of the pressing tool, such as a smooth surface or an intentionally patterned surface, is reproduced on the surface of the final ceramic coating. The coating is heated to a moderate temperature to set the ceramic of the coating, and thereafter the coating Is heated to a higher, but still intermediate temperature, to cure the coating.

Abstract: A process is described for producing porcelain, in particular high-strength porcelain and a ceramic insulator. To produce the porcelain, calcined bauxite is used instead of alumina. The simultaneous addition of clay and kaolin, in each case containing more than 5% by weight of foreign metal oxide inclusions, results in a porcelain which, compared to an alumina porcelain of the same mechanical strength, can be produced at significantly lower cost. The porcelain is suitable in particular for applications for highly mechanically loaded components used in electrical insulation.

Abstract: A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride.

Abstract: An economical and environment-friendly process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species is disclosed. The process involves reacting a slurry including an aluminum source and a magnesium source, the aluminum source including two types of aluminum-containing compounds, preferably aluminum trihydrate and/or thermally treated calcined aluminum trihydrate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or it can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.

Abstract: Disclosed is a taphole plugging composition for metal melting apparatus, the composition comprising (a) a refractory aggregate having a maximum particle size of 5 mm or less, (b) graphite and silicon nitride each having a maximum particle size of 0.2 mm or less, (c) a refractory clay, (d) a compatibilized binder mixture comprising a phenolic resin, a ketone compound and a pitch, and (e) an organic fine fiber.

Abstract: The invention relates to a porous ceramic used for producing alkali ion water. The ceramic of the invention includes finely particulate zeolite having an average particle size of 0.1 to 40 &mgr;m and an alkali ion producing material as components. Besides the above components, the invention preferably comprises a fibrous mineral and/or a clay mineral. To produce the ceramic of the invention, a slurry obtained by grinding zeolite by a wet process, a slurry obtained by grinding the alkali ion producing material and the clay mineral by a wet process and a slurry obtained by grinding the fibrous mineral are first mixed and stirred to prepare a mixed slurry. This mixed slurry is then dried and fired to obtain a sintered body.

Abstract: A ceramics dress substrate of the present invention capable of both performances of cutting a cut material with a high accuracy and dressing a diamond cutting grindstone with an excellent cutting property and an reduced wearing amount of the grindstone. This ceramics dress substrate comprises sintering a mixture of ceramics grinding particles and a silicate mineral, The ceramics grinding particles are preferably uniformed and have a scratch hardness ranging from 6 to 10. Alumina grinding particles, silicon carbide and mullite are preferably used as the ceramics grinding particles, and a kaolin mineral, pyrophyllite, montmorillonite, sericite, talc and chlorite are preferably used as the silicate mineral. The ceramics dress substrate is preferably coated with glass.

Abstract: A large-format fireclay refractory brick for use as bottom block in a tin bath and a method for its manufacture, said brick formed of material of the Al2O3—SiO2 system filling material and opening material. The preferred embodiment of the brick has an upper and a lower layer with the filling and/or opening material contained only in the lower layer. The brick has an open porosity of 20 to 25 percent by volume, a gas permeability of less than 3 nPm and an H2-diffusion of less than 150 mm H2O, resulting in a brick with improved resistance to alkali attack and decreased caloric conductivity.

Abstract: This invention is directed to ceramic metal composite useful as a refractory and having improved abrasion, corrosion, and oxidation resistance. The ceramic metal composite of the present invention is comprised of ceramic refractory aggregate, metal particulate, and a nonaqueous binder wherein the ceramic refractory aggregate, metal particulate, and binder residuals react to form a three-dimensional ceramic-metal matrix. The ceramic-metal matrix is further stabilized by bonds between the metal particulate, reaction products of the metal particulate, and the ceramic refractory aggregate.

Abstract: Inorganic media for barrel finishing produced by sintering a media green body formed from a mixed material comprising clay fine grains as a binder, abrasive grains and aluminum hydroxide fine grains as a brittleness imparting agent. The inorganic media is excellent in finishing performance, with which rough finishing can be conducted by dry barrel finishing.

Abstract: A red brick comprising waste foundry sand of 30.about.50 wt %, dusts of 5.about.10 wt %, and a remainder of clay. The waste foundry sand and dusts can be efficiently recycled, and the quantity of the sand used, the supply of which sand which is nearly exhausted, can be reduced. The heating temperature in the red brick manufacturing process is remarkably lowered, and the economical efficiency of the manufacturing process is improved greatly by using iron oxide included in dusts, instead of a chemical compound to obtain desired color.

Abstract: A ceramic and method of producing the same are disclosed, the ceramic having as principal ingredients natural zeolite and shells, wherein silver nitrate, magnesium oxide, potassium oxide, sodium oxide selenium oxide and ferric oxide are added thereto, and the resultant mixture fired to produce a granular ceramic. The granular ceramic enables the production of deoxidized water having an appropriately low oxidation reduction potential, for use as drinking water and the like.

