Abstract: Foundry sand cores are produced by a method comprising the steps of:(1) providing a core box to contain the core(2) injecting into the core box a mixture of sand and a binder capable of being cured by means of carbon dioxide gas so as to form the core(3) passing carbon dioxide gas under pressure into the core box so as to fill the core box(4) holding the core in contact with the carbon dioxide gas so as to cure the binder(5) releasing the pressure and allowing carbon dioxide gas to escape from the core box and(6) removing the cured core from the core box.The method can also be used to produce moulds and is of particular use in the production of cores or moulds from a mixture of sand and a binder consisting of an alkaline aqueous solution of a phenol-formaldehyde resin and an oxyanion such as borate capable of forming a stable complex with the resin.

Abstract: There are disclosed methods and compositions for room temperature hardening of phenolic resole resin refractory compositions containing a magnesium oxide hardening agent alone or together with an organic ester. The resin is a low viscosity, low molecular weight resin having a high free phenol content. The magnesium hardening agent has a surface area of at least 20 square meters per gram. The compositions provide adequate working times and room temperature hardening within 24 hours.

Abstract: The present invention provides methods for treating reclaimed sand obtained from dismantled foundry molds and cores which contain residue from a cured binder of an ester-cured alkaline phenolic resin. Treatment of the reclaimed sand with a silane solution containing one or more amines, particularly an aqueous solution containing a silane and one or more amines, enhances the tensile strengths of foundry molds and cores produced therefrom relative to those obtained with untreated reclaimed sand. Methods for producing foundry cores and molds which incorporate such a treatment process are also provided by this invention, as are raw batch formulations.

Abstract: The present invention provides a binder solution having a low solids level which provides improved tensile properties when used with reclaimed sand. This binder solution comprises an alkaline phenolic resin which is cured at ambient temperature with an ester-functional curing agent. Also provided by this invention are raw batch formulations comprising sand, a binder solution having a low solids level, and a curing agent. These raw batch formulations include embodiments wherein the low solids levels are obtained by the separate addition of a solvent. The methods for producing foundry molds and cores of this invention included those procedures wherein dilution water is used to reduce the solids contents of conventional, relatively high solids content binder solutions.

Abstract: A process for improving the flowability of resin coated sand which comprises the use of a flow promoter with the mixture of sand and resin. Also provided is a foundry mix comprising foundry sand, a resin binder and the flow promoter, as well as a process for making foundry cores and molds using the foundry mix. The resins are ester-curable alkaline phenolic resole resins. The flow promoter is selected from the group consisting of fatty acids, fatty alcohols, fatty amines, fatty amides and fatty alkanolamides.

Abstract: A raw batch composition for use in making a shaped article such as a foundry shape or refractory article is disclosed. The composition comprises a mixture of an aggregate material; a phenol formaldehyde novolak resin; a phenol formaldehyde resole resin; and an ester functional curing agent. A shaped article prepared from the composition and processes for making a refractory body or foundry article are also disclosed.

Abstract: A hardener composition for alkaline phenolic resole resin binders which comprises a solution of a benzylic ether resole resin in an ester. Binder compositions comprising this hardener with alkaline phenolic resole resins are further provided as are foundry molding compositions and methods for making foundry cores and molds using the molding compositions.

Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.

Abstract: A sand casting caking agent contains an acid-curable resin and an organosilicon compound of the general formula (I): ##STR1## in which R.sup.1 is hydrogen or an alkyl having from 1 to 6 carbon atoms, R is a substituted or nonsubstituted monovalent hydrocarbon group, Y is an alkoxy group having from 1 to 6 carbon atoms, n is an integer of from 1 to 6 and m is either 0 or 1. Casting molds containing the agent of the present invention exhibit superior moisture resistance.

Abstract: A process for improving the flowability of resin coated sand which comprises the use of a fluorosurfactant with the mixture of sand and resin. Also provided is a resin binder containing a fluorosurfactant and a foundry mix comprising foundry sand, a resin binder and a fluorosurfactant. The resins used are alkaline phenolic resole resins and acid-curable resins.

Abstract: The invention relates to a binder composition comprising a low molecular weight poly (orthomethylolated) phenolic compound which is combined with a phenol formaldehyde novolac resin and cured in the presence of alkali and an organic ester. Low and high density aggregates can be added to the binder to produce foundry or refractory articles. The binder can also be applied, with or without aggregate, to paper, fabrics, or concrete.

Abstract: A hardener composition for alkaline phenolic resole resin binders which comprises a solution of a benzylic ether resole resin in an ester. Binder compositons comprising this hardener with alkaline phenolic resole resins are further provided as are foundry molding compositions and methods for making foundry cores and molds using the molding compositions.

