ЛИТЕЙНАЯ ФОРМА ДЛЯ МОНОКРИСТАЛЛИЧЕСКОГО ЛИТЬЯ

Изобретение относится к области монокристаллического литья, в частности к литейной форме для монокристаллического литья, а также к ее изготовлению и способу вакуумного литья металлического материала с использованием упомянутой литейной формы. Литейная форма содержит литейную полость, содержащую первый объем и второй объем, расположенный на первом объеме в соединении с ним и имеющий по меньшей мере один горизонтальный выступ относительно первого объема, и зерновой канал с нижним концом, соединенным с первым объемом, и с верхним концом, расположенным рядом с указанным горизонтальным выступом второго объема, при этом она включает в себя разделительный элемент, расположенный между указанным вторым объемом литейной полости и верхним концом зернового канала так, чтобы разделять их. Изобретение позволяет создать литейную форму для отливки деталей с большим горизонтальным боковым выступом, соответствующим полке лопатки турбомашины. 3 н. и 6 з.п. ф-лы, 5 ил.

УСОВЕРШЕНСТВОВАНИЯ В СПОСОБАХ И СИСТЕМАХ, ТРЕБУЮЩИХ СМАЗКИ

Изобретение относится к способу передачи смазочного материала от расплавленной способной к формованию массы к части системы. Техническим результатом является повышение эффективности системы, требующей смазки. Технический результат достигается способом передачи смазочного материала от расплавленной способной к формованию массы к части или частям системы, в которой упомянутая расплавленная способная к формованию масса обрабатывается для того, чтобы сформировать формованное изделие. Причем способ включает в себя нанесение смазочной дисперсии, включающей твердый смазочный материал, на упомянутую расплавленную способную к формованию массу перед контактом с упомянутыми частью или частями системы. При этом упомянутая расплавленная способная к формованию масса не является порцией расплавленной стекломассы. 2 н. и 8 з.п. ф-лы.

СПОСОБ И УСТАНОВКА ДЛЯ ИЗГОТОВЛЕНИЯ МЕДНОГО ПОЛУФАБРИКАТА, А ТАКЖЕ СПОСОБ И УСТРОЙСТВО ДЛЯ НАНЕСЕНИЯ ФОРМОВОЧНОЙ КРАСКИ

Изобретение относится к металлургии. Способ изготовления медного полуфабриката включает расплавление меди, отливку в нескольких кокилях 12 в один выпуск медных анодов 14, получение путем электролиза с использованием медных анодов 14 медных катодов 16. На кокили наносят формовочную краску посредством устройства 40. Установка содержит рафинировочную печь 28, вращающийся стол 54 с кокилями 12, электролитическую ванну 30, в которую аноды, отлитые в кокилях, перемещают транспортиром 31. Катоды 16 из ванны 30 подают транспортером 34 к устройству 32 для дальнейшей переработки в медный полуфабрикат. Часть отлитых в кокилях заготовок перерабатывают непосредственно в медный полуфабрикат. Обеспечивается повышение КПД при выплавке меди. 2 н. и 14 з.п. ф-лы, 5 ил.

ЗАЩИТНОЕ ПОКРЫТИЕ ДЛЯ ЛИТЕЙНЫХ МЕТАЛЛИЧЕСКИХ ФОРМ

Изобретение относится к литейному производству и может быть использовано при получении отливок из медных сплавов в металлических формах. Защитное покрытие содержит, мас.%: пылевидный алюмосиликатный цеолит 57-60, анионное поверхностно-активное вещество 0,3-0,8, силиконовый пеногаситель 0,2-0,5, кремнезоль – остальное. Использование в качестве огнеупорного наполнителя алюмосиликатного цеолита обеспечивает повышение седиментационной устойчивости, кроющей способности, адгезионной прочности и создает тиксотропную структуру защитного покрытия, что позволяет повысить качество получаемых отливок за счет снижения количества газовых раковин, пригара и засоров. 2 з.п. ф-лы, 2 табл., 3 пр.

Способ нанесения разделительного покрытия на внутренних поверхностях вращаемой изложницы

Изобретение относится к литейному производству, в частности к центробежному литью. Способ нанесения разделительного покрытия на внутреннюю поверхность вращаемой в горизонтальной плоскости изложницы с применением покрасочного устройства включает нанесение краски посредством покрасочной трубы с распылительной форсункой на внутреннюю поверхность предварительно нагретой до 190-200°С изложницы. Используют цирконо-бентонитовую краску с вязкостью по вискозиметру 10-12 с, подачу которой производят под давлением 0,10-0,15 МПа. Распылительная форсунка через шланги с краской и сжатым воздухом, соединенные с баком готовой краски, распыляет краску в виде конусообразной струи на внутреннюю поверхность изложницы по направлению ее вращения, при этом покрасочная труба с распылительной форсункой совершает возвратно-поступательное движение со скоростью 0,08-0,10 м/с, распыляя краску по длине изложницы. Обеспечивается получение заготовок с чистой поверхностью без пригара и с минимальным припуском на механическую ...

ПРОТИВОПРИГАРНОЕ ПОКРЫТИЕ ДЛЯ ЛИТЕЙНЫХ ФОРМ И СТЕРЖНЕЙ

Изобретение относится к области металлургии и может быть использовано для покрытий литейных форм и стержней. Противопригарное покрытие содержит, мас.%: алюмохромфосфатное связующее - 12-15, лигносульфонат технический - 0,2-5,0, бентонит - 0,5-3,5, декстрин - 0-4, лейкоксеновый концентрат - 55-60 и воду. Диоксид титана, входящий в состав огнеупорного наполнителя – лейкоксенового концентрата, химически инертное вещество, обладающее высокой огнеупорностью и не претерпевающее полиморфных превращений при нагреве. Лигносульфонат технический улучшает смачиваемость формовочной смеси и упрочняет ее поверхностный слой. Декстрин совместно с бентонитом увеличивают структурирование покрытия и тем самым повышают его седиментационную устойчивость. Обеспечивается получение отливки с чистой поверхностью за счет повышенной термостойкости и трещиноустойчивости противопригарного покрытия. 2 табл.

Противопригарная краска для литейных форм и стержней

Изобретение относится к области литейного производства и может быть использовано для получения отливок из чугуна и стали. Противопригарная краска для литейных форм и стержней содержит цирконовый концентрат, бентонит и воду, при этом она дополнительно содержит соединение оксиэтандифосфонат оксида бора состава 4С2Н8О7Р2⋅В2О3⋅2Н2О при следующем соотношении компонентов, мас. %: цирконовый концентрат 60-70; бентонит 1-3; оксиэтандифосфонат оксида бора 8-10; вода остальное. Технический результат - улучшение технологических и эксплуатационных характеристик. 2 табл.

Способ модифицирования и легирования отливок при формообразовании литьем по газифицируемым моделям

Изобретение относится к области литейного производства, а именно к технологии изготовления отливок методом литья по газифицируемым моделям, и может быть использовано для получения модифицированных или легированных отливок из металлических сплавов. Осуществляют изготовление моделей и элементов литниково-питающей системы из пенополистирола, введение модифицирующих или легирующих добавок, сборку в модельные блоки посредствам крепления элементов литниково-питающей системы с последующим окрашиванием собранных модельных блоков противопригарным покрытием, их сушку и заливку полученных модельных блоков металлическим расплавом. В элементах литниково-питающей системы, прилегающих к модели, предварительно изготавливают технологические углубления, в которые вводят модифицирующие или легирующие добавки. Изобретение позволяет повысить универсальность получения отливок различной конфигурации без усложнения технологического процесса изготовления моделей. 6 з.п. ф-лы, 1 ил.

СОСТАВ ДЛЯ ПРИГОТОВЛЕНИЯ ПРОТИВОПРИГАРНОГО ПОКРЫТИЯ ДЛЯ ЛИТЕЙНЫХ ФОРМ И СТЕРЖНЕЙ И ПРОТИВОПРИГАРНОЕ ПОКРЫТИЕ НА ЕГО ОСНОВЕ

Изобретение относится к области литейного производства. Состав для приготовления противопригарного покрытия, представляющий собой сухую смесь, включает, мас.%: 20-28 графита скрытокристаллического, 22-30 сахара в качестве органического водорастворимого связующего и 45-55 шамотной глины. В качестве сахара используют сахарозу или глюкозу, или фруктозу, или столовый сахар. Для приготовления противопригарного покрытия в сухую смесь добавляют воду в количестве 50-500 мас.% от массы сухой смеси. Обеспечивается увеличение седиментационной устойчивости покрытия на основе заявляемого состава при повышении прочности слоя покрытия к истиранию, что способствует получению отливок без пригара. 2 н. и 4 з.п. ф-лы, 1 табл.

Противопригарное покрытие для литейных форм и стержней

Изобретение относится к области литейного производства. Противопригарное покрытие для литейных форм и стержней содержит, мас.%: триортоборатэтилендиамин состава 3Н3ВО3⋅С2Н8N2 – 10-14, скрытокристаллический графит – 40,0-50,0, бентонит – 2,0-3,0, вода – остальное. Введение в состав противопригарного покрытия триортоборатэтилендиамина позволяет повысить его седиментационную устойчивость, увеличить прочность к истиранию, уменьшить вязкость покрытия и, тем самым, увеличить толщину проникающего слоя, улучшить кроющую способность и, тем самым, получить поверхность покрытия без наплывов, что позволяет уменьшить шероховатость поверхности полученных отливок. Обеспечивается повышение качества поверхности отливки. 2 табл.

Способ получения огнеупорной оболочковой формы с использованием солевых моделей

Изобретение относится к области литейного производства. Способ получения огнеупорной оболочковой формы на готовом водном связующем с использованием водорастворимых солевых моделей для литья по растворимым моделям включает нанесение покрытия на поверхности водорастворимых солевых моделей, обеспечивающего смачивание поверхности модели и предотвращающего растворение модели в водной облицовочной суспензии. Поверхности модели покрывают равномерным слоем неводорастворимой восковой массы, используемой для получения выплавляемых моделей, толщиной 0,1-0,2 мм. Используют раствор восковой модельной массы в объеме 3-10 г на 100 мл растворителя, в качестве которого используют бензин Калоша. Сушку каждого слоя производят при комнатной температуре до полного испарения растворителя. Обеспечивается высокая геометрическая точность и качество формообразующей поверхности.

Состав разделительного покрытия для литейных металлических форм

Изобретение относится к литейному производству и может быть использовано для окрашивания литейных металлических форм, предназначенных для литья цветных металлов и сплавов. Состав разделительного покрытия для литейных металлических форм включает наполнитель, содержащий тальк и пылевидный кварц, связующее в виде жидкого стекла и воду. Наполнитель дополнительно содержит доломит, алюмосиликаты щелочных и щелочноземельных металлов и красный шлам, при этом покрытие содержит компоненты при следующем соотношении, мас. %: доломит до 5; тальк до 10; алюмосиликаты щелочных и щелочноземельных металлов до 10; красный шлам до 1; пылевидный кварц до 5; жидкое стекло 5-15; вода – остальное, причем наполнитель имеет фракцию 0,25 мм. Покрытие характеризуется высокими значениями седиментационной устойчивости, кроющей способности. 1 з.п. ф-лы, 1 табл., 1 пр.

Противопригарная краска для литейных форм и стержней

Изобретение относится к литейному производству, в частности к противопригарным термостойким краскам для песчаных и других литейных форм и стержней, наносимых на внутреннюю поверхность, и может быть использовано при получении стальных отливок. Противопригарное покрытие содержит, мас.%: огнеупорный наполнитель в виде отработанного алюмосиликатного катализатора ИМ-2201 64,2-65,0, неорганическое связующее в виде бентонита 0,70-1,00, органическое связующее в виде декстрина 1,65-2,00, вода - остальное. Технический результат: создание качественной противопригарной краски для литейных форм и стержней с высокой седиментационной устойчивостью, кроющей способностью, обеспечивающей отсутствие пригара на отливках. 2 табл.

Противопригарная краска для литейных форм и стержней

Изобретение относится к литейному производству. Противопригарная краска для литейных форм и стержней содержит, мас.%: метакаолин 18-22, в качестве наполнителя - цирконовый порошок 28-31, а в качестве связующего – бентонит 2,5-4,5 и декстрин 1,3-1,7 и воду. Обеспечивается высокая седиментационная устойчивость краски, улучшается кроющая способность и обеспечивается отсутствие пригара на отливках. 2 табл.

СПОСОБ СУШКИ ВОДНЫХ ФОРМОВОЧНЫХ КРАСОК

... 1. Способ сушки покрытия на основе воды, включающий ! а) получение покрытия на основе воды, ! b) нанесение покрытия на основе воды по меньшей мере на часть поверхности литейной формы, ! c) возможно частичное или полное матирование нанесенного покрытия на основе воды, причем в зависимости от прошедшего времени часть жидкости-носителя покрытия переходит в подложку, ! d) нанесение горючей жидкости на возможно матированный слой покрытия на основе воды и ! e) полное сгорание горючей жидкости, ! причем высушенный слой покрытия, полученный после полного сгорания горючей жидкости, имеет остаточную влажность менее 8%, определенную по карбидному методу Ридель-де-Хайена, Зеельце. ! 2. Способ по п.1, где на стадии b) покрытие на основе воды наносят по меньшей мере на часть поверхности литейной формы без покрытия. ! 3. Способ по п.1, где на стадии b) покрытие на основе воды наносят по меньшей мере на часть грунтовочного слоя, предварительно нанесенного по меньшей мере на часть поверхности литейной формы ...

ТРЕХКОМПОНЕНТНАЯ СИСТЕМА СВЯЗУЮЩЕГО НА ОСНОВЕ ПОЛИУРЕТАНА

КОМПОЗИЦИЯ ПОКРЫТИЯ ДЛЯ ЛИТЕЙНЫХ ФОРМ И СТЕРЖНЕЙ, ПРЕДУПРЕЖДАЮЩАЯ ОБРАЗОВАНИЕ ДЕФЕКТОВ ОТ РЕАКЦИОННЫХ ГАЗОВ

... 1. Формовочная краска, содержащая по меньшей мере: ! - одну жидкость-носитель; ! - по меньшей мере один порошкообразный огнеупорный материал; и ! - по меньшей мере один восстановитель. ! 2. Формовочная краска по п.1, отличающаяся тем, что восстановитель является углеродсодержащим соединением. ! 3. Формовочная краска по п.2, отличающаяся тем, что углеродсодержащее соединение является источником образования пироуглерода. ! 4. Формовочная краска по п.3, отличающаяся тем, что источник образования пироуглерода имеет содержание кислорода менее 10 мас.%. ! 5. Формовочная краска по п.3, отличающаяся тем, что источник образования пироуглерода выбран из группы, состоящей из угольных материалов и углеродсодержащих полимеров. ! 6. Формовочная краска по п.5, отличающаяся тем, что угольный материал является каменным углем. ! 7. Формовочная краска по п.5, отличающаяся тем, что углеродсодержащий полимер выбран из полистирола и сополимеров полистирола. ! 8. Формовочная краска по п.1, отличающаяся тем, что ...

Verfahren zum Verfestigen der Oberflaechen von getrockneten Sandformen

Schlichtezusammensetzung für die Gießereiindustrie, enthaltend partikuläres, amorphes Siliziumdioxid und Säure

Es wird eine Schlichtezusammensetzung beschrieben, zur Verwendung in der Gießerei, insbesondere umfassend partikuläres, amorphes Siliziumdioxid (SiO) und eine wässrige Phase mit einem pH-Wert von höchstens 5, sowie geschlichtete, wasserglasgebundene Gießereiformkörper, insbesondere geschlichtete, wasserglasgebundene Gießereiformen und Gießereikerne, welche jeweils eine erfindungsgemäße Schlichtezusammensetzung umfassen. Weiter wird beschrieben die Verwendung einer erfindungsgemäßen Schlichtezusammensetzung zur Herstellung eines Überzugs auf einem wasserglasgebundenen Gießereiformkörper und ein Verfahren zur Herstellung eines mit einer wasserhaltigen Schlichte geschlichteten wasserglasgebundenen Gießereiformkörpers (Form oder Kern). Ebenfalls wird angegeben ein Kit, u.a. enthaltend eine erfindungsgemäße Schlichtezusammensetzung.

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Formueberzug fuer Dauerformen

Verfahren zum Herstellen eines Gußteils

Verfahren zum Herstellen eines Gußteils aus einer Leichtmetallegierung, wie beispielsweise eine Aluminiumlegierung, welches Gußteil wenigstens einen Metalleinsatz C ausweist, bei dem auf eine Fläche des Einsatzes, die dazu bestimmt ist, mit der Legierung des Gußteils in Kontakt zu kommen, ein Überzug aus Gasruß angebracht wird und das Gußteil mit der geschmolzenen Legierung in einem Formhohlraum gegossen wird, in dem der Einsatz angeordnet ist. Dieses Verfahren kann insbesondere bei der Herstellung von Motorblöcken mit eingesetzten Laufbüchsen aus Gußeisen angewandt werden.

Schlichte zur Herstellung von Formüberzügen

Graphitueberzug fuer feuerfeste Giessformen und Verfahren zu seiner Herstellung

Producing wear-resistant coating on casting mould

A casting mould substrate (1) of Cu (alloy) is coated with a wear-resistant layer (2) containing hard particles of WC based material of size 5-53 mm. The spraying process is a high pressure, high speed, oxygen, fuel process which ensures that the partially non-melted particles are partially embedded in the substrate surface. The coating has a thickness of 0.01-6 mm.

Beschichtungsmassen für anorganische Gießformen und Kerne umfassend Ameisensäureester und deren Verwendung

Gegenstand der Erfindung sind Beschichtungsmasse umfassend Ameisensäureester, eine wässrige Trägerflüssigkeit und pulverförmige Feuerfeststoffe sowie deren Verwendung für Gießformen, insbesondere solche die unter Verwendung von Wasserglas als Bindemittel hergestellt werden.

Neue isolierende Schicht für Metallform und Verfahren zur Herstellung einer solchen Schicht

Verfahren und Vorrichtung zur Instandsetzung von Behaeltern fuer geschmolzene Metalle

Verfahren zum Aufbringen einer Schlichte aus einer Aufschlaemmung hitzebestaendiger Teilchen und hierfuer verwendete Schlichte

Methylpolysiloxanoles as mould release - compound

Liquid methylpolysiloxanoles having an average mol. wt. of 1000-10000 and a SiOH equiv. wt. of 250-1000 in which the polysiloxane structure is composed of 2.5-25 mol % tri-functional and 75-97.5 mol % bi-functional Si units, are used as mould release agents in the manufacture of casting moulds from heat-setting synthetic resin and sand.

Method and apparatus for blow moulding hollow articles

... 947,420. Blow moulding hollow articles. R. HAGEN, [trading as KAUTEX-WERKE REINOLD HAGEN]. Sept. 12, 1961 [Sept. 12, 1960], No. 32765/61. Heading B5A. After moulding and cooling a blow moulded article 20, relative movement between said article 20 and a stripper device detaches the flash therefrom. The flash 22 on the shoulder of the bottle and the annular flash 23 around the neck may be detached by one of the following: (1) Two two-pronged forks 25a, 25b which grip the flash 22 and accommodate the mandrel 15 and bottle neck between them. A greater force is applied to the longer prongs 25a so that both prongs move to the left as in Fig. 9 and remove the flash. The movement of the prongs may be at right angles to the movement of the mould 14 and the mandrel 15 is rotatable about a longitudinal axis as in Fig. 17 (not shown). (2) Pincers 75a, 75b, 76a, 76b grip the flash 22 and move apart to split the flash 23 along two indentations 31 formed in the flash 23 during moulding (Fig. 28). (3) ...

PROCESS FOR THE MANUFACTURE OF SILICON MOULDINGS

... 1445861 Casting silicon WACKER-CHEMITRONIC GES FUR ELEKTRONIKGRUNDSTOFFE mbH 4 Sept 1973 [8 Sept 1972] 41439/73 Heading B5A A process for the manufacture of silicon mouldings comprises casting a silicon melt into a mould having a moulding surface consisting of one or more substances selected from graphite, sintered quartz wool, sintered quartz sand, and sintered silicon nitride, either in vacuo or under an inert gas atmosphere, the temperature of the mould being such that when the silicon melt contacts the moulding surface a solid layer of silicon immediately forms thereon. In the apparatus shown, a hollow silicon article is produced in a two part mould comprising a convex part 5 of graphite having a surface 7 of silicon nitride and a concave part 6 of graphite having a surface layer of sintered quartz wool or sand. The silicon is melted in a quartz crucible 1 before being poured into the mould via a funnel 3.