Abstract: A granular ceramic is prepared by firing a powder of a natural zeolite mineral, a pre-fired powder composed of shell fragments, a pre-fired powder of a silica-alumina mineral, and a copper oxide powder. When used as a fuel additive, the ceramic makes it possible to improve the combustion efficiency of hydrocarbon oils, especially of petroleum products such as gasoline, gas oil kerosene, and heavy oil, as well as to reduce CO.sub.2 and NO.sub.x emissions in exhaust gases discharged during combustion.

Abstract: A composition suitable for admixture with refractory grains to make a refractory monolithic formulation, consisting essentially of:2 to 10 parts by weight of activated alumina;0.25 to 1.0 parts by weight of an additive material which comprises at least one of an alumino-silicate-phosphate compound; a resin derived from an aldehyde and either an amine or an aromatic hydroxy compound; cellulose; polyethylene glycol(s); and methoxy polyethylene glycols;0 to 50 parts by weight of fine alumina;0 to 10 parts by weight of fine silica;0 to 1 parts by weight of a dispersant; and0 to 1 part by weight calcium aluminate cement.

Abstract: A synthetic clay for ceramics is formed of 30-65 wt % of amorphous silica, 30-65 wt % of alumina trihydrate, and 2-20 wt % of at least one element selected from a group consisting of sepiolite, palygorskite, and bentonite. The clay may have a slurry form, partially dehydrated form, or mass or dry powder. The synthetic clay is comparable or even superior to natural clay in plasticity, water retentivity and capability of forming water film. The synthetic lay is useful for ceramic industry or pottery.

Abstract: A colored refractory material for lining an instrument/apparatus used at a high temperature is formed by mixing a powder of a raw material containing ceramics with a coloring agent and kneading with a liquid using a binder. The refractory material is put in lining for a portion being in contact with a high temperature molten substance or being exposed to a high temperature atmosphere, and is dried by heating while adjusting a temperature and a heating time on the basis of color change on the surface of the refractory material.

Abstract: A ceramic kiln-fired product which comprises glass, fly ash, and a clay binder. Further provided is a method for preparing raw material suitable for forming a shaped, kiln-fired, ceramic product. The method comprises mixing glass, fly ash, and a clay binder with from about 10 wt. % to about 15 wt. % water, on a dry weight basis, to form an aqueous mixture, separating the aqueous mixture using a mesh of from about 10 to about 12 screen into first and second portions, the first portion comprising the aqueous mixture which does not pass through the mesh and the second portion comprising the aqueous mixture which passes through the mesh, and drying the second portion until the moisture content of the second portion is less than about 0.5 wt. % to form the raw material. The present invention also provides a tile glazing formulation which may be used with the ceramic product of the present invention, as well as a method of using the formulation. The glazing formulation comprises, on a dry weight basis, about 70 wt.

Abstract: This method comprises injecting a first primary plugging mass (4), mixed with a binder, having given composition and physico-chemical properties, and allowing this primary mass to thermically solidify; after a baking of this primary mass, drilling a hole (8) of a given length and thereby achieving a degassing, and injecting in this hole a second plugging mass, termed secondary mass, having suitable composition and physico-chemical properties which is mixed with a binder and is more fluid than the primary mass and has a hardening speed lower than the hardening speed of the primary mass, so that the secondary mass can diffuse into cracks in the primary mass before solidifying. The secondary mass reinforces the zones of the primary mass which have been rendered fragile by microcracking, and thereby again provides a suitable length of the tapping hole.

Abstract: There is disclosed a process for preparing porous ceramic granules, comprising(a) preparing a foam from an aqueous mixture of a particulate aluminosiliceous material and a fluxing material;(b) dividing the foam into discrete particles to form granules; and(c) calcining the granules at an elevated temperature such that sintering of the aluminosiliceous particles occurs.

Abstract: A superduty fireclay refractory brick with at least 33 to 43 per cent by weight Al.sub.2 O.sub.3 and 1 to 3 per cent by weight alkali oxide for use as a large-format bottom block in a solder plating bath in furnaces for manufacturing flat glass according to the float technique has a compressive strength of 35 to 60 N/mm.sup.2 and a gas permeability of less than 4 nPm. The brick possesses an open porosity of approx. 20 to 25 per cent by volume, a gas permeability of less than 3 nPm, preferably 0.5 to 2 nPm, and a hydrogen diffusion of less than 150 mm H.sub.2 O, preferably 30 to 100 mm H.sub.2 O.

Abstract: A vitreous silica-based plastic refractory comprising at least 50 wt. % vitreous silica having a purity of at least 99% silica, a refractory plasticizer, and a bonding system containing an alpha alumina-containing alumina capable of reacting with phosphoric acid to form an aluminum phosphate bond and phosphoric acid.