Abstract: This invention relates to a no-bake process for preparing foundry shapes which utilizes polyurethane-forming binders containing selected polyester polyols. The resulting foundry shapes are particularly useful in preparing castings from low melting metals.

Abstract: The invention relates to foundry moulding compositions useful for producing moulds for the manufacture of metal castings wherein the moulds are capable of giving castings with good surface finish without the need for conventional separate blacking applications. A foundry moulding composition of the invention comprises refractory material such as sand, alkali phenol-formaldehyde resole resin solution, carbonifiable material such as styrenated phenol, and an effective amount of an organic ester for hardening the composition. In another embodiment, the invention is a binder composition comprising alkali phenol-formaldehyde resole resin solution and carbonifiable material capable of being hardened by reaction with organic ester. In another embodiment, the invention is a curing additive for a foundry binder comprising carbonifiable material and liquid ester such as gamma-butyrolactone, and the like.

Abstract: The binder serves to produce foundry moulds and comprises a solution (preferably an aqueous solution) of aldehyde reactive phenol substances and gaseous acetals (preferably dimethyl formal) as reaction partners and strong acids, e.g. sulphuric acid and sulphonic acids as a catalyst. The acetal is in this system hydrolysed by the acid, the basic aldehyde being formed, which will react with the aldehyde reactive phenol substance accompanied by cross-linking. The acid serves thereby simultaneously as a cross-linking catalyst. In principle, it is possible to regard as "aldehyde reactive phenol substances" any phenolic compounds which can in the acid range cross-link more or less spontaneously with aldehydes. Preferably, these are resorcinol or resorcinol products, e.g. resorcinol pitch or precondensates formed with a shortfall of aldehyde, e.g. based on resorcinol formaldehyde, phenol resorcinol formaldehyde or resorcinol melamine formaldehyde.To produce foundry moulds, a granular basic moulding material, e.g.

Abstract: A friction material composite especially suitable for an electromagnetic clutch, includes a reinforcing fiber material, optionally an organic filler, an inorganic filler, and a friction and abrasion conditioner bonded together by a thermosetting resin binder. The reinforcing fiber material contains 25 to 35 percent by volume of staple cellulose pulp of not more than 150 .mu.m in fiber length. The organic filler contains 30 to 40 percent by weight of an organic filler material of not more than 840 .mu.m in maximum grain size. The friction and abrasion conditioner contains and 0.5 to 5 percent by volume of aluminum oxide and/or magnesium oxide of not more than 250 .mu.m in maximum grain size. The material composite has a porosity in the range of 15 to 30 percent by volume.

Abstract: An adhesive paste for adhering two or more objects, a composite assembly comprising two or more elements bonded by such paste, and a process for preparing cast metal articles using such paste are provided. The adhesive paste comprises an aqueous solution of a specific alkali phenol-formaldehyde resin and a hardener for that resin, wherein the paste prepared by mixing the resin and hardener has a viscosity, as mixed, in the range of about 1,000 cps to about 15,000 cps. The composite assembly comprises at least two separate elements bonded by the adhesive paste of the invention. The process uses a mold or core assembly having at least two separate elements.

Abstract: An alkoxy-modified phenolic resole resin providing an improved binder for foundry cores and molds. The resin has predominantly ortho-ortho benzylic ether bridges joining the phenolic nuclei in the resin and at least one alkoxymethylene group for every 20 phenolic nuclei.

Abstract: Foundry molds and cores are prepared by using as a binder a phenolic resin in solution in aqueous sodium hydroxide and using an ester to cure the binder. The ester may be incorporated in the mixture prior to shaping, or the ester in gaseous form may be passed through the shaped mixture.

Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.

Abstract: Curable epoxy resin compositions are described which comprise a mixture of an acid curable epoxy resin and a minor amount of an oxidizing agent capable of reacting with sulfur dioxide to form a catalyst for curing said epoxy resin. The curable epoxy resin composition may contain solid particulate materials. The procedures for curing such epoxy resins as well as methods for forming sand cores and molds also are described. Sand cores and molds produced in accordance with the method of the invention have sufficient strength and hardness after a few seconds of curing for normal foundry applications.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: A novel organofunctional silane for use in binding agent compositions employed in foundry sands and the cores and molds made therefrom. The novel organofunctional silane is characterized in that it contains at least one sterically hindered hydrocarbon group and has attached to the silicon atom a nitrogen containing group via a carbon-silicon bond.

Abstract: Polymeric cyclopentadiene derivatives, method for preparing polymeric cyclopentadiene derivatives, and use of polymeric cyclopentadiene derivatives in curable binder compositions.