COATING OF METAL CASTINGS MOULDS/CORES

Method of and device for preparing the interior surface of foundry receptacles

... 1,145,147. Moulds; blasting. H. J. DAUSSAN. 16 Aug., 1966 [25 Aug., 1965]. No.36532/66. Headings B3D and B3F. [Also in Division B2] In the preparation of the inside surfaces of foundry receptacles 2 such as moulds, tundishes &c., particles are projected on to the surface 1 by a centrifugal blaster 11, the waste particles are sucked out by a nozzle 56 and then a coating is applied to the surface 1 by the same centrifugal blaster 11 which may also be used to air dry the said coating. Reservoirs 16, 17 contain the particles and the coating material and valves 39, 41 allow access to an air blown conduit 33, 35, 36 fed from a compressor 42. The particles may be abrasive silicaceous grains, waste or casting splinters, crushed metal turnings, grains of cast iron or silica or preferably steel balls of 5-7 mm. in diameter. The coating may include whitewash layers such as milk of lime or tar. Also the dust of the particles and worn particles may be mixed with an aqueous solution of silicates or resins ...

Protective barriers in ceramic dies

MOULD TREATMETN

... 1344834 Mould treating compositions IMPERIAL CHEMICAL INDUSTRIES Ltd 7 June 1971 [30 June 1970] 31585/70 Heading C5F The surface of a mould is treated by application of a composition comprising (1) a halogencontaining complex phosphate of aluminium containing at least one chemically-bound molecule of R-OH where R is H or an organic group, and (2) a dispersant for the complex phosphate. The complex phosphates, described generally in Specifications 1,322,722 and 1,322,724, are exemplified by AlPClH 25 C 8 O 8 (designated "aluminium chlorophosphate ethanolate"), AlPClH 11 O 9 (designated "aluminium chlorophosphate hydrate"), and AlPBrH 25 C 8 O 8 (designated aluminium bromophosphate ethanolate). The term "phosphate" includes acid phosphates and phosphate esters. The "R" is suitably aliphatic hydrocarbon or aliphatic hydrocarbon substituted by amino, phenyl, hydroxyl, carboxyl or alkoxy groups. The complex phosphates may be monomeric or polymeric. The dispersant (2) may be a solvent for the ...

Method of coating a mould cavity with release agents

Low pressure die casting powdery mold releasing agent

A low pressure die casting mold releasing agent comprising a mixture of a mold releasing base material, which is an inorganic compound, with an organic compound, at least the mold releasing base material being of powdery or granulated form. This mold releasing agent allows production of castings of high quality, with good workability and without adversely affecting environmental situations.

IMPROVEMENTS IN OR RELATING TO MOULD RELEASE AGENTS

... 1,220,381. Mould release silicone compositions. STAUFFER-WACKER SILICONE CORP. 5 Feb., 1968, No. 6696/68. Heading C3T. [Also in Division B2] A mould release composition comprises (a) 90-98 wt. per cent of a substantially hydroxylfree liquid organopolysiloxane; (b) 2-10 wt. per cent correspondingly, to total 100%, of a polymer obtained by hydrolysis of a mixture of mono- and/or di-alkyl silanes having at least two halogen atoms or alkoxy, aryloxy or amino radicals per silicon atom, to 40-70% of theoretical completion, and (c) 4 wt. per cent of (b) of a metal carboxylate or tetraoctyl titanate. In examples, a mixture of methyltrichlorosilane, dimethyldichlorosilane and propyltrichlorosilane is hydrolysed with a methanol/water mixture in xylene to give a polysiloxane containing some hydroxyl and methoxy groups, which is mixed in xylene solution with tetraoctyl titanate, and optionally CH 2 Cl 2 , and a methyl-terminated polydimethylsiloxane or a mixture of two such polydimethylsiloxanes or ...

An improved blacking for moulds for metal castings

... 263,285. Todd, H. Dec. 8, 1925. Mould materials.-Blackings for moulds comprise powdered carbon-containing material with a binder such as plaster of Paris. For instance 96 per cent by volume of ground coke dust may be mixed with 4 per cent of plaster, or 90 per cent coke dust and 5 per cent plaster with 5 per cent soapstone, or 62 per cent coke dust and 5 per cent plaster with 33 per cent sillimanite. The ingredients may be ground, separately or together,. so as to pass a <1>/120 inch mesh in the dry state and may be soused to face permanent moulds or dry sand or loam but the blacking is preferably applied mixed with clay-wash. Other aluminium silicates may be used in place of the sillimanite and if desired with soapstone.

Recovery of refractory aggregates from used casting moulds

... 962,683. Treating mould and core materials. AVNET-SHAW PROCESSES Ltd. May 21, 1963 [June 4, 1962], No. 21503/62. Heading B3F. A method for recovering refractory aggregates from used casting moulds in which acidified sodium silicate or ethyl silicate have been used as binders comprises soaking the used mould in water until it disintegrates, dewatering the disintegrated material as by centrifugal or vacuum action and then passing the dewater material over successive screens through which hot air is circulated. Specification 774,184 is referred to.

Improvements in and relating to casting

... 957,275. Casting processes. UNION CARBIDE CORPORATION. Nov. 7, 1962 [Nov. 15, 1961], No. 42037/62. Heading B3F. Copper and copper alloys are poured into a mould containing a pool of molten borax-silica slag which has been allowed to stand until a slag shell has formed on the mould walls, the pouring rate being such that only the inner surface of the shell is melted. The mould may be completely filled with molten slag so that a shell is formed on the entire inner mould walls surface, or only partially filled so that the pool of molten slag rises on the molten metal at a rate sufficient to form a thin shell on successive zones of the mould walls. In a specific example the temperature of the slag is 1300‹ C. and copper alloy is cast at 1200‹ C.

WATER-DISPERSIBLE COATINGS CONTAINING BORON NITRIDE FOR STEEL CASTING DIES

Improvements in making fine grained castings

Cast alloys have the following compositions in percentages by weight: ..A.B .C.0.10 max..0.50 .Mn.0.15 max..- .Si.0.20 max..- ..A.B .S.0.015 max..- .Cr.15.0.25.5 .Ti.3.25.- .B.0.03.- .Al.4.25.- .W.-.7.5 .Mo.5.0.- .Fe.4.0 max..2.0 max .Cu.0.10 max..- .Zr.0.06 max..- .Ni.balance.10.5 .Co.18.5.balance Reference has been directed by the Comptroller to Specification 870,745.

Method and means for casting ingots in the presence of exothermic products

... 769,586. Ingot-moulds. DOITTAU PRODUCTS METALLURGIE. Sept. 24, 1954, No. 27625/54. Class 83 (1). A method of casting ingots consists in laying along at least part of the wall of the ingot-mould 1 a lining 7 of agglomerated exothermic products, while leaving an at least partly gaspermeable heat-insulating layer 10 between at least part of the exothermic lining and the inner wall of the ingot-mould. The lining is made in four parts and is secured by heat-resisting adhesives to ribs 5 on the top 1. Alternatively, the ribs may be formed on the linings.

Thickening Agents

Mold coating method in centrifugal casting

COATING COMPOSITIONS CONTAINING HUMIC ACID SALTS

... 1,216,771. Coatings. NALCO CHEMICAL CO. 27 Feb., 1968 [8 May, 1967], No. 9502/ 68. Heading B2E. [Also in Divisions B3, C3 and F4] Ingot moulds, sand or ceramic foundry moulds and cores, and graphite or ceramic crucibles are coated with a composition comprising humic and lignosulphonic acids or ammonium or alkali or alkaline-earth metal salts thereof. Also present may be water, antifreeze, e.g. ethylene glycol, bactarioides, e.g. pantachlorophenol, and alkali. The pH is preferably >9.5. The mould may be coated when at room temperature to 1000‹F., e.g. by brushing, dipping, pouring or spraying an aqueous slurry, or by blowing or dusting the composition as a dry powder. The coating repels splashes of molten metal and prevents their adherence to the mould. Specification 1,216,772 is referred to.

Improvements in or relating to mold washes

A mould wash of 60 DEG to 80 DEG B<\>ae specific gravity is prepared by mixing with water, to produce a suspension, a finely-divided refractory and the hydrous oxide or hydroxide or a salt of aluminium, zirconium, magnesium, chromium, or iron, and adding thereto calcium hydroxide solution to adjust the pH to from 8.0 to 8.5. The metal salt may be a sulphate or an alum, e.g. ammonium or chrome alum. The refractory, which constitutes the bulk of the wash, may be zirconite flour, to which a small proportion of bentonite may be added. Silica flour and the oxides of aluminium, magnesium, beryllium or chromium may also be used as the refractories. Organic binders, such as dextrin, sulphite pulp liquor, molasses or sodium carboxy-methyl cellulose, may also be present.

Improvements relating to casting moulds and to the production of ingots in them

... 857,377. Mould-and-core materials. MOND NICKEL CO. Ltd. Oct. 8, 1959 [Oct. 27, 1958], No. 34170/58. Class 83 (1). A lining for an ingot-mould comprises a smooth gas-permeable-facing of refractory powder of particle size less than 250 microns, bonded to a backing of fibrous glassy material and containing from 15 to 40% voids by volume, The refractory may be zircon, magnesia. alumina, clays such as kaolin or china clay, sillimanite, topaz, ganister, magnesite, olivine, chromite, and zirconia, and may be bound with bentonite, sodium-silicate or a phenolic resin, in water or alcohol. The backing may be fibre-glass, asbestos or rock-wool, or fibrous blast-furnace slag.

Method and apparatus for producing casting shell

A ceramic casting shell is formed by a method comprising the steps of coating a wax former with one or more layers of a ceramic slurry; drying the or each layer of ceramic slurry; wherein the dried layer or layers of ceramic slurry form a ceramic shell; applying over the ceramic shell a coating of a polymer material; heating the formed assembly to melt and remove the wax former, wherein the polymer coating acts as a strengthening layer to the ceramic shell during the wax removal process; and subsequent removal of the wax former, heating the ceramic shell to melt and remove the polymer coating. The polymer coating is preferably the outer coating of the ceramic shell. The polymer may be polyvinyl alcohol, styrene butadiene, an acrylic polymer, an epoxy resin, a latex, or any combination thereof. The polymer coating preferably has low amounts or is free of refractory material, and preferably only comprises polymeric material. The polymer coating may be applied by spraying, dipping, or painting ...

CONCILIATION FOR THE PRODUCTION OF A LINING OF METALLIC SCHLEUDERGUSSKOKILLEN FOR COPPER OR ITS ALLOYS AND PROCEDURES FOR THE COATING OF A SCHLEUDERGUSSKOKILLE

REFRAKTÄRMETALLKERN

REFRAKTÄRMETALLKERN

VERFAHREN ZUR HERSTELLUNG EINER AUS SCHICHTEN AUFGEBAUTEN SCHALENFORM UND NACH DIESEM VERFAHREN HERGESTELLTE SCHALENFORM

VERFAHREN ZUM SCHUTZ VON OBERFLAECHEN

SCHLICHTE FUER DIE HERSTELLUNG EINER AUSKLEIDUNG VON METALLISCHEN SCHLEUDERGUSSKOKILLEN FUER KUPFER ODER DESSEN LEGIERUNGEN UND VERFAHREN ZUR BESCHICHTUNG EINER SCHLEUDERGUSSKOKILLE

SCHLICHTE FUER FORMEN UND FORMKERNE

Procédé de fabrication d'un élément tubulaire

Dieses Verfahren zur Herstellung eines rohrförmigen Elements aus Sphärogus durch Zentrifugation umfasst folgende Schritte: – Vorsehen einer rotierenden Form (16) mit einer Formfläche (28) für das rohrförmige Element, wobei die Formfläche keine vorübergehende Wärmedämmung umfasst, – Vorsehen eines Gießgefäßes (10), das Gussschmelze enthält, – Aufbringen eines Impfmittels auf die Formfläche (28), - Aufbringen einer Zusammensetzung, die mindestens einen die Oberflächenspannung der Gussschmelze absenkenden Bestandteil enthält, auf die Formfläche (28), - Fließenlassen der Gussschmelze auf die weder vorübergehende Wärmedämmung noch vorübergehendes feuerfestes Material aufweisende, mit Impfmittel versehene Formfläche, wobei die Gussschmelze dann bei Kontakt mit dem auf die Formfläche aufgebrachten Impfmittel geimpft wird, – Verfestigen der in die Form gegossenen Gussschmelze, was einen Rohling des rohrförmigen Elements ergibt.

PROCEDURE FOR THE PROTECTION OF SURFACES

PROCEDURE AND EQUIPMENT FOR THE DAEMPFEN OF EXPLOSIVE CHARGE EXPLOSIONS.

USE OF AN AQUEOUS ONE, FIREPROOF ONES CERAMIC CASTING MASS

Procedure for inoculating cast iron melts

Procedure for lining Ingotformen as well as soft layer for the use in this procedure

Procedure for the lining of cavities, in particular of Ingotkokillenköpfen or warm hoods hiefür

THERMAL SHOCK-SAFE DEVICE FOR FORMING THIXOTROPEM MATERIAL

Use of Organosilanen as form lubricants

FLEXIBLE REFRACTORY COMPOSITION - CONTAINING INORGANIC FIBRES AND CARBON

MAKING DIRECTIONALLY SOLIDIFIED CASTINGS

COATED GRAPHITE MOLD

CONTINUOUS CASTING CONTRIVANCE AND METHOD FOR ITS PRODUCTION

METAL CASTING PROCESS

METHOD OF PRODUCING A CAST IN A CASTABLE MATERIAL OF OBJECTS WITH A SOFT AND IRREGULAR SURFACE STRUCTURE

MOLD RELEASING AGENT FOR CENTRIFUGAL CASTING MOLD

A mold releasing agent suitable for easily casting a cylindrical cast member which is superior in adhesion on cast parts at low cost, is provided. A mold releasing agent for a centrifugal casting mold comprises a binder, a heat insulating agent, and a foaming component having a foaming property, is dissolved in a solvent so as to form a slurry having a specific viscosity, and a mold releasing agent layer having crater shaped concave portions is formed by coating on the inside of an integral centrifugal casting mold.

REFRACTORY CORES

FORMING MEMBERS FOR SHAPING A REACTIVE METAL AND METHODS FOR THEIR FABRICATION

Coatings of doped chromium nitride protect forming members such as dies from the corrosive effects of molten aluminum and other reactive metals.

METAL CASTING PROCESS

EXPENDABLE CORES FOR DIE CASTING

NL-1627 INVENTOR: Enno H. Page 5055 Jamieson Drive Toledo, Ohio 43613 TITLE: EXPENDABLE CORES FOR DIE CASTING 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.

COATING COMPOSITIONS

Flammable foundry coatings are disclosed in which the carrier liquid is safer to handle than the 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").TM ...

REFRACTORY CORES

RELEASE COATING FOR GLASS MANUFACTURE

A composition and method of preparation are herein described for molten release and parting compositions adaptable for use in glass-forming operations. The novel composition comprises an aqueous dispersion of a mixture of a solid lubricant, a water-soluble silicate binder, a setting agent, and a water-soluble phosphate. A preferred composition comprises a mixture of flake graphite, boron nitride, sodium silicate, zinc oxide and potassium phosphate tribasic.

MOULD TREATMENT

CASTING OF COPPER ANODES

In the coating of interior surfaces of copper molds with a slurry of a release material prior to the casting thereinto of molten impure copper for the production of anodes for use in the electrolytic refining of such impure copper, the improvement wherein the slurry is heated to a temperature of from about, 150.degree. to about 200.degree.F. prior to its being applied, resulting in greatly increasing the operating life of the molds.

METHOD OF MANUFACTURING A FOUNDRY MOLD FOR CASTING MOLTEN METAL

COATING COMPOSITIONS

FOUNDRY MOLD TREATING COMPOSITIONS AND METHODS OF MAKING SAME

REFRACTORY DRESSINGS

METHOD FOR COATING A SURFACE WITH A SEPARATING AGENT

The invention relates to a method for coating a surface with a separating agent, characterised in that a BN powder is applied to the surface by means of electrostatic coating.

CASTING METHOD FOR ALUMINUM OR ALUMINUM ALLOYS AND A MOLD THEREFOR

TITANIC ACID ESTER-CONTAINING BINDER FOR COATING MATERIALS AND REFRACTORY SHAPED BODIES AS WELL AS PROCESS FOR THE PRODUCTION OF THESE BINDERS

Method of Releasing High Temperature Films and/or Devices From Metallic Substrates

Films and electronic devices can be released from metallic substrates by: (i) applying a coating of a polysilsesquioxane resin to a metallic substrate, (ii) heating the coated metallic substrate to a temperature sufficient to cure the polysilsesquioxane resin, (iii) applying a polymeric film to the cured coating on the metallic substrate, (iv) further heating the coated metallic substrate to a temperature sufficient to cure the polymeric film, (v) optionally fabricating electronic devices on the polymeric film, and (vi) releasing the polymeric film from the metallic substrate.

Polycrystalline silicon ingot casting mold and method for producing same, and silicon nitride powder for mold release material for polycrystalline silicon ingot casting mold and slurry containing same

A polycrystalline silicon ingot casting mold, and method for producing same. Mold release material being obtained by blending a silicon nitride powder (A) having an average particle diameter along the short axis of 0.6 to 13 μm with a silicon nitride powder (B) having an average particle diameter along the short axis of 0.1 to 0.3 μm at a weight ratio of 5:5 to 9:1; coating the mold surface with the slurry; and a heating the mold at 800 to 1200° C. in an atmosphere containing oxygen.

Coating material for aluminum die casting mold and method of manufacturing the coating material

Disclosed is a coating material for an aluminum die casting mold and a method of manufacturing the coating material. The coating material includes a CrN bonding layer formed on a surface of a substrate, a TiAlN/CrN nano multi-layer disposed on a surface of the CrN bonding layer, and a TiAlN/CrSi(C)N nano multi-layer disposed on a surface of the TiAlN/CrSiCN nano multi-layer. The coating material for an aluminum die casting mold may maintain the physical properties of a mold under a high temperature environment due to the superior seizure resistance, heat resistance and high-temperature stability of the coating material, thereby extending the lifespan of the mold.

COMPOSITIONS AND METHODS FOR IMPROVING CASTING QUALITY AND MOLD SAND ADDITIVES

A method of forming a dry molding sand additive may include recovering a non-sand fraction from a foundry waste material and adding the non-sand fraction to a dry molding sand additive formulation to form a dry molding sand additive. Adding the non-sand fraction to the dry molding sand additive formulation may reduce the amount of fresh clay and carbon to produce the dry molding sand additive. A method of forming a molding sand additive may include recovering a waste molding sand additive composition having a clay or carbon content differing from a desired clay and carbon content, recycling the waste molding sand additive as a raw material in production of a fresh molding sand additive, and adjusting the amount of fresh clay or carbon added during production of the fresh molding sand additive to achieve the desired clay and carbon content. 1. A method of forming a dry molding sand additive , comprising the steps of:recovering a non-sand fraction from a foundry waste material, wherein said non-sand fraction comprises a recovered clay component and a recovered carbon component; andadding the non-sand fraction to a dry molding sand additive formulation to form a dry molding sand additive to reduce the amount of fresh clay and carbon to produce the dry molding sand additive.2. The method of forming a dry molding sand additive of claim 1 , wherein said foundry waste material comprises bag house dust.3. The method of forming a dry molding sand additive of claim 1 , wherein said foundry waste material comprises overflow green sand.4. The method of forming a dry molding sand additive of claim 1 , wherein said foundry waste material comprises a mixture of bag house dust and overflow green sand.5. The method of forming a dry molding sand additive of claim 1 , wherein said foundry waste material comprises molding waste.6. The method of forming a dry molding sand additive of claim 1 , wherein the moisture content of the dry molding sand additive is in a range from about 0% to ...

CASTING MOLD, METHOD OF MANUFACTURING SAME, TiAl ALLOY CAST PRODUCT, AND METHOD OF CASTING SAME

A casting mold to cast a TiAl alloy includes a casting mold body formed into a bottomed shape and provided with a cavity. The casting mold body includes a reaction-resistant layer provided on the cavity side, formed from a refractory material containing at least one of cerium oxide, yttrium oxide, and zirconium oxide and a back-up layer formed on the reaction-resistant layer. The back-up layer includes a weakening layer formed from a refractory material including a silica material in a range from 80% by mass to 100% by mass inclusive, the silica material containing cristobalite in a range from 26% by mass to 34% by mass inclusive and the rest being fused silica, the weakening layer being designed to reduce casting mold strength and a shape-retention layer formed from a refractory material. 1. A casting mold to cast a TiAl alloy , comprising:a casting mold body formed into a bottomed shape and provided with a cavity into which a molten TiAl alloy is to be poured, wherein a reaction-resistant layer provided on the cavity side, formed from a refractory material containing at least one of cerium oxide, yttrium oxide, and zirconium oxide, and configured to suppress a reaction with the molten TiAl alloy, and', 'a back-up layer formed on the reaction-resistant layer, and, 'the casting mold body includes'} a weakening layer formed from a refractory material including a silica material in a range from 80% by mass to 100% by mass inclusive, the silica material containing cristobalite in a range from 26% by mass to 34% by mass inclusive and the rest being fused silica, the weakening layer being designed to reduce casting mold strength, and', 'a shape-retention layer formed from a refractory material and designed to retain a casting mold shape., 'the back-up layer includes'}2. The casting mold according to claim 1 , wherein the refractory material forming the weakening layer includes the silica material in a range from 90% by mass to 100% by mass inclusive.3. The casting mold ...