Abstract: It is disclosed that the properties of a ceramic mullite-kaolinite based passivating coating composition applied as a collar to metal oxide varistor valve block cylindrical surfaces are improved by including in the coating composition from 0.03 to 15% by weight of the coating composition one or more of the following additive compounds: TiO.sub.2 ; Y.sub.2 O.sub.3 ; ZrO.sub.2 ; ZnO; Boroflux (2ZNO.sup.. 3B.sub.2 O.sub.3.sup.. 7H.sub.2 O; or 3ZnO.sup.. 2B.sub.2 O.sub.3.sup.. 5H.sub.2 O); or Si.sub.3 N.sub.4. The coating composition comprises by dry weight a mixture of 55-85% mullite and 15-45% kaolinite, one or a mixture of the above additive compounds, and sufficient water to form a sprayable slurry. The inclusion of the additive compound results in enhanced contact adhesion between the collar and the metal oxide varistor peripheral surface.

Abstract: The occurrence of efflorescence has been reduced or eliminated in ceramic articles formed from a novel vitreously bonded cement-containing composition. The articles also exhibit improved strength, reduced firing shrinkage and increased frost resistance. The articles are produced by combining hydraulic cement containing calcium silicate and/or calcium aluminate components, vitrifiable inorganic powders forming molten liquid-flowing substances, and reactive or sinterable mineral powders selected from the group consisting of magnesium silicates, aluminum silicates and mixtures thereof; combining the ingredients with water to form a mixture; molding the mixture into an article; hardening the article by hydration; and firing the molded article to a maximum temperature of between about 1000.degree. C. to 1400.degree. C.

Abstract: A refractory mix for forming high strength, low thermal conductivity refractory shapes comprising from about 40 to 75% by weight of at least one dense refractory aggregate, about 10 to 30% by weight of a bonding agent, and about 5 to 25% by weight of hollow ceramic microspheres having a diameter of about 1 to 350 microns.

Abstract: It is disclosed that the properties of a ceramic mullite-kaolinite based passivating coating composition applied as a collar to metal oxide varistor valve block cylindrical surfaces are improved by including in the coating composition from 0.03 to 15% by weight of the coating composition one or more of the following additive compounds: TiO.sub.2 ; Y.sub.2 O.sub.3 ; ZrO.sub.2 ; ZnO; Boroflux (2ZnO.multidot.3B.sub.2 O.sub.3 .multidot.7H.sub.2 O; or 3ZnO.multidot.2B.sub.2 O.sub.3 .multidot.5H.sub.2 (O); or Si.sub.3 N.sub.4. The coating composition comprises by dry weight a mixture of 55-85% mullite and 15-45% kaolinite, one or a mixture of the above additive compounds, and sufficient water to form a sprayable slurry. The inclusion of the additive compound results in enhanced contact adhesion between the collar and the metal oxide varistor peripheral surface.

Abstract: An improved casting composition utilizes an aqueous finely dispersed silica binder to provide reduced drying times and reduced cracking and explosion of troughs, runners and other containment equipment designed for use by the iron and steel industry. The composition is prepared by mixing 8-14% by weight of the aqueous silica binder with 55-90% by weight of a refractory base material and up to 35% by weight of silicon carbide. Preferably, the composition will also include 5-10% by weight of calcined alumina, 1-10% by weight of microsilica, and 0.02-1% by weight of a setting agent. Troughs and runners manufactured from the composition also exhibit increased strength and improved resistance to oxidation, corrosion and erosion.

Abstract: A method of producing ceramic composites of Al.sub.2 O.sub.3 reinforced by shaped SiC particles preferably shaped as fine particles (random), platelets, whiskers or fibres by in situ production of SiC particles by heating a mixture of carbon particles of the desired shape with silicates of Al.sub.2 O.sub.3 to a temperature above 1500.degree. C., convert the silicates and carbon to Al.sub.2 O.sub.3 and SiC to produce in situ SiC particles of the desired shape and provide a ceramic powder that may be densified by techniques such as hot pressing, isostatic pressing or sintering.

Abstract: A method of producing ceramic composites of Al.sub.2 O.sub.3 reinforced by shaped SiC particles preferably shaped as fine particles (random), platelets, whiskers or fibres by in situ production of SiC particles by heating a mixture of carbon particles of the desired shape with silicates of Al.sub.2 O.sub.3 to a temperature above 1500.degree. C., convert the silicates and carbon to Al.sub.2 O.sub.3 and SiC to produce in situ SiC particles of the desired shape and provide a ceramic powder that may be densified by techniques such as hot pressing, isostatic pressing or sintering.

Abstract: A thermal storage brick for use with thermal storage heaters comprised of predetermined amounts of crushed taconite pellets, clay and talc. The ingredients are formed into a brick shape under approximately 4000 p.s.i. and are fired at approximately 2150.degree. F. and are allowed to soak for approximately five hours.