Abstract: The subject invention relates to modifiers for aqueous basic solutions of phenolic resins. The modifiers are open-chain ether alcohols or ketone alcohols. They assist in stabilizing the aqueous basic solutions of phenolic resole resins and improve the tensile strength of foundry shapes prepared from foundry mixes made with the aqueous basic solutions.

Abstract: A mold material for forming sandmolds for manufacturing metal castings, consisting essentially of an organic binder: 0.4-3.0 percent, a catalyst for curing the organic binder: 0.2-2.0 percent of, a ceramic binder: 0.05-2.0 percent in terms of SiO.sub.2, a catalyst for curing the ceramic binder: 0.05-2.0 percent, and foundry sand: the balance. The mold material can be formed into a sandmold which is excellent in both strength after exposure under a room temperature atmosphere and strength after pouring molten metal thereinto and requires no mold wash or a very small amount of mold wash as obtained by spraying or the like. The mold material may preferably further includes, if required, anti-infiltration fire-proof powder; 0.1-3.0 percent, a high-temperature reinforcing material: 0.1-3.0 percent, a viscosity adjuster: 0.1-2.0 percent, and/or a grannular carbon stabilizer: 0.03-0.5 percent.

Abstract: The subject invention relates to a hot box process for forming foundry shapes. The foundry shapes are formed with a mixture of an aggregate and certain aqueous basic solutions of phenolic resole resins which act as binders. The use of these binders results in foundry shapes which are cured by heating at elevated temperatures without requiring an acid-generating curing catalyst.

Abstract: Molding material composed of casting sand coated with a thermosetting resin and hydrous magnesium silicate clay mineral which may be impregnated with an acid and/or coated with a thermosetting resin, and a shell mold produced from the molding material. This material and mold minimize generation of smoke and irritating gases at the time of mold making and casting.

Abstract: A process for preparing modified phenolic resole resins providing improved binders for refractories and foundry cores and molds. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of an alkaline catalyst followed by further reaction at a pH below 7 in the presence of a catalyst which promotes formation of ortho-ortho benzylic ether bridges between the phenolic nuclei.

Abstract: An additive to foundry sand molding and core aggregates used to produce cores and molds which improves the quality of castings by reducing thermal expansion and gas defects. The additive comprises a composition containing from about 15% to about 95% titanium dioxide (TiO.sub.2). Preferably, the composition of the additive comprises about 2-38% silicon dioxide (SiO.sub.2), about 5-40% ferric oxide (Fe.sub.2 O.sub.3), about 15-95% titanium dioxide (TiO.sub.2), and about 2-45% aluminum oxide (Al.sub.2 O.sub.3).

Abstract: An improved particulate material for use in treating subterranean formations as a proppant and/or as a fluid loss agent in hydraulic fracturing and as a screening material in gravel packing comprised of heat curable particles capable of forming a cohesive mass, said particles comprised of a high strength center, a coupling agent chemically bound to the center with a heat curable resin coated over the center.

Abstract: This disclosure relates to novel desensitized ketone peroxide compositions containing as desensitizing agent 2,2,4-trimethyl-1,3-pentanediol diisobutyrate. It further relates to the use of these compositions in the manufacture of foundry cores or moulds.

Abstract: Refractory shaped articles are prepared by heating refractory mixes comprised of refractory particles and an alkoxy modified phenolic resole resin having at least one alkoxy methylene group for every 20 phenolic hydroxyl groups.

Abstract: A cold-setting foundry binder composition, which provides foundry cores and molds with improved curing speed, comprising a particulate refractory material, a resin binder, an acid curing catalyst, and an accelerator. The accelerator is selected from the group: dihydroxybenzenes, derivatives of dihydroxybenzenes, trihydroxybenzenes, and their mixtures.

Abstract: A monolithic refractory composition having relatively high thermal conductivity and a relatively high degree of water insolubility consisting essentially of, by weight, 50-75% coarse grain flake graphite; 5-30% fine grain flake graphite; and the remainder crude clay; and the addition based upon the total weight of said mix of 10-25% liquid phenolic resin in combination with an alcoholic solvent, and a resin curing agent.

Abstract: Binding agent compositions for inorganic fillers or oxides containing a curable binder such as a hardenable resin, and a ureido-functional organosilicon compound as described. Foundry sand compositions including binding agent compositions as described, sand and a catalyst for the hardenable resin. Shaped products comprising inorganic oxide particles, e.g., sand, a binding agent composition as described and catalyst for the hardenable resin wherein the hardenable resin is in its hardened form. Novel ureido-functional organosilicon compounds having two hydrolyzable or hydroxy groups to the molecule and at least one ureido-functional group in which the ureido group is connected to silicon by means of a group containing at least five carbon atoms.