MOULD POWDER AND MOULD COATING

The present invention relates to a mould powder for coating cast moulds for reducing surface defects, such as pinholes, in ductile cast iron products. The mould powder comprises 10-99.5% by weight of a ferrosilicon alloy, 0.5-50% by weight of iron sulphide, and optionally 1-30% by weight of CaSi, and/or 1-10% by weight of CaF. The invention further relates to a mould coating on and internal surface of a casting mould comprising 10-99.5% by weight of a ferrosilicon alloy, 0.5-50% by weight of iron sulphide, and optionally 1-30% by weight of CaSi, and/or 1-10% by weight of CaF. 1. A mould powder for coating the internal surface of one or more casting moulds , comprising10-99.5% by weight of a ferrosilicon alloy,0.5-50% by weight of an iron sulphide, and optionally1-30% by weight of CaSi alloy, and/or{'sub': '2', '1-10% by weight of CaF.'}2. Mould powder according to claim 1 , wherein the mould powder comprises from 50 to 95% by weight of ferrosilicon alloy and from 5 to 50% by weight of iron sulphide.3. Mould powder according to claim 2 , wherein the mould powder comprises from 70 to 90% by weight of ferrosilicon alloy and from 10 to 30% by weight of iron sulphide.4. Mould powder according to claim 2 , wherein the mould powder comprises from 50 to 70% by weight of ferrosilicon alloy and from 30 to 50% by weight of iron sulphide.5. Mould powder according to claim 1 , wherein the mould powder comprises30-90% by weight of a ferrosilicon alloy;0.5-30% by weight of an iron sulphide;5-30% by weight of CaSi alloy; and{'sub': '2', '1-10% by weight of CaF.'}6. Mould powder according to claim 1 , wherein the iron sulphide is FeS claim 1 , FeSor a mixture thereof.7. Mould powder according to claim 1 , wherein the ferrosilicon alloy comprises between 40% and 80% by weight of silicon; up to 6% by weight of calcium; up to 11% by weight of barium; up to 5% by weight of one or more of the elements: aluminum claim 1 , strontium claim 1 , manganese claim 1 , zirconium claim 1 , rare ...

REFRACTORY COATING FOR PRODUCING MOLD COATINGS

A refractory coating for producing mold coatings by application to inorganically or organically-bound molding materials in lost molds or to cores for iron and steel casting is disclosed. The refractory coating can have a proportion by weight of 0.001% or more and less than 1% of inorganic hollow bodies, which partially or fully consist of crystalline material and have a softening point of 1000° C. or higher. 1. A mold or core for iron and steel casting , wherein the mold or the core on the surface facing towards the casting metal has a coating on the basis of a refractory coating comprising the dried product of a refractory coating , and wherein a thickness of the coating on the basis of the refractory coating is 0.05 mm or more , (a) 0.0011 to 3.5 parts by weight of inorganic hollow bodies, which partially or fully consist of crystalline material;', '(b) 20 to 75 parts by weight of one or a plurality of refractory materials, which are not hollow bodies as defined under (a);', '(c) at least 15 parts by weight of at least one carrier fluid;', '(d) 0.1 to 10 parts by weight of one or a plurality of suspending agents;', '(e) 0.01 to 0.6 parts by weight of one or a plurality of biocides;', '(f) 0 to 4 parts by weight of one or a plurality of wetting agents;', '(g) 0 to 2 parts by weight of one or a plurality of floating agents and/or rheological additives; and', '(h) 0 to 2 parts by weight of one or a plurality of binding agents., 'wherein said refractory coating contains a proportion by weight of 0.001% through 0.99% of inorganic hollow bodies, characterized in that wherein the inorganic hollow bodies in part or in full consist of comprise a crystalline material, wherein the refractory wash comprises2. A mold or core for iron and steel casting according to claim 1 , wherein the thickness of the coating on the basis of the refractory coating is 0.15 mm or more.3. A mold or core for iron and steel casting according to claim 1 , wherein the thickness of the coating on the ...

METHODS AND APPARATUS FOR FORMING BULK METALLIC GLASS PARTS USING AN AMORPHOUS COATED MOLD TO REDUCE CRYSTALLIZATION

Embodiments herein relate to methods and apparatuses for casting of BMG-containing parts. The surfaces of the mold that come into contact with the molten amorphous alloy comprise an amorphous material. In accordance with the disclosure, the mold may be coated with an amorphous material, e.g., to reduce, minimize, or eliminate crystallization of the molded BMG-containing part. The surfaces of the mold are coated, in certain aspects, so as to reduce or eliminate potential grain-boundary nucleation sites for BMG crystallization. The amorphous material may be selected based on the particular molten amorphous alloy to be cast, e.g., based on the wetting properties, the melting and cooling properties, etc. 1. A method of forming a metallic glass , comprising:placing a softened or molten metallic glass-forming alloy in contact with a surface of a mold, wherein said surface is amorphous;cooling the metallic glass-forming alloy to form a metallic glass.2. The method of claim 1 , wherein the surface comprises a material selected from diamond-like carbon (DLC) claim 1 , electroless nickel claim 1 , electroless nickel-phosphorus (EN) claim 1 , silicon dioxide claim 1 , silicon carbide claim 1 , silicon nitride claim 1 , silicon carbonitride claim 1 , boron carbide claim 1 , amorphous alumina claim 1 , and metallic glass.3. The method of claim 2 , wherein the surface comprises EN.4. The method of claim 3 , wherein the coating comprises greater than 10.5% P content.5. The method of claim 4 , wherein the coating comprises boron nitride or polytetrafluoroethylene (PTFE).6. The method of claim 1 , wherein the metallic glass-forming alloy is a platinum-based alloy.7. The method of claim 6 , wherein the platinum-based alloy comprises Pt claim 6 , Cu claim 6 , Ni claim 6 , and Al.8. The method of claim 1 , wherein the shaping is selected from molding claim 1 , die-casting claim 1 , and counter-gravity casting.9. The method of claim 1 , wherein the formed metallic glass is a part for an ...

COMPOSITIONS AND METHODS FOR REFRACTORY COATINGS WITH ESTER CARRIERS

This technology relates to refractory coatings used in metal casting by the foundry industry. Refractory coatings are often used to coat foundry cores and molds for the purpose of improving the quality of castings formed in connection with the cores or molds, particularly at the surface of the casting. Whereas traditional coatings comprise water based solvents that require excessive drying times or HAPs that emit hazardous VOCs, preferred embodiments of the present invention comprise refractory coatings having VOC-exempt ester based solvents, such as DMC. Other preferred embodiments of the present invention comprise methods for reduction of VOC content in a foundry article. 1. A refractory coating composition for foundry use comprising:a liquid carrier comprising an ester carrier, the ester carrier being provided at approximately 25% to 100% by weight of the liquid carrier and approximately 20% to 80% by weight of the composition;a suspending agent provided at up to approximately 2% by weight of the composition;a binder provided at approximately 1.5% to 3% by weight of the composition;water provided at up to approximately 2% by weight of the composition;one or more additives provided at up to approximately 2% by weight of the composition;and a particulate refractory material provided at approximately 13 to 78.5% by weight of the composition.2. The refractory coating composition of claim 1 , wherein the ester carrier is a carbonate ester.3. The refractory coating composition of claim 2 , wherein the carbonate ester is dimethyl carbonate.4. The refractory coating composition of claim 1 , wherein the ester carrier is t-butyl acetate.5. The refractory coating composition of claim 2 , the liquid carrier further comprising a volatile organic carrier.6. The refractory coating composition of claim 5 , wherein the volatile organic carrier is isopropyl alcohol.7. The refractory coating composition of claim 2 , wherein the binder is a vinyl acetate and vinyl laurate copolymer ...

SURFACE-TREATED MOLD AND METHOD OF PRODUCING SURFACE-TREATED MOLD

A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer. 1. A method of producing a surface-treated mold , comprising:forming an amorphous metal layer that contains at least one metal selected from the group consisting of nickel, chromium, tungsten and brass on a surface of a mold; andforming a carbon film over the metal layer while heating the metal layer at a temperature of 410° C. to 510° C.2. The method according to claim 1 , wherein the amorphous metal layer is formed by electroless nickel plating.3. The method according to claim 1 , wherein a gaseous mixture of a hydrocarbon gas and a diluent gas is supplied for at least a part of the time period during which the carbon film is formed on the surface of the metal layer.4. The method according to claim 1 , wherein a gaseous mixture of acetylene and ammonia is supplied for at least a part of the time period during which the carbon film is formed on the surface of the metal layer.5. The method according to claim 4 , wherein the carbon film on the surface of the metal layer is formed by supplying a gaseous mixture of acetylene and ammonia and subsequently supplying only ammonia. This is a Divisional of U.S. Ser. No. 12/945,085 filed on Nov. 11, 2010, now pending, which claims priority to Japanese patent application JP 2009-269826, filed Nov. 27, 2009. The disclosure of each of the prior applications is considered part of and is incorporated herein by reference in its entirety.1. Field of InventionThe present invention relates to a surface-treated mold, and a method of ...

Binder System For Producing A Slurry And Component Produced Using The Slurry

The invention relates to a binder system for production of a slip, e.g., for a green casting core compact. The invention also relates to a component that has been produced by means of such a slip. The invention may be employable for relatively inexpensive production of complex metal blades in all kinds of gas turbines and propulsion turbines. According to an embodiment, the invention provides a novel binder system that combines short gel times at room temperature without solvent while retaining a high glass transition of 55 to 60° C. with shortened hardening periods. 1. A binder system for the production of a slip comprising an inorganic constituent , the binder system comprisingan epoxy resin;a silicone copolymer; anda reaction accelerator.2. The binder system as claimed in claim 1 , wherein the binder system comprises up to 10% by weight reaction accelerator.3. The binder system as claimed in claim 1 , wherein the reaction accelerator is selected from the group consisting of imidazoles claim 1 , mono- and/or disubstituted imidazoles claim 1 , 1 claim 1 ,2-; 1 claim 1 ,3-; 1 claim 1 ,4-substituted imidazoles claim 1 , alkyl-substituted imidazoles claim 1 , aryl-substituted imidazoles claim 1 , 1 claim 1 ,2-dimethylimidazole and mixtures thereof.4. The binder system as claimed in claim 1 , wherein the reaction accelerator is obtained by introducing calcium ions into concentrated nitric acid.5. The binder system as claimed in claim 4 , wherein the binder system comprises up to 2% by weight reaction accelerator.6. The binder system as claimed in claim 1 , wherein the epoxy resin component and the silicone copolymer are present in the binder system in a ratio of 1.5:0.7 to 0.7:1.5.7. The binder system as claimed in claim 1 , wherein the epoxy resin component and the silicone copolymer are present in the binder system in a stoichiometric ratio of 1:1.8. The binder system as claimed in claim 1 , wherein at least part of the epoxy resin component is a mobile epoxy resin ...

COMPOSITION AND METHOD TO FORM DISPLACEMENTS FOR USE IN METAL CASTING

A method to form a displacement includes disposing a powder blend (comprising a plurality of ground ceramic particles and a plurality of ground resin particles) into a mold, densifying the powder blend while in the mold, heating the mold to form a first displacement, impregnating said first displacement with a polymer precursor compound to form a second displacement, and heating the second displacement to form a third displacement. 1. A method for forming a displacement for a metallic casting , the method comprising:disposing a powder blend into a mold, the powder blend comprising a plurality of ground ceramic particles and a plurality of ground resin particles;densifying said powder blend while in said mold;heating said mold to form a first displacement;impregnating said first displacement with a polymer precursor compound to form a second displacement; andheating said second displacement at about 1000° C. for about 24 hours to form a third displacement.2. The method of claim 1 , wherein said impregnating comprises:immersing said first displacement in a liquid mixture comprising said polymer precursor compound;monitoring a weight increase of said first displacement;when a weight of said first displacement no longer increases with time, determining that said second displacement is formed.3. The method of claim 1 , further comprising:heating said first displacement at about 1000° C. for about 24 hours before the impregnating said first displacement with the polymer precursor compound to form the second displacement.4. The method of claim 1 , wherein the disposing includes disposing the power blend comprising the plurality of ground ceramic particles with a maximum dimension claim 1 , of a ground ceramic particle claim 1 , of less than about 150 microns.5. The method of claim 1 , wherein the disposing includes disposing the power blend comprising the plurality of ground resin particles with a maximum dimension claim 1 , of a ground resin particle claim 1 , of less ...

Mould for monocrystalline casting

The invention relates to the field of monocrystalline casting, and more specifically to a mold ( 1 ) for monocrystalline casting, and also to fabricating and using the mold. In particular, the mold ( 1 ) presents a mold cavity ( 7 ) comprising a first volume ( 7 a ), a second volume ( 7 b ) and a grain duct ( 4 ). The second volume ( 7 b ) is situated on the first volume ( 7 a ), being in communication therewith, and includes at least one horizontal projection relative to the first volume ( 7 a ). The grain duct ( 4 ) has a bottom end ( 4 a ) connected to the first volume ( 7 a ) and a top end ( 7 b ) adjacent to said horizontal projection of the second volume ( 7 b ). The mold ( 1 ) also has a separator member ( 11 ) interposed between the second volume ( 7 b ) of the mold cavity ( 7 ) and the top end ( 4 b ) of the grain duct ( 4 ).

DIE RELEASE AGENT COMPOSITION

A die release agent composition is provided that is used by being applied to a die used for the squeeze casting, low-pressure casting, or the like of a metal or a die used for die forging. The die release agent composition includes a mineral oil or a synthetic oil, a solid lubricant, a thermosetting resin, and a polymer compound. The die release agent composition is used by being applied to the inner surface of a die for casting or forging. 1. A die release agent composition comprising:a mineral oil or a synthetic oil;a solid lubricant;a thermosetting resin; anda polymer compound,wherein the die release agent composition is used by being applied to an inner surface of a die for casting or forging.2. The die release agent composition according to claim 1 ,wherein the solid lubricant is at least one of talc, boron nitride, graphite, mica, molybdenum disulfide, and fullerene.3. The die release agent composition according to claim 1 ,wherein an average particle diameter of the solid lubricant is in a range between 0.5 micrometers and 30 micrometers, andwherein a content of the solid lubricant is in a range between 1 mass percentage and 10 mass percentages when a total content of the mineral oil or the synthetic oil, the solid lubricant, the thermosetting resin, and the polymer compound is 100 mass percentages.4. The die release agent composition according to claim 1 ,wherein the thermosetting resin is at least one of a phenol resin, an epoxy resin, a urea resin, a melamine resin, an alkyd resin, and an unsaturated polyester resin.5. The die release agent composition according to claim 1 ,wherein the thermosetting resin provides a binder when the die release agent composition is applied to the die, andwherein the thermosetting resin is decomposed at a temperature during forming.6. The die release agent composition according to claim 1 ,wherein, when a number average molecular weight of the thermosetting resin is in a range between 5,000 and 500,000 and a forming ...

METHOD OF FABRICATING AN INVESTMENT CASTING MOLD AND SLURRY THEREFOR

A method of investment casting includes casting a liquid nickel- or cobalt-based superalloy in an investment casting mold. The superalloy includes an yttrium alloying element that is subject to reactive loss during the casting. Loss of the yttrium is limited by using a zircon-containing facecoat on a refractory investment wall in the investment casting mold. The facecoat contacts the liquid nickel- or cobalt-based superalloy during the casting. Prior to the casting, a zircon-containing slurry is used to form the facecoat. After solidification of the nickel- or cobalt-based superalloy, the refractory investment wall is removed from the solidified superalloy. 1. A method of investment casting , the method comprising:casting a liquid nickel- or cobalt-based superalloy in an investment casting mold, the liquid nickel- or cobalt-based superalloy having a composition including at least one alloying element that is subject to reactive loss during the casting, the at least one alloying element including yttrium;limiting the loss of the yttrium element from the composition by using a zircon-containing facecoat on a refractory investment wall in the investment casting mold, the facecoat contacting the liquid nickel- or cobalt-based superalloy during the casting, wherein the facecoat includes, by weight, at least 70% of zircon; andafter solidification of the nickel- or cobalt-based superalloy, removing the refractory investment wall from the solidified superalloy.2. The method as recited in claim 1 , wherein the refractory investment wall includes multiple refractory layers that back the facecoat.3. The method as recited in claim 1 , wherein the refractory investment wall includes a mold shell that surrounds a mold cavity claim 1 , and the mold shell includes the facecoat.4. The method as recited in claim 1 , wherein the facecoat includes colloidal silica.5. The method as recited in claim 1 , wherein the facecoat includes claim 1 , by weight claim 1 , at least 10% colloidal ...

METHOD OF MANUFACTURING PRECISION CAST PARTS FOR VEHICLE EXHAUST SYSTEMS

A method of manufacturing precision cast parts for vehicle exhaust systems includes fabricating a model of a product to be manufactured using a substance selected from the group consisting of a wax and a plastic, forming a first coating layer on a surface of the model using a first slurry, forming a second coating layer on the surface of the model coated with the first coating layer using a second slurry, drying the first and second coating layers to form a mold and heating the mold to remove the model, pre-heating the mold, placing the mold in a ceramic box with a top portion open, and filling an inner part of the ceramic box with ceramic balls, and producing a product by injecting a molten metal into the mold to cast the product. 1. A method of manufacturing precision cast parts for vehicle exhaust systems , comprising:fabricating a model of a product to be manufactured using a substance selected from the group consisting of a wax and a plastic;forming a first coating layer on a surface of the model using a first slurry;forming a second coating layer on the surface of the model coated with the first coating layer using a second slurry;drying the first and second coating layers to form a mold and heating the mold to remove the model;pre-heating the mold, placing the mold in a ceramic box with a top portion open, and filling an inner part of the ceramic box with ceramic balls; andproducing a product by injecting a molten metal into the mold to cast the product.2. The method of claim 1 , further comprising heating the ceramic balls to a temperature of 500 to 700° C. to remove foreign substances from surfaces of the ceramic balls prior to the cast preparation.3. The method of claim 1 , wherein the cast preparation comprises pre-heating the mold to 500 to 1 claim 1 ,200° C.4. The method of claim 1 , wherein the step of producing a product comprises casting the product in a vacuum state to prevent oxidation of the molten metal.5. The method of claim 1 , wherein the ...

Three component polyurethane binder system

An organic binder system is mixed with molding material for sand casting in the metals industry. The organic binder system has three parts, the first two of which are conventional and are used in the cold box or no bake process. The third part, which is combined with the first two parts at the time of use, contains at least an alkyl silicate and, optionally, a bipodal aminosilane. In some embodiments, an amount of hydrofluoric acid is included in one or both of the first two parts. Use of the organic binder system provides improved tensile strength in the mold, especially in high relative humidity.

METHOD OF PREPARATION OF SAND CASTING MOULDS WITH A PROTECTIVE COATING

A method of making sand casting moulds with a protective coating for a multiple process of reactive moulding of insulation components and products made by filling up a mould cavity with polymer materials, including composites, based particularly on epoxy resins or composites based on cellulose materials, the method wherein the process of infiltration of the mould structure is performed chemically by soaking through the raw mould structure with chemosetting or thermosetting material. The application of a protective layer on external surfaces of a sand casting mould is done by means of any spraying, immersion or deposition method, whereas material with anti-adhesive properties is used for the protective coating in the form of organic chemosetting, thermosetting, light-curing material or in the form of inorganic material, including metal. 1. A method of making sand casting moulds with a protective coating , comprisingprinting of a sand casting mould in 3D technology, infiltration of a sand casting mould structure and the application of a protective layer on external surfaces of the sand casting mould, wherein the infiltration process of the mould structure is performed chemically, thus avoiding vacuum suction of infiltrating resin through a plurality of layers of foundry sand with a mixture of activator, whereas the infiltration process is realised through a soaking of raw mould structure with chemosetting or thermosetting material, by a surface method on the external layer of a mould or by means of a volume method throughout the volume of mould structure, whereas the application of a protective layer on external surfaces of a sand casting mould is performed by any spraying, immersion, powder painting method or a deposition method, whereas material with anti-adhesive properties in the form of organic chemosetting, thermosetting, light-curing material or in the form of inorganic material in that metal is used as material for a protective coating, and the applying of an ...