Abstract: High strength porcelain having an unglazed bending strength of greater than 1,400 kg/cm.sup.2 and consisting essentially of 22-85% by weight of SiO.sub.2, 10-73% by weight of Al.sub.2 O.sub.3, and 1.5-6.5% by weight of K.sub.2 O and/or Na.sub.2 O. The porcelain has a total degree of crystallinity of more than 40% by weight, and a crystalline grain size of not greater than 20 .mu.m, and it is free from defects of larger than 40 .mu.m. The porcelain is produced by pulverizing a starting material mixture of quartz-feldspar-alumina system so that 85-95% by weight of particles thereof have a grain size of not greater than 10 .mu.m, calcining the mixture, adding clay-mineral material therein, pulverizing so that the clay-mineral-added mixture contains less than 85% by weight of particles with a grain size of not greater than 10 .mu.m, forming, drying, and firing at 1,100.degree.-1,400.degree. C.

Abstract: A ceramics-based manufacturing material and a coating material are disclosed, both of which are used in high-temperature structures and applications. The ceramics-based manufacturing material may be used for building structural blocks or members, such as refractory bricks, that require the mechanical strength and thermal resistance when they are exposed to the high temperatures of 1,500.degree. C. or above. Those bricks made of the material disclosed provides the mechanical strength and heat resistance better than the conventional ones. The coating material may be used for forming a thermal resistant layer on metal or other material bases. Both materials have substantially the similar compositions, either of which may have the alternative use, such as the manufacturing material or the coating material. Simply adding an appropriate amount of water to either makes it a coating material. In either case, the requirements for the high temperature resistance and mechanical strength can be satisfied.

Abstract: A two-phase ceramic particulate useful as a proppant in hydraulic fracturing operations is provided which comprises a vitreous matrix phase containing a crystalline alumina phase. The new ceramic particles are characterized by:(i) a concentration gradient of alumina which increases from very low in the center to relatively high near the surface of the particles;(ii) a fired density less than about 2.9 g/cc; and(iii) closed cell microporosity.Certain embodiments of the inventive ceramic particulate are also characterized by a Krumbein roundness of at least 0.8 and are chemically stable.The ceramic is made by a process comprising the steps of:a. mixing and pelletizing, with the aid of water, the dry raw materials including a mineral particulate such as nepheline syenite and a binder such as bentonite;b. drying the wet pelletizer product;c. mixing the dried pellets with a parting agent; andd.

Abstract: A refractory composition for use in contact with molten aluminum alloys containing a refractory aggregate, a binder and 9Al.sub.2 O.sub.3.2B.sub.2 O.sub.3. The aluminum borate may be of the type produced as a by-product in the production of ferro-boron alloys and known as aluminum boron slag.

Abstract: Aggregate-containing products bonded by an aluminosilicate hydrogel are disclosed. A system of two-part mixing and blending of binder components with various granular-like aggregates, modifiers and/or fillers is described in which the resulting compositions are temporarily fluid and formable for short, controllable periods of time but which thereafter become strong, rigid, adherent, erosion resistant composites, requiring little or no external heat supply to achieve full set. The compositions can be formulated for molding on suitable forms or patterns, and may also be prepared in slurry form suitable for spray coating or sealing applications. A wide variety of products can be manufactured of the compositions, including investment molds and cores for foundry use, as well as non-foundry products such as heat and electrical insulators, construction blocks, panels, coating slurries, etc. which may be of essentially solid or foamed (cellular) construction.

Abstract: Granular compositions are disclosed for use in preparing hard, water and erosion-resistant, shapes such as foundry molds and cores, that are self-setting under ambient atmospheric conditions to allow such shapes to be stripped from patterns on which they are formed, such pattern stripping being possible immediately after forming in the case of foundry cores and the like, and within controllable pattern strip times as low as 60 seconds for foundry molds. The shapes may be used without baking and, in the case of foundry molds and cores, are ready for casting molten metal within as little as one hour. Molds and/or cores free of organic materials can be formed with the novel compositions, providing essentially carbon-free surfaces at the mold-metal interface, as well as being free of other deleterious elements such as sulfur, phosphorus and boron, thereby avoiding alloy composition alteration at the interface due to migration during casting.

Abstract: A method of manufacturing a grate for support of combustible solids comprises mixing a kaolin-type clay with water and a small percentage of stainless steel needles, pouring the mixture into a prepared mold, allowing the mixture to harden, drilling holes through the hardened mixture for the purpose of allowing air to pass therethrough, and curing the hardened mixture at an elevated temperature. The curing of the hardened mixture is preferably accomplished by increasing the temperature gradually to a maximum of 2,000.degree. F. and slowly decreasing the temperature to an ambient temperature.