Abstract: A particulate material adapted to be poured into the opening in the bottom of a top pouring ingot mold, tamped in the opening and then cured therein to form a mold plug is comprising of a plug forming aggregate and first and second binders of thermosetting resinous material having different temperatures at which polymerization of the corresponding resin commences.

Abstract: A disintegration assistant is added to a molding composition made up of foundry sand and a binder whose major part is a condensation-reactive compound or resin having methylol groups in a molecule. The molding composition is formed into a mold and a core by solidifying the resin so that individual grains of the foundry sand are bound each other. The disintegration assistant is mainly made of calcium hydroxide, calcium carbonate, barium hydroxide and/or barium carbonate, thereby promoting the heat deterioration of the resin to improve the disintegration characteristics of the mold and the core.

Abstract: A method for producing an improved particulate material for use in treating subterranean formations as a proppant and/or as a fluid loss agent in hydraulic fracturing and as a screening material in gravel packing comprised of heat curable particles capable of forming a cohesive mass, said particles comprised of a high strength center, a coupling agent chemically bound to the center with a heat curable resin coated over the center.

Abstract: A binder composition containing a phenolic resin in an organic solvent, a polyisocyanate, wherein said organic solvent is substantially free from polar solvents, and methods of making and using the same.

Abstract: A refractory for use in casting of molten metal which essentially comprises refractory material comprising corundum and monoclinic zirconia as principal mineral phase and including Al.sub.2 O.sub.3 and ZrO.sub.2, silicon-containing powder and carbon-containing powder and which optionally includes first additional refractory material comprising mullite, baddellite and corundum as principal mineral phase and including Al.sub.2 O.sub.3, ZrO.sub.2 and SiO.sub.2, one or more second additional refractory materials and/or alumina.

Abstract: Hardenable molding masses are disclosed containing an organic binder material, fillers and additives wherein the binder material after the shaping and hardening is pyrolytically decomposed. The development of harmful substances such as aromatic hydrocarbons is considerably reduced through the addition of a boron containing compound.

Abstract: A method of accelerating the breakdown of phenolic resin bonded cores by means of adding a basic salt of alkali metals in powder form to phenolic resin coated sand is disclosed. The basic salt is selected from the group consisting of alkali metal carbonates, bicarbonates and organic acid salts, and mixtures thereof, and is microcapsulated with plastic.

Abstract: Curable epoxy resin compositions are described which comprise a mixture of an acid curable epoxy resin and a minor amount of an oxidizing agent capable of reacting with sulfur dioxide to form a catalyst for curing said epoxy resin. The curable epoxy resin composition may contain solid particulate materials. The procedures for curing such epoxy resins as well as methods for forming sand cores and molds also are described. Sand cores and molds produced in accordance with the method of the invention have sufficient strength and hardness after a few seconds of curing for normal foundry applications.

Abstract: A refractory composition or mixture utilizing basic aggregates is disclosed which does not discolor when a phenolic binder is used, and provides improved flexural strength. The composition contains specific proportions of phenolic resin and a compound having a pKa of less than 9.5 at 25.degree. C. and basic aggregates.

Abstract: Thermosettable polymeric cyclopentadiene derivatives, method for preparing polymeric cyclopentadiene derivatives, and use of polymeric cyclopentadiene derivatives in curable binder compositions.

Abstract: A phenolic resin for application in foundry shell molding operations having improved properties is disclosed. The phenolic resin is prepared by reacting aldehydes and a mixture of bisphenol A and bisphenol F to prepare a phenolic resin for coating foundry aggregates or sand to prepare shell molds having low thermal expansion and improved shake out properties.

Abstract: A foundry moulding composition comprising (a) a granular refractory material, and (b) from 0.5% to 8% based on the weight of the refractory material of a binder comprising (i) an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50% to 75% and said resin having a weight average molecular weight (M.sub.w) of from 600 to 1500, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.2:1 to 1.2:1 and (ii) at least one silane in an amount of from 0.05% to 3% based on the weight of said aqueous solution, said binder being curable by contact therewith of from 5% to 60% based on the weight of said aqueous solution of a C.sub.1-3 alkyl formate.

Abstract: A foundry moulding composition comprising(a) a granular refractory material,(b) from 0.25 to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50 to 75% and said resin having a weight average molecular weight (M.sub.wr) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1;(c) from 0.05 to 3% based on the weight of said aqueous solution, of at least one silane, and(d) from 20 to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin.

Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.