CASTING GREEN SAND MOLD FOR FORMING CAST STEEL ARTICLE AND ITS PRODUCTION METHOD, AND METHOD FOR PRODUCING CAST STEEL ARTICLE USING SUCH GREEN SAND MOLD

A green sand mold for producing a cast steel article, which is formed by casting sand comprising sand, a binder, and 3 parts or less by mass of a carbonaceous component per 100 parts by mass of sand, and provided with a coating layer of a thermosetting resin formed at least on a recess including a cavity for forming the cast steel article, the coating layer having average hardness (measured by a self-hardening hardness meter) of 50-95 and a thickness of 0.5-2.5 mm. 1. A green sand mold for producing a cast steel article , which is formed by casting sand comprising sand , a binder , and 3 parts or less by mass of a carbonaceous component per 100 parts by mass of sand;at least a recess including a cavity for forming said cast steel article being provided with a coating layer of a thermosetting resin; andsaid coating layer having average hardness (measured by a self-hardening hardness meter) of 50-95 and a thickness of 0.5-2.5 mm.2. The green sand mold according to claim 1 , wherein the amount of the thermosetting resin forming said coating layer is 100-500 g/mon a solid basis.3. The green sand mold according to claim 1 , wherein the amount of carbon remaining in a unit volume of said coating layer is 20-200 mg/cmafter heated to 800° C. at a speed of 10° C./minute in the air.4. A method for producing the green sand mold recited in claim 1 , comprisingforming casting sand comprising sand, a binder, and 3 parts or less by mass of a carbonaceous component per 100 parts by mass of sand, into at least a pair of green sand mold parts comprising a recess including a cavity for forming said cast steel article;coating at least said recess with a coating solution comprising a thermosetting resin and an organic solvent; andthermally curing said thermosetting resin coated on said recess to form a coating layer having average hardness (measured by a self-hardening hardness meter) of 50-95.5. The method for producing a green sand mold according to claim 4 , wherein said ...

MOLD FLUX FOR CONTINUOUS-CASTING Ti-CONTAINING HYPO-PERITECTIC STEEL AND METHOD THEREFOR

A mold flux is used in continuous casting of Ti-containing hypo-peritectic steel so as to prevent longitudinal cracks from forming on a surface of a slab. The mold flux contains CaO, SiO, an alkali metal oxide and a fluorine compound as major components. f(1), f(2) and f(3), which are calculated from the initial chemical composition, are (1.1−0.5×T) to (1.9−0.5×T), 0.05 to 0.40 and 0 to 0.40, respectively, if the Ti content of the molten steel (mass %) is T. The TiOcontent in the melting state during the casting is no more than 20 mass % and the ratio of the first peak height of perovskite to the first peak height of cuspidine in the mold flux film is no more than 1.0. 1{'sub': '2', 'the mold flux contains CaO, SiO, an alkali metal oxide and a fluorine compound as major components,'}chemical composition of the mold flux before the mold flux is put into a mold satisfies the formulas (1), (2) and (3),{'sub': '2', 'a TiOcontent of the mold flux in a melting state during the casting is no more than 20 mass %, and'} [{'br': None, 'i': ×T≦f', '×T, '1.1−0.5(1)≦1.9−0.5\u2003\u2003(1)'}, {'br': None, '0.05≦f(2)≦0.40 \u2003\u2003(2)'}, {'br': None, '0≦f(3)≦0.40 \u2003\u2003(3),'}, {'br': None, 'wherein in the formulas (1) to 3),'}, {'br': None, 'i': 'f', 'sub': h', '2', 'n, '(1=CaO)/(SiO)\u2003\u2003(A)'}, {'br': None, 'i': 'f', 'sub': 2', 'h', 'h', '2', 'h', '2', 'h, '(2)=(CaF)/{(CaO)+(SiO)+(CaF)}\u2003\u2003(B)'}, {'br': None, 'i': 'f', 'sub': h', 'h', '2', 'h', 'h, '(3)={(alkali metal fluoride)}/{(CaO)+(SiO)+(alkali metal fluoride))}\u2003\u2003(C)'}, {'br': None, 'wherein in the formulas (A) to (C),'}, {'br': None, 'sub': h', 'CaO', '2', 'h, '(CaO)=W−(CaF)×0.718 \u2003\u2003(D)'}, {'br': None, 'sub': 2', 'h', 'SiO2, '(SiO)=W\u2003\u2003(E)'}, {'br': None, 'sub': 2', 'h', 'F', 'Li2O', 'Na2O', 'K2O, '(CaF)=(W−W×1.237−W×0.613−W×0.406)×2.05 \u2003\u2003(F)'}, {'br': None, 'sub': h', 'Li2O', 'Na2O', 'K2O, '(alkali metal fluoride)=W×1.74+W×1.35+W×1.23 \u2003\u2003(G)'}], 'a ...

INVESTMENT-DIECASTING MOLD

An investment-diecasting mold has a thin inner investment casting ceramic layer surrounded by a thicker outer metallic diecasting material. The two layers, inner ceramic and outer metallic, provide a hybrid mold for the fabrication of near-to-net or near net shape amorphous alloy composed parts. The inner ceramic layer being appropriate for thermoconductivity and the casting of intricately designed parts, and the outer metallic diecasting mold for support of the inner investment casting layer and as a heat sink for quench of the molten amorphous alloys during use. 1. An investment-diecasting mold comprising:an inner investment casting mold for defining a cavity, the cavity shaped as a negative imprint for at least a portion of a part; andan outer diecasting mold, the outer diecasting mold encasing and operatively contacting the inner investment casting mold.2. The investment-diecasting mold of claim 1 , wherein the inner investment casting mold is composed of a thermally conductive ceramic material.3. The investment-diecasting mold of wherein the thermally conductive ceramic material is selected from the group consisting of alumina claim 2 , silicon claim 2 , nitride claim 2 , and silicon nitride.4. The investment-diecasting mold of claim 2 , wherein the inner investment casting mold has a thickness of from about 1 mm and about 4 mm.5. The investment-diecasting mold of claim 1 , wherein the outer diecasting mold is composed of a material selected from the group consisting of steel claim 1 , stainless steel claim 1 , aluminum claim 1 , copper claim 1 , and brass.6. The investment-diecasting mold of claim 5 , wherein the outer diecasting mold has an appropriate mass to act as a heat sink for quenching parts made of amorphous metals.7. The investment-diecasting mold of claim 6 , wherein the outer diecasting mold defines one or more cooling conduits for inclusion of water claim 6 , brine claim 6 , NaOH or oil.8. A method comprising:filling a gap formed between a wax ...

PREPARATION METHOD OF FOAMED ALUMINUM SPECIAL-SHAPED PART

Disclosed is a preparation method of a foamed aluminum special-shaped part. The preparation method comprises the following steps: S1, pressing wax molds; S2, making a shell; S3, carrying out smelting; S4, carrying out casting; and S5, vibrating the shell. Finally, the foamed aluminum special-shaped part is obtained for a preparation process of a foamed aluminum compound casting.

COMPONENT PART FOR ALUMINUM DIE-CASTING MOLD

A component part for an aluminum die-casting mold has an exposed surface that is a surface exposed to a cavity part of the aluminum die-casting mold and has diamond-like carbon coating formed at least on a part of the exposed surface, wherein the diamond-like carbon coating contains hydrogen in a content rate of 10 at % or more and 30 at % or less. The diamond-like carbon coating may further contain silicon in a content rate of less than 10 at %. Preferably, the content rate of silicon in the diamond-like carbon coating is 0.5 at % or more and 7 at % or less. Thereby, a component part for an aluminum die-casting mold which has excellent seizure resistance against molten metal containing aluminum can be provided. 1. A component part for an aluminum die-casting mold which has an exposed surface that is a surface exposed to a cavity part of the aluminum die-casting mold and has diamond-like carbon coating formed at least on a part of said exposed surface , wherein:said diamond-like carbon coating contains hydrogen in a content rate of 10 at % or more and 30 at % or less.2. The component part for an aluminum die-casting mold according to claim 1 , wherein:said diamond-like carbon coating further contains silicon in a content rate of less than 10 at %.3. The component part for an aluminum die-casting mold according to claim 2 , wherein:the content rate of silicon in said diamond-like carbon coating is 0.5 at % or more and 7 at % or less. The present invention relates to a component part for an aluminum die-casting mold. More specifically, the present invention relates to a component part for an aluminum die-casting mold which has excellent seizure resistance against molten metal containing aluminum.Seizure in a die-casting method is a phenomenon in which injected aluminum alloy reacts and fusionbonds with the surface of a mold or core pin, etc., and may lead to problems, such as deterioration of dimensional accuracy, productivity and appearance quality of a die-casting ...

MOLD RELEASE AGENT FOR CORE

An inorganic mold release agent for a core that is applied to a surface of a core containing an aggregate and an inorganic binder, and the mold release agent for a core is a powder containing silica powder, which is applied in a powder form to the surface of the core. 1. An inorganic mold release agent for a core that is applied to a surface of a core containing an aggregate and an inorganic binder ,wherein the mold release agent for a core is a powder containing silica powder, and is applied in a powder form to the surface of the core.2. The mold release agent for a core according to claim 1 , further containing magnesium hydroxide powder.3. The mold release agent for a core according to claim 2 , containing 0 parts by mass to 50 parts by mass of the magnesium hydroxide powder with respect to a total of 100 parts by mass of the silica powder and the magnesium hydroxide powder.4. The mold release agent for a core according to claim 1 , wherein the silica has an amorphous structure. This application claims priority to Japanese Patent Application No. 2020-186471 filed on Nov. 9, 2020, incorporated herein by reference in its entirety.The present disclosure relates to a mold release agent for a core.Cores used for casting are formed from an aggregate such as sand using a binder. In this case, if a core is formed using an organic binder, tar, soot, offensive odor (gas), and the like are generated due to heat of a molten metal. Therefore, it is desirable to form a core using an inorganic binder.On the other hand, since there are fine holes on the surface of the core, the molten metal enters the holes, and sand of the core adheres to the surface of a coarse material taken out from the core. Therefore, a process of removing the sand adhered to the surface of the coarse material is required. Therefore, in order to prevent sand from adhering to the surface of the coarse material, a mold release agent is applied to the surface of the core. However, when an organic mold release ...

Coated Casting Core and Manufacture Methods

A casting core assembly includes a metallic core, a ceramic core having a compartment in which the portion of the metallic core is received, and a ceramic coating at least partially covering the metallic core and the ceramic core. 1. A casting core assembly comprising:a metallic core;a ceramic core having a compartment in which a portion of the metallic core is received; anda ceramic coating at least partially covering the metallic core and the ceramic core and having a median thickness of 0.5 mil to 1.5 mil.2. The assembly of wherein:a ceramic adhesive joint between the portion and the ceramic core.3. The assembly of wherein:the ceramic core is an airfoil feedcore; andthe metallic core is an outlet core.4. The assembly of wherein:the metallic core is a refractory metal core.5. The assembly of wherein:the ceramic core is silica-based.6. The assembly of wherein:the coating comprises at least 50% mullite and/or alumina by weight.7. The assembly of wherein:the coating is a single sole layer atop both the ceramic core and the metallic core.8. A pattern comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'the assembly of ; and'}a wax material in which the assembly is partially embedded.9. A mold comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'the assembly of ; and'}a shell, the metallic core having a distal portion embedded in the shell and the metallic core spanning a gap between the ceramic core and the shell.10. A process for forming a casting core assembly of claim 1 , the process comprising:molding a ceramic core over a portion of a metallic core; andapplying a ceramic coating at least partially covering the metallic core and the ceramic core.11. The process of further comprising:applying an additional ceramic coating to the metallic core before the molding.12. The process of wherein:the applying of the ceramic coating is to the ceramic core in an unfired state.13. The process of wherein:the applying is by chemical vapor deposition.14. The ...

PRECISION-CASTING CORE, PRECISION-CASTING CORE MANUFACTURING METHOD, AND PRECISION-CASTING MOLD

A coating layer including solely silicon alkoxide or mixed alkoxide of silicon alkoxide and aluminum alkoxide is formed on a surface of a sintered precision-casting core body mainly including silica particles so as to seal holes formed in the surface. As a result, it is possible to prevent the breakage of the core during casting. 1. A precision-casting core obtained by forming a coating layer of two kinds of silica materials having different particle diameters on a surface of a sintered precision-casting core body mainly including silica particles.2. The precision-casting core according to claim 1 ,wherein two kinds of silica materials having different particle diameters comprise silica sol and silica fume.3. (canceled)4. A precision-casting core obtained by forming a coating layer including a silica material claim 1 , an alumina material claim 1 , and silica fume on a surface of a sintered precision-casting core body mainly including silica particles.5. The precision-casting core according to claim 4 ,wherein the silica material is silica sol and the alumina material is alumina sol.{'b': '6', '. (Currently Amended) A precision-casting mold used to manufacture cast metal, comprisinga precision-casting core obtained by forming a coating layer of two kinds of silica materials having different particle diameters on a surface of a sintered precision-casting core body mainly including silica particles having a shape corresponding to a cavity inside the cast metal; andan outer mold corresponding to the shape of the outer peripheral surface of the cast metal.7. A precision-casting core manufacturing method comprising:immersing a sintered body of a precision-casting core body mainly including silica particles into a coating material including two kinds of silica materials having different particle diameters;drying the sintered body; andheating the sintered body so as to form a coating layer on the surface of the precision-casting core body.8. The precision-casting core ...

SEMICONDUCTOR-MOUNTING HEAT DISSIPATION BASE PLATE AND PRODUCTION METHOD THEREFOR

In a semiconductor-mounting heat dissipation base plate including: an insulating substrate to which a metal circuit layer for mounting a semiconductor chip thereon is fixed; a heat dissipation base formed from the same metal material as the metal circuit layer at a side opposite to the metal circuit layer across the insulating substrate and fixed to the insulating substrate similar to the metal circuit layer; and a strengthening member provided in the heat dissipation base so as to be separated from the insulating substrate, the sizes of crystal grains of a metal structure at a part of the heat dissipation base or the metal circuit layer are reduced by a crystal size reducing material adhered to a mold, thereby preventing an adverse effect of a columnar crystal structure. 1. A method for producing a semiconductor-mounting heat dissipation base plate including: an insulating substrate which is formed from a ceramic and to which a metal circuit layer for mounting a semiconductor component thereon and formed from aluminum is fixed by direct bonding through casting; and a heat dissipation base formed from aluminum and fixed to the insulating substrate at a side opposite to the metal circuit layer across the insulating substrate by direct bonding through casting , the method comprisingadhering at least one or more types of a crystal grain size reducing material to a part of a cavity-side surface of a mold during casting of the heat dissipation base and the metal circuit layer, thereby forming a crystal grain diameter regulated region in which crystal grain diameter is regulated, in at least a part of a surface of the heat dissipation base or the metal circuit layer.2. The method for producing the semiconductor-mounting heat dissipation base plate according to claim 1 , wherein the crystal grain diameter regulated region is selectively formed at an outermost surface side of the metal circuit layer.3. The method for producing the semiconductor-mounting heat dissipation ...

Mold material mixture containing additives for reducing casting defects

The subject matter of the invention is mold material mixtures for producing molds or cores for metal casting, consisting of at least one refractory base mold material, a binder and an additive based on factice. The invention also relates to a component system, a method for producing molds and cores using the mold material mixtures or the component system respectively, and to molds and cores produced by said method.

SEMICONDUCTOR-MOUNTING HEAT DISSIPATION BASE PLATE AND PRODUCTION METHOD THEREFOR

In a semiconductor-mounting heat dissipation base plate including: an insulating substrate to which a metal circuit layer for mounting a semiconductor chip thereon is fixed; a heat dissipation base formed from the same metal material as the metal circuit layer at a side opposite to the metal circuit layer across the insulating substrate and fixed to the insulating substrate similar to the metal circuit layer; and a strengthening member provided in the heat dissipation base so as to be separated from the insulating substrate, the sizes of crystal grains of a metal structure at a part of the heat dissipation base or the metal circuit layer are reduced by a crystal size reducing material adhered to a mold, thereby preventing an adverse effect of a columnar crystal structure. 1. A semiconductor-mounting heat dissipation base plate comprising:an insulating substrate which is formed from a ceramic and to which a metal circuit layer mounting a semiconductor component thereon and formed from aluminum is fixed; anda heat dissipation base fixed to the insulating substrate at a side opposite to the metal circuit layer across the insulating substrate and formed from aluminum, whereina crystal grain diameter regulated region in which crystal grain diameter is regulated is provided in at least a part of a surface of the heat dissipation base or the metal circuit layer, andthe average crystal grain diameter in the crystal grain diameter regulated region is smaller than an average crystal grain diameter in other regions of the metal circuit layer and the heat dissipation base.2. The semiconductor-mounting heat dissipation base plate according to claim 1 , further comprising a fastening portion provided in the heat dissipation base claim 1 , whereinthe crystal grain diameter regulated region is provided in a surface of the heat dissipation base including at least a surface of the fastening portion.3. The semiconductor-mounting heat dissipation base plate according to claim 1 , ...

Foundry Mold Insulating Coating

Tubular metal articles such as pipe and cylinder liners are produced by centrifugal casting on a permanent metal mold coated by refractory glass on the active surface. A coating suspension mix is evenly distributed onto the mold to form a uniform layer of insulation on the surface of the mold. The material for the coating includes essentially a waterborne suspension mix of glass particles. The suspension is given time to dry on the surface of the mold. The glass particles dispersed in the suspension are both non-crystalline and nonporous. The glass particles in the suspension and forming the coating are not dissolved and do not chemically attract the polar water molecule or cause it to bond to the surface of glass in the suspension or to the mold active surface. Articles cast as such are smooth surfaced and require only limited machining. The coating provides thermal protection to the mold, but more importantly, the water in the suspension vaporizes quickly on a warm mold because the water is not attracted or bonded to the refractory glass particles. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. (canceled)9. (canceled)10. A molten metal mold having an active surface for contact by molten metal , said surface being coated by a non-crystalline and non-porous insulating coating , said insulating coating forms a thermal barrier to protect said metal mold , said coating comprising a suspension mix of:a quantity of a refractory glass that constitutes from 10.0% to 55.0% by weight of the suspension mix,said refractory glass being inert and nonreactive at the temperature of the molten metal to be cast and maintaining a brittle state at a temperature equal to the temperature of the molten metal being cast,a carrier liquid for suspending said quantity of refractory glass, wherein said carrier liquid and said refractory glass combined constitute at least 95.0% by weight of the suspension mix,wherein said refractory glass is ...

MOLD RELEASE AGENT COMPOSITION FOR USE IN CASTING

The present invention provides a novel mold release agent composition which can cope with a higher temperature range than that of the conventional mold release agent composition. That is, a mold release agent composition for use in casting of the present invention contains a silicone oil and a solvent, wherein the silicone oil contains 30% by mass or more of a first silicone oil represented by the formula (1) and 70% by mass or less of a second silicone oil represented by the formula (2), with respect to the total amount of the silicone oil. In the formula (1), Ris an alkyl group having 1 to 6 carbon atoms; and Ris an aralkyl group, a phenyl group, or a mercaptoalkyl group. In the formula (2), Ris an alkyl group having 8 or more carbon atoms; and Ris an aralkyl group, a phenyl group, or a mercaptoalkyl group. 2. The mold release agent composition according to claim 1 , wherein an amount of the silicone oil is 15% by mass or more with respect to a total amount of the silicon oil and the solvent.3. The mold release agent composition according to claim 1 , wherein an amount of the solvent is 55% by mass or more with respect to a total amount of the mold release agent composition.4. The mold release agent composition according to claim 1 , further comprising:a mineral oil and/or a synthetic oil.5. The mold release agent composition according to claim 1 , further comprising:a radical capture agent.6. The mold release agent composition according to claim 5 , wherein when the total amount of the silicone oil is taken as 100 parts by mass claim 5 , a blended amount of the radical capture agent is 1 part by mass or more.7. The mold release agent composition according to claim 5 , further comprising:an organometallic compound as an auxiliary agent for the radical capture agent.8. The mold release agent composition according to claim 7 , wherein the aralkyl group is an α-methylstyrene group.9. The mold release agent composition according to claim 1 , wherein:n1 satisfies the ...

Coating compositions for casting moulds and cores for avoiding maculate surfaces

The invention relates to a size composition (coating composition) for casting moulds and cores, comprising at least one metal additive which contains a metal or a compound of a metal, wherein the metal is selected from one of groups 7 or 9 to 12 of the Periodic Table of the Elements. The invention also relates to a process for producing a casting mould, which comprises a mould coating of the size (coating) according to the invention, and to the use of said mould for the casting of metals.

