EP2010464A1 - Manufacture of ceramic molds - Google Patents

Manufacture of ceramic molds

Info

Publication number
EP2010464A1
EP2010464A1 EP20070754241 EP07754241A EP2010464A1 EP 2010464 A1 EP2010464 A1 EP 2010464A1 EP 20070754241 EP20070754241 EP 20070754241 EP 07754241 A EP07754241 A EP 07754241A EP 2010464 A1 EP2010464 A1 EP 2010464A1
Authority
EP
European Patent Office
Prior art keywords
slurry
ceramic
mold
cloth
silica
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20070754241
Other languages
German (de)
French (fr)
Inventor
David Smith
Paul Pattillo
Peter Hoagland
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vesuvius Crucible Co
Original Assignee
Vesuvius Crucible Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vesuvius Crucible Co filed Critical Vesuvius Crucible Co
Publication of EP2010464A1 publication Critical patent/EP2010464A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0022—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors
    • C04B38/0032—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00939—Uses not provided for elsewhere in C04B2111/00 for the fabrication of moulds or cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to the manufacture of forms or molds to be utilized in the formation of refractory shapes.
  • molten metal is flowed through or conveyed by refractory articles.
  • the articles such as inductors, ladles and other channels are comprised of refractory materials.
  • the various refractory shapes are formed by the use of molds or forms, as is well known in the art.
  • Forms are typically comprised of materials such as paper, wood or metal.
  • the refractory material is placed around the form, forcing the material into the desired shape.
  • the form material must then be removed from the lining either during heat up or before heat is applied to the refractory because they are not refractory materials and cannot withstand high temperatures. In many applications it is very difficult to remove the mold due to irregular geometry or other constraints. If the mold can be left in place permanently, the problem is eliminated.
  • refractory materials currently used are prone to the formation of cracks.
  • the inflexibility of the working surface of these refractory materials permits crack formation and propagation.
  • the present invention relates to a method of manufacturing a ceramic mold.
  • the method comprises impregnating ceramic cloth with slurry, wrapping the cloth around a form or placing the cloth upon a form, and allowing the slurry to harden.
  • the method further comprises removing the form.
  • the low temperature forming element can be left in place if its presence would not be detrimental to the use of the ceramic mold.
  • the method of forming a ceramic mold comprises impregnating ceramic cloth with slurry. Interstices in the weave of a woven textile accommodate impregnation.
  • the ceramic cloth is ceramic cloth tape about 1" to about 2" wide. The width allows for easier handling of the tape. However, any acceptable width of ceramic cloth tape may be used.
  • the cloth tape is impregnated with the slurry by soaking the cloth tape in the slurry. The impregnation can be carried out at atmospheric pressure, or by using vacuum, pressure, or a combination of vacuum and pressure to force the slurry into the cloth.
  • the ceramic cloth may contain, for example, silica or chrome oxide.
  • the slurry comprises any suitable material that will harden upon drying and will with stand the temperatures associated with the use of the refractory article.
  • cement- bonded slurry is used, although any suitable bonding system may be used.
  • the slurry is alumina-chrome slurry with silica fiber reinforcement.
  • Constituents of the slurry of the present invention may include a refractory calcine
  • MULCOA 60 may include aluminum oxide, silicon dioxide and titanium dioxide; calcined alumina; cement; clay (such as M&D clay) such as a Ball Clay or other montmorillonitic bearing clay; micronized silica; a deflocculant (such as BUDIPUR 8H, a phosphate deflocculant); colloidal silica; chrome oxide; kyanite; water; silica fiber: silicon carbide; carbon; zircon; zirconia; magnesium; and other metals.
  • clay such as M&D clay
  • a deflocculant such as BUDIPUR 8H, a phosphate deflocculant
  • colloidal silica chrome oxide; kyanite
  • water silica fiber: silicon carbide; carbon; zircon; zirconia; magnesium; and other metals.
  • the ceramic cloth tape is impregnated with the slurry, it is wrapped around a form, or placed on a form, that is shaped to produce the appropriate geometric shape or form the appropriate surface in the resulting refractory article.
  • the form may be made of a material that may be removed after the refractory article is made, such as by burning the form.
  • the form is made of polystyrene foam, although any suitable material may be used.
  • the form may be removed from the ceramic mold.
  • the form may be removed by heating the ceramic mold and the form until the form burns out of the mold. The ash may then be removed by conventional means. Chemical solvents may also be used on appropriate form materials to remove the form.
  • the form may be a flat surface, so that the mold produced constitutes a panel having a flat surface.
  • a sample slurry was made, having the following composition:
  • Refrasil tape was soaked in the slurry and wrapped around a polystyrene foam form.
  • the form was shaped for an inductor loop.
  • the slurry was air-dried.
  • refractory material was packed around the form, and the material was pre-heated, thus burning out the polystyrene foam form.
  • the slurry may also be made according to the proportions presented above, but without chrome oxide.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Mold Materials And Core Materials (AREA)
  • Catalysts (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

The present invention relates to a method of forming a ceramic mold. The method comprises impregnating ceramic cloth with slurry, wrapping the cloth around a form, and allowing the slurry to harden. The method further comprises removing the form.