ADDITIVELY MANUFACTURED TURBINE SHROUD SEGMENT

A turbine system includes a turbine shroud segment. The turbine shroud segment includes a backside, a flow path surface opposite to the back side and configured to be disposed adjacent a hot gas path of the turbine system, and side walls extending between the backside of the turbine shroud segment and the flow path surface of the turbine shroud segment. The turbine shroud segment also includes cooling channels disposed in a thickness of the turbine shroud segment between the backside and the flow path surface, where each cooling channel includes an outlet at one of the side walls of the turbine shroud segment. 1. A turbine system having a turbine shroud segment , wherein the turbine shroud segment comprises:a backside;a flow path surface opposite to the back side and configured to be disposed adjacent a hot gas path of the turbine system;side walls extending between the backside of the turbine shroud segment and the flow path surface of the turbine shroud segment; anda plurality of cooling channels disposed in a thickness of the turbine shroud segment between the backside and the flow path surface, wherein each cooling channel of the plurality of cooling channels comprises an outlet at one of the side walls of the turbine shroud segment.2. The turbine system of claim 1 , wherein each cooling channel of the plurality of cooling channels extends parallel to the flow path surface a distance comprising at least fifty percent a total length of the flow path surface of the shroud segment.3. The turbine system of claim 1 , wherein a first subset of the plurality of cooling channels is configured to route coolant in a first direction claim 1 , and wherein a second subset of the plurality of cooling channels is configured to route the coolant in a second direction transverse to the first direction.4. The turbine system of claim 1 , wherein a cross-section of each cooling channel of the plurality of cooling channels comprises a non-circular shape.5. The turbine system of ...

WASH COMPOSITION FOR REDUCING FORMALDEHYDE EMISSIONS

What is described is the use of a composition containing one or more formaldehyde scavengers for production of a coating on a main body of a mold or core for metal casting that emits formaldehyde when heated, wherein the coating forms a surface of the mold or core that comes into contact with a metal melt in the casting operation. 1. A method of production of a coating on a main body of a mold or core for metal casting , comprising:applying on the main body of the mold or core for metal castinga composition comprising(a) particles of one or more refractories β-dicarbonyl compounds', 'di- and trihydric phenols', 'phenol-formaldehyde novolaks and resorcinol-formaldehyde novolaks', 'amino acids', 'primary and secondary aminosilanes', 'melamine, benzoguanamine, urea and derivatives thereof', 'hydrazine and carbonohydrazide and derivatives thereof', 'primary and secondary amines', 'tree resins, tannins and lignins, '(b) one or more compounds selected from the group consisting of'}where the total mass of compounds (b) is 0.1% by weight to 10% by weight, based on the total mass of the particles (a) of the refractories,(c) optionally a carrier liquid selected from the group consisting of water, alkanols and mixtures thereof, 'wherein the coating forms a surface of the mold or core that comes into contact with a metal melt in the casting operation.', 'wherein the composition emits formaldehyde when heated, and'}2. The method as claimed in claim 1 , whereinthe compounds (b) are selected from the group consisting of dialkyl esters of malonic acid, resorcinol, pyrogallol, phloroglucinol, glycine, urea, melamine, carbonohydrazide, and tannins and lignins that are soluble in the carrier liquid (c)and/or (i) one or more refractories selected from the group consisting of quartz, alumina, zirconia, aluminum silicates, nonswellable layered silicates, zirconium silicates, olivine, talc, mica, graphite, coke, feldspar, diatomite, kaolins, calcined kaolins, metakaolinite, iron oxide and ...

COMPOSITION USEFUL AS MORTAR OR COATINGS REFRACTORIES

This invention relates to a composition comprising: ceramic refractory particulates made from alumina, one or more rare earth oxides, one or more oxides of a transition metal, the transition metal being Sc, Zn, Ga, Y, Cd, In, Sn, Tl, or a mixture of two or more thereof; an alumina and phosphate containing composition; and water. The composition is free of SiOor substantially free of SiO, and is useful as a mortar or coating for molten aluminum or steel contact refractories. 1. A composition , comprising:ceramic refractory particulates made from an as-batched refractory composition which comprises alumina particulates, one or more rare earth oxides, and one or more oxides of a transition metal, the transition metal being Sc, Zn, Ga, Y, Cd, In, Sn, Tl, or a mixture of two or more thereof, the as-batched refractory composition being fired to form a ceramic refractory;a phosphate and alumina containing composition; andwater;{'sub': 2', '2, 'the composition being free of SiOor substantially free of SiO.'}2. The composition of wherein the ceramic refractory is in the form of a solid structure which is ground to form the ceramic refractory p articulates.3. The composition of wherein the ceramic refractory is in the form of pellets or briquettes which are reduced in size to form the ceramic refractory p articulates.4. The composition of wherein the as-batched composition for making the ceramic refractory particulates further comprises chopped ceramic fibers containing nanofibrils claim 1 , alumina fibers claim 1 , or a mixture thereof.5. The composition of wherein the chopped ceramic fibers comprise strands of ceramic fiber chopped to a median length in the range from about 0.1 to about 5 cm claim 4 , and having a median diameter in the range from about 1 to about 50 microns.6. The composition of wherein the nanofibrils extend the surface area of the chopped ceramic fibers by at least about 100 times the surface area of the chopped ceramic fiber without the nanofibrils.7. ...

SILICON CARBIDE-CONTAINING MOLD AND FACECOAT COMPOSITIONS AND METHODS FOR CASTING TITANIUM AND TITANIUM ALUMINIDE ALLOYS

The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to silicon carbide-containing mold compositions, silicon carbide-containing intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded. 1. A mold for casting a titanium-containing article , comprising:a calcium aluminate cement comprising calcium monoaluminate, calcium dialuminate, and mayenite, wherein said mold has a silicon carbide-containing intrinsic facecoat of about 10 microns to about 500 microns between a bulk of the mold and a mold cavity.2. The mold as recited in claim 1 , wherein the silicon carbide-containing intrinsic facecoat is a continuous intrinsic facecoat.3. The mold as recited in claim 1 , wherein the silicon carbide is present at about 15% to about 45% by weight.4. The mold as recited in claim 1 , wherein the mold comprises the bulk of the mold and the silicon carbide-containing intrinsic facecoat claim 1 , and wherein the bulk of the mold and the silicon carbide-containing intrinsic facecoat have different compositions and wherein the silicon carbide-containing intrinsic facecoat comprises calcium aluminate with a particle size of less than about 50 microns.5. The mold as recited in claim 1 , wherein the mold comprises the bulk of the mold and the silicon carbide-containing intrinsic facecoat claim 1 , and wherein the bulk of the mold and the silicon carbide-containing intrinsic facecoat have different compositions and wherein the bulk of the mold comprises alumina particles larger than about 50 microns.6. The mold as recited in claim 1 , wherein the mold comprises the bulk of the mold and the silicon carbide-containing intrinsic facecoat claim 1 , and wherein the bulk of the mold comprises alumina particles larger than about 50 microns and the silicon carbide-containing intrinsic facecoat comprises calcium aluminate ...

HIGH THERMAL CONDUCTIVITY SHELL MOLDS

A shell mold is described. The shell mold includes a facecoat, a sealcoat, and a support disposed in between the facecoat and the sealcoat. The support includes a stucco in a concentration greater than about 40 volume percent of the support. The stucco includes a material that has a thermal conductivity greater than about 285 W/m-K. 1. A shell mold , comprising:a facecoat disposed on an inner surface of the shell mold;a sealcoat disposed on an outer surface of the shell mold; anda support in between the facecoat and sealcoat, comprising a stucco in a concentration greater than about 40 volume percent, wherein the stucco comprises a material having a thermal conductivity greater than 285 W/m-K.2. The shell mold of claim 1 , wherein the stucco comprises a plurality of ceramic particulates claim 1 , and wherein a median size of the plurality of particulates is greater than about 80 microns.3. The shell mold of claim 2 , wherein the median size of the plurality of particulates is in a range from about 100 microns to about 300 microns.4. The shell mold of claim 1 , wherein the material comprises silicon carbide claim 1 , aluminum nitride claim 1 , diamond claim 1 , graphite claim 1 , or a combination of any of the foregoing.5. The shell mold of claim 4 , wherein the stucco is made of silicon carbide material.6. The shell mold of claim 1 , wherein the support further comprises silica.7. The shell mold of claim 1 , wherein the support further comprises alumina fine particle dispersion.8. The shell mold of claim 1 , wherein the support has a thickness less than about 8 mm.9. The shell mold of claim 1 , wherein the shell mold has a thermal conductivity value greater than about 2 W/m-K.10. The shell mold of claim 1 , wherein the support comprises multiple layers.11. The shell mold of claim 1 , wherein the concentration of stucco is greater than about 50 volume percent of the support.12. The shell mold of claim 1 , wherein the facecoat comprises alumina claim 1 , chromia claim ...

CASTING CORES AND METHODS FOR MAKING

Embodiments of the present invention include methods for forming ceramic articles, such as cores and core dies used in investment casting. The method may provide ceramic articles having improved strength and smoothness compared to articles manufactured by conventional methods. One embodiment is a method that comprises introducing a liquid comprising a silicon-bearing fluid into pores of a porous ceramic body; and heating the porous ceramic body in an oxygen-bearing atmosphere to form silica within the pores of the body. 1. A method comprising:introducing a liquid comprising a silicon-bearing fluid into pores of a porous ceramic body; andheating the porous ceramic body in an oxygen-bearing atmosphere to form silica within the pores of the body.2. The method of claim 1 , wherein the fluid comprises a siloxane or a silane.3. The method of claim 1 , wherein the liquid is neat.4. The method of claim 1 , wherein the liquid further comprises a second fluid.5. The method of claim 4 , wherein the second fluid has a lower viscosity than the silicon-bearing fluid.6. The method of claim 4 , further comprising volatilizing the second fluid after the liquid has been introduced into the pores of the ceramic body.7. The method of claim 1 , wherein reacting comprises heating the fluid to a temperature above about 200 degrees Celsius.8. The method of claim 1 , wherein the liquid comprises a mixture of silicone monomers.9. The method of claim 8 , further comprising curing the mixture of silicone monomers prior to the reacting step.10. The method of claim 9 , wherein the liquid further comprises a catalyst claim 9 , and wherein curing comprises thermally curing the mixture of silicone monomers in the presence of the catalyst.11. The method of claim 1 , wherein the liquid further comprises a plurality of particles suspended within the silicon-bearing fluid.12. The method of claim 11 , wherein the plurality of particles comprises oxide particles.13. The method of claim 1 , wherein ...

Methods for Die Casting Metals Using Phase Separable Fluids

The present invention provides processes for die casting metals which are more energy efficient and less expensive than the current metal die casting processes. The die casting processes discussed herein utilize a water-soluble die release fluid and hydraulic equipment which uses water-insoluble hydraulic fluid. By doing so, the hydraulic fluid and die release fluid present in the waste collected from the die casting process can be collected via separation techniques. One or both of the collected hydraulic fluid and die release fluid may then be re-used in the same die casting process, another die casting process, or another processes altogether. 1. A process for die casting a metal , said process comprising die casting said metal using a die coated with a water-soluble die release fluid and hydraulic equipment comprising water-insoluble hydraulic fluid;wherein said die release fluid and said hydraulic fluid are immiscible.2. The process according to claim 1 , wherein said die release fluid and said hydraulic fluid do not emulsify when combined.3. The process according to claim 2 , wherein said hydraulic fluid does not reduce the effectiveness claim 2 , efficiency claim 2 , or a combination thereof of said die release fluid for re-use in die casting said metal.4. The process according to claim 1 , wherein said hydraulic fluid is biodegradable.5. The process according to claim 1 , wherein said hydraulic fluid comprises a vegetable oil.6. The process according to claim 5 , wherein said vegetable oil comprises canola oil.7. The process according to claim 1 , wherein said die release fluid comprises water claim 1 , surfactants claim 1 , antimicrobials claim 1 , petroleum oil claim 1 , esters claim 1 , silicones claim 1 , waxes claim 1 , or a combination thereof.8. The process according to claim 1 , wherein one or both of said die release fluid and hydraulic fluid are recyclable.9. The process according to claim 1 , wherein said die release fluid further comprises an ...

Aluminum member

An aluminum member produced by casting a molten metal composed of predetermined ingredients is disclosed. The aluminum member is casted by supplying the molten metal to a space between a fixed die, a movable die, and a sand core disposed between the fixed die and the movable die, and then cooling the molten metal moderately.

USE OF A COATING COMPOSITION AND CORRESPONDING METHOD FOR PRODUCING A CENTRIFUGAL CASTING MOULD WITH A COATING

A description is given of the use of a refractory coating composition having a solids fraction of more than 69 wt %, based on the total mass of the coating composition, and also having a loss on ignition of less than 0.6 wt %, based on the total mass of the solids fraction of the coating composition, for producing a refractory coating on the inner walls of a centrifugal casting mold by means of a spray application. Further described is a method for producing a centrifugal casting mold provided on its inner walls with a refractory coating, for use in the centrifugal casting process, and also a method for producing a casting in the centrifugal casting process, preferably having a structured surface. Also described is a centrifugal casting mold for use in the centrifugal casting process, having a refractory coating on the inner walls of the centrifugal casting mold. 1. A method of producing a refractory coating on the inner walls of a centrifugal casting mold by means of a spray application of a refractory coating composition , wherein the refractory coating composition has:a solids fraction of more than 69 wt %, based on the total mass of the coating composition, anda loss on ignition of less than 0.6 wt %, based on the total mass of the solids fraction of the coating composition,wherein the refractory coating composition is a dispersion of refractories in an aqueous phase, the refractories at least comprising wherein the particulate amorphous oxide comprises a fraction of 85 wt % or more of silicon dioxide, based on the total amount of the particulate amorphous oxide,', {'sub': '95', 'wherein the particulate amorphous oxide possesses a mass-based Dof less than 5 μm, determined by laser diffraction,'}, 'wherein the particulate amorphous oxide possesses a porosity of less than 50%, based on the total amount of the particulate amorphous oxide, and', 'wherein 90 wt % or more of the particles of the particulate amorphous oxide possess a sphericity of greater than 0.9, ...

Method of fabricating an investment casting mold and slurry therefor

A method of fabricating an investment casting mold includes using a zircon-containing slurry to form a facecoat of a refractory investment wall of a mold cavity in an investment casting mold. The zircon-containing slurry includes, by weight, at least 70% of zircon powder. Also disclosed is a slurry for use in an investment casting mold. The slurry includes, by weight, at least 70% of zircon powder, 10%-30% of colloidal silica material, and 1%-10% of a carrier solvent. The method and slurry can be used to fabricate an investment casting mold that has a refractory investment wall with a facecoat having, by weight, at least 70% zircon.

CASTING MEMBER, CASTING METHOD, AND METHOD OF MANUFACTURING LUBRICANT USED FOR CASTING

In the invention, a nano carbon layer that is constituted by a nano carbon group is formed on a molten metal contact surface of a casting member, and a lubricant that has a pulverulent body, which is constituted by BN, graphite, talc or silica, as a main component is applied onto the nano carbon layer. It is preferable that a nitrided layer be formed between the nano carbon layer and the molten metal contact surface of the casting member when the nano carbon layer is formed, and that the lubricant applied to the nano carbon layer have a BN pulverulent body as a main component. According to the invention, the mold releasability and fluidity of the casting member can be maintained even if the number of times of casting is increased, and the cost of the process of subjecting the molten metal contact surface of the casting member to the surface treatment can be reduced. 1. A casting member comprising:a nano carbon layer that is formed on a molten metal contact surface of a casting member and constituted by a nano carbon group; anda lubricant that is applied onto the nano carbon layer and has a pulverulent body that is constituted by BN, graphite, talc or silica as a main component.2. The casting member according to claim 1 , further comprising:a nitrided layer that is formed between the nano carbon layer and a cavity surface when the nano carbon layer is formed, whereinthe lubricant that is applied to the nano carbon layer has a BN pulverulent body as a main component.3. The casting member according to claim 1 , whereinirregularities of 10 μm or less are formed on a surface of the nano carbon layer, anda powder diameter of the pulverulent body contained in the lubricant is smaller than a size of the irregularities of the nano carbon layer.4. A casting method comprising:forming a nano carbon layer that is constituted by a nano carbon group, on a molten metal contact surface of a casting member; andapplying a lubricant, which has a pulverulent body constituted by BN, ...

CASTING MOLD AND CAST ARTICLE PRODUCED USING THE SAME

A casting mold includes a carbon film with which at least a surface of the casting mold which forms a cavity is covered, and mold oil with which a surface of the carbon film is coated. In the casting mold, aluminum powder is added to the mold oil. 1. A casting mold comprising:a carbon film with which at least a surface of the casting mold which forms a cavity is covered; anda mold oil with which a surface of the carbon film is coated, whereinan aluminum powder is added to the mold oil.2. The casting mold according to claim 1 , wherein the aluminum powder comprises flake aluminum particles.3. The casting mold according to claim 1 , wherein a graphite powder is further added to the mold oil.4. The casting mold according to claim 3 , wherein the graphite powder comprises flake graphite particles.5. The casting mold according to claim 3 , wherein the mold oil contains 10 to 34 mass % of the aluminum powder claim 3 , 24 mass % or less of the graphite powder claim 3 , and 40 to 64 mass % of refined mineral oil having a heatproof temperature of 250° C. or higher.6. The casting mold according to claim 1 , wherein the carbon film contains at least one type of nanocarbons selected from the group consisting of carbon nanocoils claim 1 , carbon nanotubes claim 1 , and carbon nanofilaments.7. A cast article produced by using the casting mold according to . 1. Field of the InventionThe invention relates to a casting mold in which at least a surface of the casting mold which forms a cavity is covered with a carbon film, and a cast article produced using the casting mold.2. Description of Related ArtA technology of casting a metal product using a casting mold makes it possible to manufacture a large quantity of products having a certain shape and a certain level of quality, and this technology is applied to production of cast articles made of various metal materials. In a casting process, a surface of the casting mold, which forms a cavity to be filled with molten metal, is ...

COATING COMPOSITIONS FOR INORGANIC CASTING MOLDS AND CORES, COMPRISING FORMIC ACID ESTERS, AND USE THEREOF

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. 1. A sizing composition comprising:(A) esters of formic acid;(B) a carrier fluid comprising or consisting of water, and(C) refractory materials.2. The sizing composition according to claim 1 , wherein the alcohol group(s) of the formic acid ester(s) in each case contain fewer than 10 carbon atoms.3. The sizing composition according to claim 2 , wherein the concentration of the formic acid esters in the sizing composition amounts to 1 to 8% by weight.4. The sizing composition according to claim 1 , wherein the carrier fluid comprises of more than 50% by weight of water.5. The sizing composition according to claim 1 , wherein the solids content of the sizing composition amounts to 30 to 70% by weight.6. The sizing Sizing composition according to claim 1 , wherein the sizing composition comprises 10 to 85% by weight of refractory material claim 1 , based on the solids content of the sizing composition.7. The sizing composition according to claim 1 , wherein the refractory materials are selected from the group consisting of: quartz claim 1 , aluminum oxide claim 1 , zirconium dioxide claim 1 , aluminum silicates claim 1 , zirconium sands claim 1 , zirconium silicates claim 1 , olivine claim 1 , talc claim 1 , mica claim 1 , coke claim 1 , feldspar claim 1 , diatomite claim 1 , kaolins claim 1 , calcined kaolins claim 1 , kaolinite claim 1 , metakaolinite claim 1 , iron oxide claim 1 , bauxite and mixtures thereof.8. The sizing composition according to claim 1 , in which the refractory materials have particle sizes of 0.1 to 500 μm claim 1 , measured by light scattering according to DIN/ISO 13320.9. The sizing composition according to claim 1 , wherein the sizing composition comprises 0.1 to 20% by weight claim ...

Method for producing salt core

A method for producing a salt core includes a step A of adding a saturated sodium chloride aqueous solution to a sodium chloride crystal that is granular, to prepare a slurry mixed material of sodium chloride and water, a step B of subjecting the slurry mixed material to pressure molding to obtain a molded article, and a step C of drying the molded article to remove moisture.

COATING COMPOSITIONS FOR INORGANIC CASTING MOLDS AND CORES AND USE THEREOF AND METHOD FOR SIZING

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.

METHOD AND ASSEMBLY FOR FORMING COMPONENTS HAVING INTERNAL PASSAGES USING A JACKETED CORE

A mold assembly for use in forming a component having an internal passage defined therein includes a mold defining a mold cavity therein, and a jacketed core positioned with respect to the mold. The jacketed core includes a hollow structure, and an inner core disposed within the hollow structure and positioned to define the internal passage within the component when a component material in a molten state is introduced into the mold cavity and cooled to form the component. The jacketed core also includes a first coating layer disposed between the hollow structure and the inner core. 1. A mold assembly for use in forming a component having an internal passage defined therein , said mold assembly comprising:a mold defining a mold cavity therein; and a hollow structure;', 'an inner core disposed within said hollow structure and positioned to define the internal passage within the component when a component material in a molten state is introduced into said mold cavity and cooled to form the component; and', 'a first coating layer disposed between said hollow structure and said inner core., 'a jacketed core positioned with respect to said mold, said jacketed core comprising2. The mold assembly of claim 1 , wherein said first coating layer is disposed on at least a portion of an interior portion of said hollow structure.3. The mold assembly of claim 1 , wherein said first coating layer is formed from a first coating material selected to modify a performance of the internal passage when the component is formed.4. The mold assembly of claim 3 , wherein said first coating material is selected from one of (i) an oxidation-inhibiting material claim 3 , (ii) a corrosion-inhibiting material claim 3 , (iii) a carbon-deposition-inhibiting material claim 3 , (iv) a thermal barrier material claim 3 , (v) a water vapor barrier material claim 3 , and (vi) a wear-inhibiting material.5. The mold assembly of claim 1 , wherein said first coating layer is one of a plurality of coating ...

REFRACTORY SLURRY OF REDUCING CARBON PICKUP IN LOST FOAM CASTING, FOAM PATTERN AND PROCESSES FOR MANUFACTURING AND USING THE SAME

Refractory slurry for use in coating a foam cluster to provide a foam pattern for lost foam casting is provided. The slurry includes a catalyst capable of catalyzing reactions for vaporizing the foam cluster. A foam pattern with a refractory coating including the catalyst and processes for preparing the foam pattern and using the foam pattern are also provided. 1. A lost foam casting method , comprising:{'sub': 2', 'x', '2', '2', '2', '8', 'a', 'b', 'c', 'd', '3−δ, 'providing a foam pattern comprising a foam cluster and a refractory coating coated on the foam cluster, wherein the refractory coating comprises a foam cluster vaporizing catalyst, the foam cluster vaporizing catalyst comprising at least a carnegieite-like material of formula (NaO)Na[AlSiO] or a perovskite material of formula ABCDO, wherein0 Подробнее

METHOD AND ASSEMBLY FOR FORMING COMPONENTS HAVING INTERNAL PASSAGES USING A JACKETED CORE

A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, an inner core disposed within the hollow structure, and a core channel that extends from at least a first end of the inner core through at least a portion of inner core. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component. 1. A method of forming a component having an internal passage defined therein , said method comprising: a hollow structure formed from a first material;', 'an inner core disposed within the hollow structure; and', 'a core channel that extends from at least a first end of the inner core through at least a portion of inner core;, 'positioning a jacketed core with respect to a mold, wherein the jacketed core includesintroducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from the jacketed core within the cavity; andcooling the component material in the cavity to form the component, wherein the inner core defines the internal passage within the component.2. The method of further comprising removing the inner core from the component to form the internal passage.3. The method of claim 2 , wherein removing the inner core comprises flowing a fluid into the core channel.4. The method of claim 3 , wherein the inner core is formed from a ceramic material claim 3 , and wherein flowing the fluid into the core channel comprises flowing the fluid configured to interact with the ceramic ...

METHOD AND ASSEMBLY FOR FORMING COMPONENTS HAVING INTERNAL PASSAGES USING A JACKETED CORE

A method of forming a component having an internal passage defined therein includes forming a precursor core having a shape corresponding to a shape of the internal passage, and forming a hollow structure around the precursor core. The method also includes removing the precursor core from within the hollow structure, and disposing an inner core within the hollow structure to form a jacketed core. The method further includes positioning the jacketed core with respect to a mold, and introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity. Additionally, the method includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component. 1. A method of forming a component having an internal passage defined therein , said method comprising:forming a precursor core having a shape corresponding to a shape of the internal passage;forming a hollow structure around an outer wall of the precursor core;removing the precursor core from within the hollow structure;disposing an inner core within the hollow structure such that the hollow structure and the inner core form a jacketed core;positioning the jacketed core with respect to a mold;introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity; andcooling the component material in the cavity to form the component, wherein the inner core defines the internal passage within the component.2. The method of claim 1 , wherein forming the hollow structure around the outer wall of the precursor core comprises complementarily shaping an interior portion of the hollow structure by the outer wall of the precursor core.3. The ...

Polycrystalline Silicon Powder for Slurry and Method for Producing Same, Polycrystalline Silicon Powder Slurry for Mold Release Material and Method for Producing Same, Polycrystalline Silicon Powder for Mold Release Material, Mold Release Material, and Polycrystalline Silicon Ingot Casting Mold and Method for Producing Same

A silicon nitride powder to be used in a slurry for forming a mold release layer of a polycrystalline silicon casting mold, wherein the specific surface area thereof is 5-50 m/g, the proportion of amorphous silicon nitride is 1.0-25.0 mass %, and the oxygen content is 0.6-2.5 mass %. A silicon nitride powder slurry for use in mold release material and capable of forming, on a polycrystalline silicon casting mold, a mold release layer which exhibits favorable mold release properties and exhibits favorable adhesion to the casting mold after casting the polycrystalline silicon ingot, and a method for producing the same. A silicon nitride powder for mold release material, a silicon nitride powder for a slurry use for obtaining the silicon nitride powder slurry for use in the mold release material, and a method for producing the same. A polycrystalline silicon casting mold which exhibits favorable mold release properties of a polycrystalline silicon ingot; and method for producing the same. 1. A silicon nitride powder to be used in a slurry for forming a mold release layer of a polycrystalline silicon casting mold , which has a specific surface area of 5-50 m/g , a proportion of amorphous silicon nitride of 1.0-25.0 mass % , and an oxygen content of 0.6-2.5 mass %.2. A silicon nitride powder slurry for mold release material claim 1 , which is obtained by blending the silicon nitride powder according to and water.3. A silicon nitride powder for mold release material claim 1 , which is obtained by blending the silicon nitride powder according to and water to form a slurry claim 1 , and drying the slurry claim 1 , and which has an oxygen content of 0.7-5.0 mass %.4. Mold release material for forming a mold release layer to be formed on a polycrystalline silicon casting mold claim 3 , which comprises the silicon nitride powder according to .5. A polycrystalline silicon casting mold claim 4 , which comprises a mold release layer formed on a casting mold claim 4 , the mold ...

INVESTMENT MOLD HAVING METALLIC DONOR ELEMENT

An investment mold includes a refractory investment wall that has a surface region that bounds at least a portion of a mold cavity for receiving a molten metallic material. At least a portion of the surface region includes at least one metallic donor element with respect to the molten metallic material. Upon exposure of the surface region to the molten metallic material, the metallic donor element dopes into the molten metallic material. The method can be used to fabricate a cast article. The cast article can include a body formed of a metallic material having at least one reactive metallic element with respect to reactive-element-loss in an investment casting process. The body can include at least one internal passage that has a surface region that is compositionally rich in the reactive metallic element, which is doped into the body from the surface region of the refractory investment wall. 1. An investment mold comprising:a refractory investment wall having a surface region bounding at least a portion of a mold cavity for receiving a molten metallic material, at least a portion of the surface region including at least one metallic donor element with respect to the molten metallic material, such that upon exposure of the surface region to the molten metallic material the at least one metallic donor element dopes into the molten metallic material.2. The investment mold as recited in claim 1 , wherein the at least one metallic donor element is selected from the group consisting of yttrium claim 1 , lanthanum claim 1 , hafnium claim 1 , erbium claim 1 , calcium claim 1 , magnesium claim 1 , and combinations thereof.3. The investment mold as recited in claim 1 , wherein the at least one metallic donor element includes yttrium.4. The investment mold as recited in claim 1 , wherein the refractory investment wall is an investment core having a refractory body and a coating of the at least one metallic donor element thereon.5. The investment mold as recited in claim 1 , ...

NEEDLE-SHAPED CYLINDER LINER AND PREPARATION METHOD THEREFOR, AND COATING LIQUID FOR PREPARING NEEDLE-SHAPED CYLINDER LINER

A coating liquid for preparing a needle-shaped cylinder liner, comprising the following components: 0.05-0.4 parts of an anionic surfactant; 0.05-0.5 parts of tannic acid; 0.15-0.7 parts of caustic soda; 22-38 parts of diatomite; 3-10 parts of montmorillonite; and 62-75 parts of water. A method for preparing a needle-shaped cylinder liner comprises spraying a coating liquid for preparing the needle-shaped cylinder liner onto the inner wall of a hollow cylindrical mould, and drying the coating liquid to obtain a mould with a coating attached to the surface of the inner wall; adding an inoculated iron liquid into the rotary mould, and cooling and demoulding to obtain a cylinder liner blank; and subjecting the blank to outer surface cleaning and forming machining to obtain the needle-shaped cylinder liner. 2. The coating solution according to claim 1 , wherein the anionic surfactant comprises one or more selected from the group consisting of sodium dodecyl benzene sulfonate claim 1 , triethanolamine dodecyl benzene sulfonate claim 1 , surfactant AS and ammonium dodecyl sulfate.3. The coating solution according to claim 1 , wherein the diatomaceous earth has a permeability of 2 to 3.4. The coating solution according to claim 1 , wherein the diatomaceous earth has a bulk density of 0.33 to 0.65 g/cm.5. The coating solution according to claim 1 , wherein the diatomaceous earth has a particle size of 100 to 800 mesh.6. The coating solution according to claim 1 , wherein the montmorillonite has a density of 2.0 to 2.7 g/cm.7. The coating solution according to claim 1 , wherein the montmorillonite has an expansion ratio of 30 to 50.8. The coating solution according to claim 1 , wherein the montmorillonite has a particle size of 0.2 to 1 μm.10. A method for producing a needle-shaped cylinder liner claim 1 , comprising the steps of:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'a) spraying the coating solution according to into an inner wall of a hollow cylindrical mold ...

MOLTEN ALUMINUM RESISTANT ALLOYS

Embodiments of methods for protection a material from a reaction from molten aluminum. In some embodiments, a coating can be applied over a substrate which has significantly less of a reaction rate with molten aluminum, thus preventing damage or chemical changes to the substrate. The coating alloy can be formed from cast iron in combination with niobium in some embodiments. 1. A method of protecting a component from molten aluminum reaction , the method comprising:coating a component formed from a base material with an alloy;wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K; andwherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.2. The method of claim 1 , wherein the alloy is a Nb—Zr alloy with 30-60 wt. % Zr.3. The method of claim 1 , wherein the alloy has a reaction rate to molten aluminum less than 50% than that of the base material.4. The method of claim 1 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)Nbwith x ranging from 10 to 30 wt. %.5. The method of claim 1 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)Nbwith x ranging from 0 to 10 wt. %.6. The method of claim 1 , wherein the alloy has a reaction rate less than 10% than that of the base material.7. The method of claim 1 , wherein the alloy has a reaction rate less than 5% than that of the base material.8. An alloy resistant to molten aluminum claim 1 , the alloy comprising:two or more elements;a reaction level of less than 38 atom %, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K; anda minimum ...

REFRACTORY SLURRY OF REDUCING CARBON PICKUP IN LOST FOAM CASTING, FOAM PATTERN AND PROCESSES FOR MANUFACTURING AND USING THE SAME

Refractory slurry for use in coating a foam cluster to provide a foam pattern for lost foam casting is provided. The slurry includes a catalyst capable of catalyzing reactions for vaporizing the foam cluster. A foam pattern with a refractory coating including the catalyst and processes for preparing the foam pattern and using the foam pattern are also provided. 1. A foam pattern for lost foam casting , the foam pattern comprising:a foam cluster; and{'sub': 2', 'x', '2', '2', '2', '8', 'a', 'b', 'c', 'd', '3-δ, 'claim-text': 0 Подробнее

Casting mold, and production method thereof

A casting mold and a production method thereof with which exfoliation of coating is controlled and liquidity of molten metal can be maintained are provided. This casting mold 1 includes a surface processing part 3 in which a plurality of groove parts 5 of a grid groove 4 formed in a surface of a molten metal contact part of a mold material 2 is coated with a carbon film 6 . In this surface processing part 3 , a width W 1 of the groove parts 5 is 35 μm or narrower, skewness Ssk of three-dimensional surface roughness is in a range of −0.8 to −0.2, and indentation hardness of the carbon film 6 tested by a nanoindenter is 1000 N/mm 2 or higher. With this arrangement, it is possible to optimize the surface processing part 3 in such a manner that a penetration rate of the molten metal (aluminum 10 ) is controlled to be low and the coating (carbon film 6 ) is unlikely to exfoliate from the groove parts 5.

CASTING MEMBER AND METHOD FOR MANUFACTURING SAME

Disclosed are an inexpensive casting member on which a film with high peel strength is formed, and a method for manufacturing the casting member. A surface-treated mold () includes a metal mold () having the molding surface including a plurality of protrusions () each having an inverse-slope shape, and a carbon film () formed on the molding surface of the metal mold (). The surface-treated mold () is manufactured through a step (S) including a modeling step (S) for producing the metal mold (), by means of selective laser sintering, which has the molding surface including the plurality of protrusions () each having the inverse-slope shape, and a film-forming step (S) for forming the carbon film () on the molding surface of the metal mold () produced in the modeling step (S). 1. A casting member used for casting , comprising:a base material manufactured by means of selective laser sintering, which has a surface including a plurality of minute irregularities each having an inverse-slope shape; anda film formed on the surface of the base material.2. The casting member according to claim 1 , whereinthe base material is a metal mold having a molding surface, andthe film is formed on the molding surface of the metal mold.3. A method for manufacturing a casting member used for casting claim 1 , comprising:a modeling step for producing a base material, by means of selective laser sintering, which has a surface including a plurality of minute irregularities each having an inverse-slope shape; anda film-forming step for forming a film on the surface of the base material produced in the modeling step.4. The method according to claim 3 , whereinthe film is a carbon film including at least one kind of nanocarbon, andin the film-forming step, the carbon film is formed on the surface of the base material by heating the base material while supplying a reactive gas used to make the carbon film.5. The method according to claim 4 , whereina temperature and a time for heating the base ...

Metallurgical vessel lining with enclosed metal layer

A lining structure for a refractory vessel contains a first layer containing refractory material; a second layer, in communication with and parallel to the first layer, containing a metal layer or component; and a third layer, in communication with and parallel to the second layer, containing refractory material. The metal component in the second layer contains filled transverse passages, between the surface of the second layer in contact with the first layer and the surface of the second layer in contact with the third layer, producing support structures to maintain the structural integrity of the refractory vessel in use.

POLYURETHANE CASTING COMPOUND FOR PRODUCING WEAR PROTECTION COATINGS IN CASTING HOUSE APPLICATIONS

The present invention relates to multi-component compositions including an isocyanate component and an amine component, wherein the isocyanate component includes a prepolymer, obtainable from toluene isocyanate and a polytetramethylene polyol, and the amine component includes a dialkylthio aryl diamine and possibly a polytetramethylene oxide polyamine. Corresponding compositions can be advantageously used as flowable or spreadable resin systems for producing surface protection coatings in casting house applications and are characterized by a significantly improved resistance to abrasion in comparison with conventional casting resin systems based on hexamethylene diisocyanate and dimethyl thiotoluene diamine. 1. A multi-component composition , comprising an isocyanate component and an amine component , wherein the isocyanate component comprises a prepolymer , obtainable from toluene diisocyanate and a polytetramethylene polyol , and the amine component comprises a dialkylthio aryl diamine.2. The multi-component composition according to claim 1 , wherein the composition essentially consists of the isocyanate and amine components.3. The multi-component composition according to claim 1 , wherein the prepolymer has an isocyanate content in the range of 7 to 10%.4. The multi-component composition according to claim 1 , wherein the polytetramethylene polyol has a calculated molecular weight (Mw) in the range of 500 to 1500.5. The multi-component composition according to claim 1 , wherein the dialkylthio aryl diamine is present in the form of dimethyl thiotoluene diamine.6. The multi-component composition according to claim 1 , wherein the amine component additionally contains a polytetramethylene oxide polyamine in the form of a diamine claim 1 , wherein the amine is preferably connected to the polytetramethylene oxide over a linker molecule.7. The multi-component composition according to claim 1 , wherein the polytetramethylene oxide part of the polytetramethylene oxide ...

MOLD RELEASE AGENT FOR WATER GLASS-CONTAINING SAND MOLD MOLDING

[Task] There is provided a mold release agent for forming a water glass-containing sand mold with high release properties which can prevent attachment of a water glass to a flask and the accumulation of the water glass on the flask in the formation of the sand mold when using the water glass as a binder. 1. A mold release agent for forming a water glass-containing sand mold characterized by comprising an organic compound having a proton-donating functional group that reacts with water glass to produce silicon dioxide in the functional group.2. The mold release agent for forming a water glass-containing sand mold according to claim 1 , characterized in that the proton-donating functional group is a carboxyl group.3. A mold release agent for forming a water glass-containing sand mold characterized by comprising a chain organic compound having a carboxyl group in an amount of more than 0.0001 mol/kg and 0.0500 mol/kg or less. The present invention relates to a mold release agent used in forming a sand mold using water glass as a binder (mold release agent for forming a water glass-containing sand mold).Conventionally, a technique of forming a casting mold using foundry sand to which water glass is added was used (Patent Document 1). This technique is a technique in which 1 to 4% (% by weight) of water glass is added and kneaded in foundry sand, and a casting mold is formed from the kneaded mixture, and then dried.Patent Document 1: Japanese Patent Application Publication No. H9-174194 (JP H9-174194 A)When a sand mold (casting mold: main mold and core) is formed using water glass as a binder as in BACKGROUND ART described above, water glass (sodium silicate) is easily attached (fixed) to a flask used in forming the sand mold, and the sand mold is likely to collapse during mold release. This is because water glass has high affinity to another substance such as metal.Water glass is likely to accumulate on the flask, even though the sand mold can be released. The flask has ...

GREEN SAND MOLD AND ITS PRODUCTION METHOD, AND PRODUCTION METHOD OF IRON-BASED CASTING

A green sand mold comprising at least one pair of green sand mold parts each comprising a recess and a mating surface, wherein a cured layer comprising a thermosetting resin as a main component is formed on the recess and mating surface of each green sand mold part, and wherein the cured layer has hardness of 40-98, a thickness of 0.5-6 mm, and gas permeability of 70-150, is produced by applying a curing material comprising the thermosetting resin as a main component and having viscosity of 1-100 mPa·S to the recess and mating surface of each green sand mold part, combining the green sand mold parts, and then heat-hardening the curing material. 1. A green sand mold comprising at least one pair of green sand mold parts each comprising a recess and a mating surface ,a cured layer comprising a thermosetting resin as a main component being formed on the recess and mating surface of each of the green sand mold parts; andsaid cured layer having hardness of 40-98, a thickness of 0.5-6 mm, and gas permeability of 70-150.2. The green sand mold according to claim 1 , wherein said thermosetting resin is at least one of a phenol resin claim 1 , an epoxy resin and a furan resin.3. A method for producing the green sand mold recited in claim 1 , comprising the steps ofapplying a curing material comprising a thermosetting resin as a main component and having viscosity of 1-100 mPa·S to a recess and a mating surface of each of the green sand mold parts;combining the green sand mold parts; and thenheat-hardening the curing material.4. The method for producing the green sand mold according to claim 3 , wherein the curing material is a solution of the thermosetting resin in alcohol.5. The method for producing the green sand mold according to claim 3 , wherein the amount of the curing material applied is 100-550 g/m.6. The method for producing the green sand mold according to claim 3 , comprising the steps ofapplying a curing material having viscosity of 1-15 mPa·S to a recess and a ...

CASTING GREEN SAND MOLD, AND METHOD FOR PRODUCING CAST ARTICLE USING IT

A casting green sand mold comprising at least a pair of green sand mold parts each having a cavity portion, which are stacked with their cavity portions aligned to form a metal-melt-receiving cavity; each of the green sand mold parts being formed by casting sand containing a binder and water; a hardening-resin-based coating layer being formed on at least the cavity portion of each green sand mold part; the coating layer having gas-permeable pores having sufficient permeability to permit a gas generated by pouring a metal melt to escape; and a water content in a surface layer including the coating layer in a range from the cavity surface to the depth of 5 mm being smaller than that in the inner portion of the green sand mold. 1. A casting green sand mold comprising at least a pair of green sand mold parts each having a cavity portion , said green sand mold parts being stacked with their cavity portions aligned to constitute a metal-melt-receiving cavity;each of said green sand mold parts being formed by casting sand containing a binder and water;a hardening-resin-based coating layer being formed on at least said cavity portion of each green sand mold part;said coating layer having gas-permeable pores having sufficient permeability to permit a gas generated by pouring a melt to escape; anda surface layer including said coating layer in a range from the cavity surface to the depth of 5 mm having a water content, which is smaller than the average water content of a green sand mold portion excluding said surface layer.2. The casting green sand mold according to claim 1 , wherein said gas-permeable pores are composed of large numbers of communicating fine pores substantially uniformly distributed in said coating layer.3. The casting green sand mold according to claim 1 , wherein said coating layer has permeability (measured by an accelerated method using a large orifice according to JIS Z2601) of 50-200.4. The casting green sand mold according to claim 1 , wherein said ...

Refractory coating composition for making facings on temporary molds or on cores for iron and steel casting operations

The invention relates to a refractory coating composition for producing mold coatings on non-permanent molds or on cores for the casting of iron and steel, comprising a) an alkali metal salt or alkaline earth metal salt of carbonic acid and/or an alkali metal salt or alkaline earth metal salt of diphosphoric acid, b) a carrier liquid and c) refractory materials.

COMPOSITION OF A CERAMIC LAYER FOR MANUFACTURING A CASTING MOULD AND OTHER PRODUCTS

A composition of a ceramic layer for manufacturing a casting mould and other products, in particular intended for making castings by investment casting, comprising a liquid ceramic mass consisting of in weight %, 50-75% of a ceramic material which is a mixture with particle-size distribution comprising minimum 90% of particles of size less than 0.04 mm, having the following phase composition: 30-90% of forsterite MgSiO, 5-15% of fayalite FeSiOand 5-65% of a mixture of phase components such as chrysolite 2(MgFe)SiO, enstatite MgSiO, tremolite CaMgSiO(OH), ringwoodite (Mg,Fe), diopside Ca(Mg,AI)(Si,AI)Oand others, and of 25-50% of a binder comprising an aqueous or aqueous-organic colloidal solution of a metallic oxide and modifiers, and a ceramic material for sprinkling which is a mixture having the following phase composition, in weight %: 30-90% of forsterite MgSiO, 5-15% of fayalite FeSiO, and 5-65% of a mixture of phase components such as chrysolite 2(MgFe)SiO, enstatite MgSiO, tremolite CaMSiO(OH), ringwoodite (Mg,Fe), diopside Ca(Mg,AI)(Si,Al)Oand others. 1. A composition of a ceramic layer for manufacturing a casting mould , in particular intended for making castings by investment casting , comprising:a) a liquid ceramic mass and b) a ceramic material for sprinkling-characterized in that the composition comprises:{'sub': 2', '4', '2', '4', '0.88', '0.12', '2', '3', '2', '5', '8', '22', '2', '2', '4', '2', '6, 'a1) the liquid ceramic mass consisting of, in weight %, 50-75% of the ceramic material which is a mixture with particle-size distribution comprising minimum 90% of particles of size less than 0.04 mm, and the following phase composition: 30-90% of forsterite MgSiO, 5-15% of fayalite FeSiOand 5-65% of a mixture of phase components such as chrysolite 2(MgFe)SiO, enstatite MgSiO, tremolite CaMgSiO(OH), ringwoodite (Mg,Fe)[SiO] and diopside Ca(Mg,Al)(Si,Al)O,'}anda2) 25-50% of a binder comprising an aqueous or aqueous-organic colloidal solution of a metallic ...

CASTING METHOD USING LOST FOAM

Provided is a casting method using lost foam capable of forming a small highly-finished hole with a diameter of 18 mm or less and a length of 50 mm or more by casting. A casting method using lost foam of the present embodiment includes the steps of embedding, in foundry sand, a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern, the foam pattern having a hole with a diameter of D (mm); replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; and forming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, and the method satisfies the following formulas (0) and (1): 1. A casting method using lost foam comprising the steps of embedding , in foundry sand , a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern , the foam pattern having a hole with a diameter of D (mm);replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; andforming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, [{'br': None, '2 Подробнее

AQUEOUS COMPOSITION

According to an aspect of the present invention, an aqueous composition contains at least one selected from a group consisting of a carboxylic acid compound represented by the following formula (1), a carboxylic anhydride represented by the following formula (2), and a trimellitic anhydride; a basic compound; and water. In the formula (1), “R” represents an alkanediyl group having 2 to 4 carbons, a vinylene group, or a benzene ring, and “a” represents 2 or 3. In the formula (2), “R” represents an alkanediyl group having 2 to 4 carbons, a vinylene group, or a benzene ring. 2. The aqueous composition according to claim 1 , whereinthe carboxylic acid compound is at least one selected from a group consisting of a succinic acid, an adipic acid, a maleic acid, a fumaric acid, a phthalic acid, an isophthalic acid, a terephthalic acid, and a trimellitic acid.3. The aqueous composition according to claim 2 , whereinthe carboxylic acid compound is at least one selected from a group consisting of an adipic acid, a terephthalic acid, and a trimellitic acid.4. The aqueous composition according to claim 1 , whereinthe carboxylic anhydride is at least one selected from a group consisting of a succinic anhydride, an adipic anhydride, a maleic anhydride, and a phthalic anhydride.5. The aqueous composition according to claim 1 , wherein the carboxylic acid compound consists of:an aliphatic carboxylic acid compound represented by the formula (1), wherein “R” represents an alkanediyl group having 2 to 4 carbons; andan aromatic carboxylic acid compound represented by the formula (1), wherein “R” represents a benzene ring.6. The aqueous composition according to claim 5 , whereinthe aliphatic carboxylic acid is an adipic acid, andthe aromatic carboxylic acid is a terephthalic acid.7. The aqueous composition according to claim 1 , wherein a total content of the carboxylic acid compound claim 1 , the carboxylic anhydride claim 1 , and the trimellitic anhydride is 3 to 30 mass % to a total ...

Ceramic coating for foundry core

A process for coating a refractory alloy part is provided and includes coating an area of a refractory alloy part by means of a treatment composition including a type of preceramic polymer and a solvent, and heat treating the part coated with the treatment composition. The heat treating partially converts the preceramic polymer and forms a ceramic coating obtained by conversion, the ceramic coating protecting the refractory alloy from oxidation. The treatment composition also includes active fillers to form an alloy coating on a surface of the part by solid diffusion in addition to the ceramic coating obtained by conversion, and the alloy coating generates a protective oxide layer when subjected to oxidizing conditions.

Sizing composition, method for coating a casting mould and use of the sizing composition for coating a casting mould

The present invention relates to a coating composition comprising a solid component comprising a clay and mica, wherein the clay comprises from about 50 to about 90% by weight of kaolinite and from about 5 to about 35% by weight of montmorillonite and the coating composition comprises, based on the solid component, from about 5 to about 50 parts by weight of clay. Furthermore, a process for coating a casting mold and the use of the coating composition for coating a casting mold are disclosed.

COATING COMPOSITIONS FOR INORGANIC CASTING MOLDS AND CORES, CONTAINING SALTS, AND USE THEREOF

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. 1. A sizing composition comprising:(A) salts of at least one of the metals magnesium and manganese, the salts present in a concentration, of greater than 1% by weight, based on the sizing composition,(B) a carrier fluid comprising or consisting of water, and(C) refractory materials.2. The sizing composition according to claim 1 , wherein the salts have as an anion at least one of: sulfate ion(s) and chloride ions.3. The sizing composition according to claim 1 , wherein manganese is used in the +2 or +4 oxidation state and magnesium is used in the +2 oxidation state.4. The sizing composition according to claim 1 , wherein the concentration of the salts is greater than 3% by weight based on the sizing agent composition.5. The sizing composition according to claim 1 , wherein the salt concentration corresponds claim 1 , at maximum claim 1 , to the saturation concentration of the salt in the carrier fluid used.6. The sizing composition according to claim 1 , wherein the concentration of the salts is less than 10% by weight claim 1 , based on the sizing composition.7. The sizing composition according to claim 1 , wherein the carrier liquid comprises more than 50% water.8. The sizing composition according to claim 1 , wherein the solids content of the sizing composition amounts to 30 to 70% by weight.9. The sizing composition according to claim 1 , wherein the sizing composition comprises 10 to 85% by weight of refractory materials claim 1 , based on the solids content of the sizing composition.10. The sizing composition according to claim 1 , wherein the refractory materials are selected from the group consisting of: quartz claim 1 , aluminum oxide claim 1 , zirconium dioxide claim 1 , aluminum ...

PRECISION CASTING MOLD AND METHOD OF PRODUCING THE SAME

Provided is a precision casting mold to be used to produce a cast product. The precision casting mold includes a core having a shape corresponding to an internal hollow portion of the cast product and an outer mold corresponding to a shape of an outer peripheral surface of the cast product, and the outer mold is made up of: a prime layer which is formed on an inner peripheral surface and is formed from a slurry film obtained by drying slurry for the precision casting mold including mono-dispersed ultrafine alumina particles having a particle size of 1.0 μm or smaller; and a multi-layered backup layer which is formed on the outside of the prime layer by repeatedly forming a first backup layer obtained by forming and drying a slurry layer formed from the slurry for the precision casting mold and a stucco layer in which silicon carbide (SiC) as a stucco material is adhered to the slurry layer. 1. A precision casting mold which is used to produce a cast product , comprising:a core having a shape corresponding to an internal hollow portion of the cast product; andan outer mold corresponding to a shape of an outer peripheral surface of the cast product, wherein the outer mold is made up of: a prime layer which is formed on an inner peripheral surface and is formed from a slurry film obtained by drying slurry for the precision casting mold including ultrafine alumina particles having a particle size of 0.3 μm to 0.6 μm; and a multi-layered backup layer which is formed on the outside of the prime layer by repeatedly forming a backup layer obtained by forming and drying a slurry layer formed from the slurry for the precision casting mold and a stucco layer in which silicon carbide as a stucco material is adhered to the slurry layer.2. The precision casting mold according to claim 1 , wherein the prime layer has the stucco layer in which the stucco material is adhered to the slurry layer formed from the slurry for the precision casting mold.3. A method of producing a ...

PRECISION CASTING MOLD AND METHOD OF PRODUCING THE SAME

Provided is a precision casting mold to be used to produce a cast product. The precision casting mold includes a core having a shape corresponding to an internal hollow portion of the cast product and an outer mold corresponding to a shape of an outer peripheral surface of the cast product, and the outer mold is made up of: a prime layer which is formed on an inner peripheral surface and is formed from a slurry film obtained by drying slurry for the precision casting mold including mono-dispersed alumina (AlO) ultrafine particles having a particle size of 1.0 μm or smaller; and a multi-layered backup layer which is formed on the outside of the prime layer by repeatedly forming a first backup layer obtained by forming and drying a slurry layer formed from the slurry for the precision casting mold and a stucco layer in which a stucco material is adhered to the slurry layer. 1. A precision casting mold which is used to produce a cast product , comprising:a core having a shape corresponding to an internal hollow portion of the cast product; andan outer mold corresponding to a shape of an outer peripheral surface of the cast product,wherein the outer mold is made up of: a prime layer which is formed on an inner peripheral surface and is formed from a slurry film obtained by drying slurry for the precision casting mold including mono-dispersed ultrafine alumina particles having a particle size of 0.3 μm to 0.5 μm; and a multi-layered backup layer which is formed on the outside of the prime layer by repeatedly forming a backup layer obtained by forming and drying a slurry layer formed from the slurry for the precision casting mold and a stucco layer in which a stucco material is adhered to the slurry layer.2. The precision casting mold according to claim 1 , wherein the slurry for the precision casting mold contains either of zircon powders or alumina powders having an average particle size of 50 μm or smaller claim 1 , andthe stucco material is either of zircon stucco ...

USE OF A CEMENTITIOUS COMPOSITION AS A COATING FOR DISPOSABLE FOUNDRY CORES AND RELATIVE COATED CORE

The use of a cementitious composition is described, as a coating for disposable foundry cores, said cementitious composition comprising at least one binder or hydraulic cement in a quantity ranging from 40% to 99.9% by weight with respect to the total weight of the cementitious composition; possibly one or more fillers in a quantity ranging from 0.1% to 60% by weight, with respect to the total weight of the cementitious composition, said filler preferably having a D99<100 μm; at least one rheology modifying agent selected from cellulose, derivatives of cellulose such as methylhydroxyethylcellulose, vinyl acetate/versatate copolymers, polycarboxylate ether polymer, or a mixture thereof, in a quantity ranging from 0.1% to 5% by weight with respect to the total weight of the cementitious composition. A disposable foundry core is also described, having at least one coating layer based on said cementitious composition. 1. Use of a cementitious composition as a coating for disposable foundry cores , said cementitious composition comprising:at least one binder or hydraulic cement in a quantity ranging from 40% to 99.9% by weight, with respect to the total weight of the cementitious composition;optionally, one or more fillers in a quantity ranging from 0.1% to 60% by weight, with respect to the total weight of the cementitious composition;at least one rheology modifying agent selected from cellulose, derivatives of cellulose such as methylhydroxyethylcellulose, vinyl acetate/versatate copolymers, polycarboxylate ether polymer, or a mixture thereof, in a quantity ranging from 0.1% to 5% by weight, with respect to the total weight of the cementitious composition.2. The use according to claim 1 , wherein the binder or hydraulic cement is selected from Portland cement claim 1 , sulfoaluminate cement and/or aluminous cement and/or rapid natural cement of the “ciment prompt” type claim 1 , alone or mixed with each other and/or in a mixture with common cement claim 1 , optionally ...

Boron nitride coatings for metal processing and methods of using the same

The present invention relates to a release agent and methods of using a release agent. In particular, the present invention relates to a release agent comprising boron nitride and a fumed metal oxide, which may find use, for example, in metal processing applications.

WORKING ADDITIVELY MANUFACTURED PARTS

A method of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed. 1. A method of working an additively manufactured part , the method comprising:applying a layer of wax to a part manufactured with an additive manufacturing process;forming a mold over the layer of wax on the part;removing the layer of wax between the mold and the part;melting the part in the mold;re-solidifying the part in the mold; andremoving the mold.2. The method of claim 1 , wherein the part is manufactured with an additive manufacturing process selected from the group consisting of direct metal laser sintering claim 1 , electron beam freeform fabrication claim 1 , electron-beam melting claim 1 , selective laser melting claim 1 , selective laser sintering claim 1 , and combinations thereof.3. The method of claim 1 , wherein the part has an aerodynamic surface and the layer of wax that is applied to the part fully covers the aerodynamic surface of the part so that no portion of the aerodynamic surface of the part extrudes through the layer of wax.4. The method of claim 1 , wherein interior surfaces of the mold have an average surface roughness Requal to or less than 125 microinches (3.2 micrometers).5. The method of claim 4 , wherein interior surfaces of the mold have an average surface roughness Rbetween 60 microinches (1.5 micrometers) and 125 microinches (3.2 micrometers).6. The method of claim 1 , wherein the part is re-solidified on a chill block to control the crystallization of the part as it re-solidifies.7. The method of claim 6 , wherein the crystallization of the part is controlled so that the part has a single crystal microstructure or a columnar grain microstructure when it ...

COATING COMPOUNDS FOR CASTING MOULDS AND CORES THAT PREVENT REACTION GAS DEFECTS

The present invention relates to a coating and a method for producing a casting mold. The method provides for castings whereby gas defects are largely or completely suppressed. 119-. (canceled)20. A casting mould which comprises at least sections of a coating layer produced from a coating comprising: a carrier liquid; wherein the carrier liquid is water or an alcohol having 1 to 10 carbon atoms or a mixture of water and at least one volatile organic component having a boiling point of less than 130° C. , at least one pulverulent refractory material; and at least one reducing agent , wherein the reducing agent is selected from one or more members of the group consisting of styrene butadiene , styrene (meth)acrylate and butadiene (meth)acrylate copolymers , and wherein the coating has a solid content of 20 to 80 wt. % relative to the usable/ready-to use state and the coating is applied to surfaces of the casting mould which come into contact with liquid metal.21. The casting mould according to claim 20 , wherein the reducing agent is contained in a fraction of more than 5 wt. % relative to the weight of the ready-to-use coating.22. The casting mould according to claim 20 , wherein the coating contains a binder.23. The casting mould according to claim 20 , wherein the casting mould at least comprises a core and the core is coated with said coating.24. The casting mould according to claim 20 , wherein said mould is for metal casting.25. The casting mould according to claim 24 , wherein the metal casting is an iron or steel casting.26. The casting mould according to claim 20 , wherein the reducing agent is a polystyrene polymer or polystyrene co-polymer wherein the fraction of styrene in the polymer is at least about 25 mol %.27. The casting mould according to claim 20 , wherein the reducing agent is a polystyrene polymer or polystyrene co-polymer wherein the fraction of styrene in the polymer is at least about 50 mol %.28. The casting mould according to claim 26 , ...

DIE-CASTING SYSTEM WITH A REFRACTORY METAL ALLOY SURFACE

A die-casting mold, includes a die insert including a mold surface with a refractory metal alloy layer and a method of manufacturing a die-casting mold, including machining a mold surface of a die insert such that the mold surface is a near net shape with respect to a workpiece and applying a refractory metal alloy layer onto the die insert. 1. A die-casting mold , comprising:a die insert including a near net shape mold surface with a refractory metal alloy layer, wherein the refractory metal alloy layer is manufactured from a compositionally homogeneous powder mixture that is utilized in a laser cladding operation to produce the refractory metal alloy layer.2. The mold as recited in claim 1 , wherein the mold surface is undersized with respect to a workpiece.3. The mold as recited in claim 2 , wherein the refractory metal alloy layer is sized to form the workpiece.4. The mold as recited in claim 1 , wherein the refractory metal alloy layer includes Anviloy®.5. The mold as recited in claim 1 , wherein the refractory metal alloy layer includes Tungsten (W).6. The mold as recited in claim 1 , wherein the refractory metal alloy layer is W90Ni4Mo4Fe2.7. The mold as recited in claim 1 , wherein the refractory metal alloy layer is manufactured from a compositionally homogeneous powder mixture that is utilized in a laser cladding operation to produce the refractory metal alloy layer.8. The mold as recited in claim 7 , wherein the compositionally homogeneous powder mixture includes tungsten (W) powder of less than about 44 microns particle size and other powders of less than about 74 microns particle size.9. The mold as recited in claim 8 , wherein the other powders include Nickel (Ni) claim 8 , Molybdenum (Mo claim 8 ,) and Iron (Fe) powder.10. The mold as recited in claim 1 , wherein the refractory metal alloy layer is about 0.010″ in thickness.11. The mold as recited in claim 1 , further comprising a die housing claim 1 , the die insert at least partially receivable into ...

METHOD OF MAKING AIRFOILS

A method of method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil. 1. A method of making an airfoil , the method comprising:making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process;making a mold that defines an exterior of the airfoil;inserting the refractory metal core into the mold; andpouring an airfoil material between the refractory metal core and the mold to cast the airfoil.2. The method of claim 1 , further comprising:removing the airfoil from the mold; andremoving the core from the airfoil.3. The method of claim 2 , wherein removing the core from the airfoil comprises applying an acid treatment.4. The method of claim 1 , further comprising:applying a ceramic coating to the refractory metal core prior to pouring the airfoil material.5. The method of claim 1 , wherein the refractory metal core comprises one of the following materials: molybdenum claim 1 , tantalum claim 1 , niobium claim 1 , or tungsten.6. The method of claim 1 , wherein the tomo-lithographic process comprises:forming a first layer of the refractory metal core out of a first material;forming a second layer of the refractory metal core out of the first material;bonding the first and second layers together to form a laminate master pattern;forming a flexible mold around the laminate master pattern;removing the laminate master pattern from the flexible mold;pouring a pulverulent refractory metal material mixed with a binder into the flexible mold; andsintering the pulverulent refractory metal material in an oxygen-free environment to form the refractory metal core.7. The method of claim 4 , further comprising:applying a metallic layer to the refractory metal core.8. ...

METHOD FOR PRODUCING A CAST COMPONENT WITH AN INSERT

A method for producing a cast component may include providing an insert part including an insert body having a circumferential face; coating the circumferential face with an adapter layer made of silicone oxide; arranging the insert part in a casting mold; and positively locking a casting encapsulation of the insert part and the adapter layer with an aluminum alloy to produce the cast component, wherein the aluminum alloy has a magnesium proportion of at least % by weight. 1. A method for producing a cast component , comprising:a) providing an insert part including an insert body having a circumferential face,b) coating the circumferential face with an adapter layer made of silicon oxide,c) arranging the insert part in a casting mold,d) positively locking a casting encapsulation of the insert part and the adapter layer with an aluminum alloy to produce the cast component, wherein the aluminum alloy has a magnesium proportion of at least 0.3% by weight.2. The method as claimed in claim 1 , wherein:the insert part is a cylinder liner and the cast component is a cylinder block for an internal combustion engine, orthe insert part is a piston ring carrier and the cast component is a piston for an internal combustion engine.3. The method as claimed in claim 1 , wherein b) coating the circumferential face with an adapter layer further includes:b1) applying a silicone resin to the circumferential face, andb2) curing the silicone resin to form a silicon oxide via heating the insert body.4. The method as claimed in claim 3 , wherein the silicone resin has a layer thickness of 5 μm to 10 μm before the curing to form the silicon oxide.5. The method as claimed in claim 3 , further comprising diluting the silicone resin with a solvent before b1) applying the silicone resin to the circumferential face.6. The method as claimed in claim 1 , wherein b) coating the circumferential face with an adapter layer further includes:b1) dipping the insert body into a solution comprising a ...

EMULSION AND MOLD-RELEASING AGENT USING THE SAME

Disclosed is an emulsion formed using, as an emulsifier, 0.01 to 30 parts by weight of a perfluoroalkylethyl phosphonic acid salt represented by the general formula: CFCHCHP(O)(OM)(OM) [III] (M: a hydrogen atom, ammonium salt, or organic amine salt, M: an ammonium salt or organic amine salt, n: 1 to 6), based on 100 parts by weight of a perfluoropolyether oil represented by the general formula: RfO(CFO)(CFO), (CFO), Rf′ [I] (Rf and Rf′: C-Cperfluoroalkyl groups, p+q+r: 2 to 200) or the general formula: F(CFCFCFO)CFCF[II](n: 2 to 100), or a perfluorocarbon compound. In spite of using, as an emulsifier, a compound having a perfluoroalkyl group containing 6 or less carbon atoms, which is said to have low bioaccumulation potential, the emulsion exhibits excellent emulsification stability, and therefore can be effectively used as a surface-treating agent, such as a mold-releasing agent. 2. (canceled)3. (canceled)4. The emulsion according to claim 1 , wherein the emulsifier is used as an aqueous solution.5. (canceled)6. The emulsion according to claim 1 , wherein the emulsion is further diluted with an aqueous medium so as to have a solid matters content of 0.01 to 30 wt. %.7. The surface-treating agent according to claim 10 , which is used as a water- and oil-repellent claim 10 , an anti-adhesion agent claim 10 , a transfer inhibitor claim 10 , or a mold-releasing agent.8. The surface-treating agent according to claim 7 , which is used as a mold-releasing agent applied to a forming mold.9. (canceled)10. A surface-treating agent comprising an aqueous solution in which the perfluoropolyether oil emulsion according to is further diluted with an aqueous medium. This application is a continuation application of U.S. patent application Ser. No. 13/496,581, filed Mar. 16, 2012, which is a 35 U.S.C. §371 national phase filing of International Patent Application No. PCT/JP2010/065620, filed Sep. 10, 2010, which claims priority under 35 U.S.C. §119 to Japanese Patent Application ...

Improvements in methods and systems requiring lubrication

Methods and systems in which a shapable mass, which is processed according to the method or in the system, has a lubricant applied thereto. As it is processed in the system, the shapable mass having the lubricant applied thereto is used to transfer lubricant to a part or parts of the system.

Casting core and method for testing a hollow metal article

A hollow metal article can be fabricated by casting a molten metal alloy around a core, solidifying the molten metal alloy to form a metal article, and chemically removing the core from the metal article to form a hollow cavity in the metal article. The core includes a ceramic core body and an x-ray radiopaque coating disposed on the ceramic core body. A method for testing the hollow metal article includes submitting the hollow metal article to x-ray imaging and determining based upon the x-ray imaging whether any of the x-ray radiopaque coating of the core remains in the hollow metal article.

Ceramic refractory coatings

Disclosed herein are refractory coating compositions with improved drying times, defect prevention, and gas permeability and methods for using such refractory coating compositions.

SAND CORE TO ELIMINATE DEGENERATED SKIN

A sand casting apparatus, a method of forming a sand casting apparatus, and an automotive component are provided. The sand casting apparatus includes a sand casting base comprising a sand mold and/or a sand core comprising a base sand mixture, where the base sand mixture includes a sand material and a binder material. The sand casting apparatus further comprises an outer layer disposed on the sand casting base. The outer layer comprises silicon, magnesium, calcium, zirconium, manganese, carbon, aluminum, and iron. The automotive component has portions defining an aperture therein. The automotive component is formed of cast iron and has a nodular graphite structure from interior matrix to surface, where the nodular graphite structure on the surface is formed by a sand core having an outer layer that has reacted with the cast iron automotive component to form the nodular graphite structured surface.

COMPOSITION AND METHOD OF INVESTMENT CASTING FOR ADVANCED GAS TURBINE GEOMETRIES

A composition of a ceramic shell mold, a method of using the ceramic shell mold in investment casting of a structural part, and a structural part formed therefrom is provided. The ceramic shell mold has one or more investment layers formed from slurries and interlayer barriers formed over the investment layers. The interlayer barriers include a self-lubricating soluble solution and grit having a predetermined grit size that is a function of the feature spacing within the structural part. The grit size of each sequential interlayer barrier is at least as large as the grit size of each preceding sequential interlayer barrier. 1. A composition for a ceramic shell mold used in investment casting of a structural part comprising:a first investment layer formed from a first slurry;a first interlayer barrier formed over the first investment layer consisting of a self-lubricating soluble solution and grit having a predetermined grit size, the grit size being a function of feature spacing within the structural part;a second investment layer being formed over the first interlayer barrier from a second slurry; anda second interlayer barrier formed over the second investment layer consisting of a self-lubricating soluble solution and grit having a grit size that is at least as large as the grit size of the first barrier layer.2. The composition according to further comprising:at least a third investment layer formed over the second interlayer barrier from a slurry; andat least a third interlayer barrier formed over the third investment layer consisting of a self-lubricating soluble solution and grit having a grit size that is at least as large as the grit size of the second interlayer barrier;wherein when more than three investment layers and interlayer barriers are present, the grit size of each sequential interlayer barrier is at least as large as the grit size of each preceding sequential interlayer barrier.3. The composition according to claim 2 , wherein at least one of the ...

COUPLER AND METHOD FOR PRODUCTION OF A COUPLER WITH SELECTABLE CONFIGURATION OPTIONS

A process for producing a coupler and an improved coupler are provided. The process produces a coupler by constructing a mold that is a replica of the coupler and is constructed from a plurality of mold components that are selected and assembled to form a mold having the shape of the coupler. The mold components may include a front mold component section that forms the head of the coupler, a rear mold component section that forms the shank of the coupler, and, optionally one or more shelf components forming a shelf of the coupler. The front, rear and shank mold components may themselves be made from a plurality of mold components that are assembled together. The mold is formed from a consumable material, coating with a heat resistant material so that the assembled mold components are within a mold volume, and molten metal is added to the mold volume. 1. A method for producing a coupler comprising: 'assembling together the selected mold component sections to form a replica of the coupler to be produced.', 'selecting a plurality of mold component sections which when assembled together replicate the configuration of the coupler to be produced; and'}2. The method of claim 1 , including coating the assembled together mold component sections with a coating.3. The method of claim 2 , including adding molten metal to the coated mold in the locations of the assembled together mold components within the coated mold.4. The method of claim 1 , including determining a configuration for a coupler to be produced.5. The method of claim 2 ,wherein the assembled mold component sections define an interior mold surface formed therefrom, and wherein the assembled mold component sections define an exterior mold surface formed therefrom, wherein said at least one cavity is formed by the interior mold surface;wherein coating the assembled mold component sections comprises applying a refractory coating the interior and the exterior mold surfaces of said arranged mold component sections to ...

COMPOSITIONS AND METHODS FOR FOUNDRY CORES IN HIGH PRESSURE DIE CASTING

This invention relates to “lost” cores for use high pressure die casting, the cores preferably comprising a water-soluble synthetic ceramic aggregate having an appropriate strength and tolerance for various casting pressures and temperatures, an inorganic binder comprising sodium silicate, an additive comprising particulate amorphous silicon dioxide, and a refractory coating, wherein the cores have the capacity to be removed from a casting by dissolution with water. 1. A foundry core for use in high pressure die casting , the foundry core comprising a combination of:a synthetic ceramic aggregate;an inorganic binder comprising sodium silicate;an additive comprising particulate amorphous silicon dioxide;wherein the inorganic binder and the additive are provided in the core at an approximate 2:1 weight ratio of inorganic binder to additive;wherein the quantity of inorganic binder provided in the core ranges from approximately 0.9 to 4.0% inorganic binder by weight based on the weight of the synthetic ceramic aggregate; andwherein the quantity of additive provided in the core ranges from approximately 0.5 to 2.0% additive by weight based on the weight of the ceramic aggregate.2. The foundry core of claim 1 , wherein the quantity of inorganic binder provided in the core ranges from approximately 2.0 to 2.8% inorganic binder by weight based on the weight of the synthetic ceramic aggregate.3. The foundry core of claim 1 , wherein the quantity of additive provided in the core ranges from approximately 1.0 to 1.4% additive by weight based on the weight of the synthetic ceramic aggregate.4. The foundry core of claim 1 , the inorganic binder further comprising an inorganic modifier.5. The foundry core of claim 4 , wherein the inorganic modifier is lithium hydroxide.6. The foundry core of claim 1 , the inorganic binder further comprising a surfactant.7. The foundry core of claim 1 , wherein the synthetic ceramic aggregate comprises a grain fineness number that ranges from ...

METHOD OF CASTING HETEROGENEOUS MATERIALS AND A CASTING PRODUCT MANUFACTURED THEREBY

Disclosed are a method of casting heterogeneous materials and a casting produced manufactured by the same. The method may include disposing a lost foam on a cavity of a mold as the cavity being formed in a shape corresponding to a shape of a casting product; injecting a first molten metal through a low-pressure molten metal ingate formed in the mold to form a low-pressure casting portion of the casting product; and injecting a second molten metal through a gravity molten metal ingate formed in the mold to form a gravity casting portion of the casting product. 1. A method of manufacturing a casting product comprising heterogeneous materials , comprising:disposing a lost foam on a cavity of a mold, the cavity being formed in a shape corresponding to a shape of a casting product;injecting a first molten metal into the mold through a low-pressure molten metal ingate formed in the mold to form a low-pressure casting portion of the casting product; andinjecting a second molten metal into the mold through a gravity molten metal ingate formed in the mold to form a gravity casting portion of the casting product.2. The method according to claim 1 , wherein the first molten metal for the low-pressure casting portion and the second molten metal for gravity casting portion are different from each other in their material compositions thereof.3. The method according to claim 1 , wherein the point of time when the injected first molten metal for the low-pressure casting portion reaches the lost foam is same as the point of time when the injected second molten metal for the gravity casting portion reaches the lost foam.4. The method according to claim 1 , wherein an interface formed by joining of the first molten metal for the low-pressure casting portion and the second molten metal for the gravity casting portion is formed at a position where the lost foam is disposed.5. The method according to claim 1 , further comprising disposing a core in the cavity.6. A casting product ...

CASTING MOLD OF GRADING WITH SILICON CARBIDE

The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to a mold for casting a titanium-containing article, comprising calcium aluminate and silicon carbide, wherein said silicon carbide is graded in said mold such that it is in different portions of the mold in different amounts, with the highest concentration of silicon carbide being located between a bulk of the mold and a surface of the mold that opens to a mold cavity. 1. A mold for casting a titanium-containing article , comprising:calcium monoaluminate, calcium dialuminate, mayenite, and silicon carbide, wherein a concentration of said silicon carbide in the mold is graded such that it is in different portions of the mold in different concentrations, with a highest concentration of the silicon carbide is proximate a facecoat of the mold, wherein said facecoat is located between a bulk of the mold and an interior surface of the mold that opens to a mold cavity.2. The mold as recited in claim 1 , wherein the facecoat is a continuous intrinsic facecoat and comprises calcium monoaluminate and calcium dialuminate with particle sizes of less than about 50 microns.3. The mold as recited in claim 1 , wherein the facecoat is an intrinsic facecoat and said intrinsic facecoat is about 10 microns to about 500 microns thick.4. The mold as recited in claim 1 , wherein the silicon carbide is present at about 10% to about 50% by weight.5. The mold as recited in claim 1 , wherein a lowest concentration of the silicon carbide is furthest away from the facecoat.6. The mold as recited in claim 1 , wherein the silicon carbide is graded axially claim 1 , radially claim 1 , or both axially and radially.7. The mold as recited in claim 1 , further comprising alumina particles in the bulk of the mold wherein the alumina particles are larger than about 50 microns in outside dimension.8. The mold as recited in claim 1 , further comprising ...

CASTING MOLD AND METHODS FOR PRODUCTION

The invention relates to a method for producing a casting mold as well as to a casting mold (), in particular a continuous casting mold or similar. Said casting mold is made of a material which is essentially made of carbon and the casting mold is coated with pyrolytic carbon and/or boron nitride. 1. A method for producing a casting mold for metal casting , comprising the steps of:producing a casting mold of a material made essentially of carbon, andcoating the casting mold with at least one of pyrolytic carbon and boron nitride.2. The method according to claim 1 , wherein the casting mold is made of carbon.3. The method according to claim 2 , wherein the casting mold is made of graphite.4. The method according to claim 1 , wherein the step of coating the casting mold comprises coating the casting mold with a surface coating of pyrolytic carbon.5. The method according to claim 1 , further comprising the step of infiltrating the casting mold with pyrolytic carbon.6. The method according to claim 1 , wherein the step of coating the casting mold is performed using at least one of a CVD method and a CVI method.7. The method according to claim 3 , wherein the step of coating the casting mold further comprising the step of sealing the pores in the graphite of the casting mold.8. The method according to claim 1 , wherein the step of coating the casting mold is performed at a temperature between 500° C. and 1900° C.91122. The method according to claim 1 , wherein the step of coating the casting mold comprises the steps of applying the coating during a first process phase (P) at a first temperature (T) and subsequently applying the coating during a second process phase (P) at a second temperature (T) claim 1 , the first process phase being chosen to be at least one of longer than the second process phase and at a first temperature chosen to be lower than a second temperature during the second process phase.10. The method according to claim 1 , wherein no thermal post- ...

SLURRY FOR FORMING MOLD, MOLD AND METHOD FOR PRODUCING MOLD

A slurry for forming a mold includes a silica sol as a dispersion medium and niobia-stabilized zirconia dispersed in the silica sol. 1. A slurry for forming a mold comprising:a silica sol as a dispersion medium; andniobia-stabilized zirconia dispersed in the silica sol.2. A mold comprising:a primary layer and a backup layer provided from an inside in this order,{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'wherein at least one of the primary layer and the backup layer is formed by performing a heat treatment on the slurry for forming a mold according to .'}3. A method for producing a mold comprising:a slurry production process of producing a slurry in which niobia-stabilized zirconia is dispersed in a silica sol as a dispersion medium;a slurry layer formation process of forming a slurry layer in which the slurry is adhered to a surface of a wax mold;a stucco layer formation process of forming a stucco layer in which particles of a refractory material are adhered to a surface of the slurry layer; anda heat treatment process of performing a heat treatment on the slurry layer and the stucco layer. The invention relates to a slurry for forming a mold, a mold, and a method for producing a mold.Priority is claimed on Japanese Patent Application No. 2014-049226, filed Mar. 12, 2014, the content of which is incorporated herein by reference.Regarding a mold for casting a metal, an alloy, or the like, there may be cases where the strength of the mold is too high when a casting is taken out and it is difficult to separate the mold. When the casting is taken out of the mold, the mold may be destroyed by an impact of a hammer, sandblasting, steel shot, or the like. Therefore, there is a possibility that damage from the impact caused by destroying the mold may be imparted to the casting and defects may be generated.As a mold, a mold which is formed by mixing zircon, alumina, or the like with a silica sol and baking the mixture is known. Generally, such a mold is less likely ...

DIE CASTING DIE WITH REMOVABLE INSERTS

A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts. 1. A die casting apparatus for manufacturing metal parts , comprising:an upper die and a lower die providing a mold cavity therebetween,each of said dies presenting a forming surface,at least one of said dies including at least one insert and at least one sub-insert each presenting a portion of said forming surface,said at least one insert and said at least one sub-insert being removable from said dies and replaceable.2. The die casting apparatus of claim 1 , wherein a coating is applied to said at least one insert and said at least one sub-insert claim 1 , and said coating includes nitrogen.3. The die casting apparatus of claim 2 , wherein said coating is applied by nitriding or nitrocarburizing.4. The die casting apparatus of claim 3 , wherein said coating includes a compound zone having a hardness of 1880 Vickers (75+ Rockwell C) at 0.0005 inches to 0.002 inches claim 3 , and a nitrogen enriched diffusion zone which is 0.002 to 0.010 inches in depth supporting said compound zone.5. The die casting apparatus of claim 1 , wherein at least one of said dies includes a plurality of cooling channels extending through at least one of said inserts and/or at least one of said sub-inserts.6. The die casting apparatus of claim 5 , wherein said ...

MOLD RELEASE AGENT MONITOR AND CONTROL SYSTEM

A mold release agent monitoring system includes a molding tool and a supply of mold release agent is provided along with a spray device for applying the mold release agent to the molding tool. A monitoring system monitors an amount of mold release agent applied to the molding tool during a discrete spray cycle. The mold release agent monitoring system provides an output signal to an indicator system for indicating an amount of mold release agent applied during the prior discrete spray cycle. The monitoring system also monitors a total consumption of mold release agent over a determined time period and provides a warning to a consumer of a need to reorder more mold release agent when a remaining mold release agent level falls below a predetermined level. 1. A mold release agent monitoring system for monitoring an amount of mold release agent applied to a molding tool by a spray device , comprising:a monitoring system for monitoring an amount of mold release agent applied to the molding tool during a discrete spray cycle, andan indicator system for receiving an output signal from the monitoring system and displaying an amount of mold release agent applied during the discrete spray cycle.2. The mold release agent monitoring system according to claim 11 , wherein the monitoring system provides an output signal to an indicator system for providing an alarm signal when the mold release agent applied during the prior discrete spray cycle does not exceed a predetermined threshold level.3. The mold release agent monitoring system according to claim 1 , wherein the monitoring system records an amount of mold release agent applied during each discrete spray cycle.4. The mold release agent monitoring system according to claim 1 , wherein the monitoring system includes a flow meter for monitoring an amount of mold release agent applied to the molding tool.5. The mold release agent monitoring system according to claim 1 , wherein the monitoring system monitors a total consumption ...

Concentrate for producing a cooling and release agent or a cooling and lubricating agent and such cooling and release agents and cooling and lubricating agents

Known cooling and release agents or lubricating agents are not biodegradable and tend to form undesired layer buildup when applied repeatedly to the casting die. The invention therefore proposes using a concentrate for producing a cooling and release agent for reusable casting dies, particularly steel casting dies, or a cooling and lubricating agent, particularly for machining, having an active substance dissolved in water and comprising a protein having a weight proportion of 10% to 50%. Good releasability of the cast parts from the casting die and a good cooling effect on the casting die are obtained using such a cooling and release agent or lubricating agent. Said agent is further biodegradable.

一种耐热铝合金压铸脱模剂及其制备方法和使用方法

本发明提供了一种耐热铝合金压铸脱模剂及其制备方法和使用方法。本发明的耐热铝合金压铸脱模剂，按重量份计，包括如下组分：氧化聚乙烯蜡20～30份、有机改性硅油10～20份、阴离子表面活性剂5～15份、非离子表面活性剂1～5份、火山灰10～20份、黑刚玉1～5份、三乙醇胺1～5份、水20～50份。本发明的耐热铝合金压铸脱模剂，耐热性好，润滑和脱模性能佳，稳定性好，400℃以内热处理后仍然具有良好的脱模性能，脱模后铸件的表面光洁度高，具有良好的室温放置稳定性。

一种防氧化脱模剂及其制备方法和使用方法

本发明提供了一种防氧化脱模剂及其制备方法和使用方法。本发明的防氧化脱模剂按重量份计，包括如下组分：火山灰20～50份、蛭石10～30份、硅藻土10～20份、钛白粉5～10份、石墨粉2～5份、氮化硅粉5～10份、阴离子表面活性剂2～5份、抗氧剂5～10份、粘结剂5～10份和水20～40份。本发明的制备方法简单，制得的防氧化脱模剂，具有良好的润滑作用和良好的稳定性，铸件与模具分离时脱模容易，并且脱模后铸件表面的光洁度高。

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Mold surface treatment process and mold

一种应用于铝合金压铸件的水基脱模剂及其制备方法

本发明提供了本发明提供了一种应用于铝合金压铸件的水基脱模剂,其包括以下重量百分比的组分：水51.5‑70.3％；三乙醇胺0.5‑1％；硅油乳液14‑25％；硅蜡乳液8‑10％；聚乙烯蜡乳液7‑12％；杀菌剂0.2‑0.5％。本发明还提供了一种应用于铝合金压铸件的水基脱模剂的制备方法。本发明可以大幅提高表面后处理过程中的成品率，降低清洗工序的负担，有效提高表面处理的成品率，减少非计划停机时间，显著降低成本；并且维持水基脱模剂乳液的稳定性，对体系中的其他成分都有很好的配伍性和亲和力。