Description

MANUFACTURE OF CERAMIC MOLDS
FIELD OF THE INVENTION
[0001] This invention relates to the manufacture of forms or molds to be utilized in the formation of refractory shapes.
BACKGROUND OF THE INVENTION
[0002] In the metals industry, molten metal is flowed through or conveyed by refractory articles. The articles, such as inductors, ladles and other channels are comprised of refractory materials.
[0003] The various refractory shapes are formed by the use of molds or forms, as is well known in the art. Forms are typically comprised of materials such as paper, wood or metal. The refractory material is placed around the form, forcing the material into the desired shape. The form material must then be removed from the lining either during heat up or before heat is applied to the refractory because they are not refractory materials and cannot withstand high temperatures. In many applications it is very difficult to remove the mold due to irregular geometry or other constraints. If the mold can be left in place permanently, the problem is eliminated.
[0004] In certain applications, such as the processing of molten zinc or aluminum, refractory materials currently used are prone to the formation of cracks. The inflexibility of the working surface of these refractory materials permits crack formation and propagation.
[0004] One proposed solution has been to make a ceramic mold from slip casting techniques. However, these are brittle and are difficult to make.
[0005] It would be beneficial if the form or mold is formed of material that can function at the use temperature of the refractory shape. SUMMARY OF THE INVENTION
[0006] The present invention relates to a method of manufacturing a ceramic mold. The method comprises impregnating ceramic cloth with slurry, wrapping the cloth around a form or placing the cloth upon a form, and allowing the slurry to harden. The method further comprises removing the form. In certain geometries, however the low temperature forming element can be left in place if its presence would not be detrimental to the use of the ceramic mold.
DETAILED DESCRIPTION OF THE INVENTION
[0007] In accordance with an embodiment of the present invention, the method of forming a ceramic mold comprises impregnating ceramic cloth with slurry. Interstices in the weave of a woven textile accommodate impregnation. In one embodiment of the invention, the ceramic cloth is ceramic cloth tape about 1" to about 2" wide. The width allows for easier handling of the tape. However, any acceptable width of ceramic cloth tape may be used. The cloth tape is impregnated with the slurry by soaking the cloth tape in the slurry. The impregnation can be carried out at atmospheric pressure, or by using vacuum, pressure, or a combination of vacuum and pressure to force the slurry into the cloth. The ceramic cloth may contain, for example, silica or chrome oxide.
[0008] The slurry comprises any suitable material that will harden upon drying and will with stand the temperatures associated with the use of the refractory article. Preferably, cement- bonded slurry is used, although any suitable bonding system may be used. In one embodiment, the slurry is alumina-chrome slurry with silica fiber reinforcement.
[0009] Constituents of the slurry of the present invention may include a refractory calcine
(such as MULCOA 60) that may include aluminum oxide, silicon dioxide and titanium dioxide; calcined alumina; cement; clay (such as M&D clay) such as a Ball Clay or other montmorillonitic bearing clay; micronized silica; a deflocculant (such as BUDIPUR 8H, a phosphate deflocculant); colloidal silica; chrome oxide; kyanite; water; silica fiber: silicon carbide; carbon; zircon; zirconia; magnesium; and other metals.
[0010] Once the ceramic cloth tape is impregnated with the slurry, it is wrapped around a form, or placed on a form, that is shaped to produce the appropriate geometric shape or form the appropriate surface in the resulting refractory article. The form may be made of a material that may be removed after the refractory article is made, such as by burning the form. In one embodiment, the form is made of polystyrene foam, although any suitable material may be used. [001 1 ] After the slurry-impregnated tape is placed upon or around the form, the ceramic cloth tape is dried. As it dries, it forms a flexible composite matrix of fiber-reinforced ceramic that will withstand high temperatures, resists cracking and resists corrosion. This flexibility enables the product of the invention, when used on the working surface in the processing of molten metals such as zinc and aluminum, to act as a barrier to crack formation. [0012] Once the ceramic cloth tape is dry, the form may be removed from the ceramic mold. In an embodiment utilizing a polystyrene foam form, the form may be removed by heating the ceramic mold and the form until the form burns out of the mold. The ash may then be removed by conventional means. Chemical solvents may also be used on appropriate form materials to remove the form.
(0013] In a configurational embodiment of the invention, the form may be a flat surface, so that the mold produced constitutes a panel having a flat surface. [0013] A sample slurry was made, having the following composition:
MULCOA 60-200M 18.98% Calcined Alumina 6.33%
CEMENT 8.86%
M&D CLAY 0.79%
Elkem Microsilica 3.16%
BUDIPUR 8H 0.16%
Colloidal Silica 4.74%
Chrome oxide 3.16%
-100m Kyanite 12.65%
Water 6.17%
Silica fiber 35.00%
Refrasil tape was soaked in the slurry and wrapped around a polystyrene foam form. The form was shaped for an inductor loop. The slurry was air-dried. Finally, refractory material was packed around the form, and the material was pre-heated, thus burning out the polystyrene foam form. The slurry may also be made according to the proportions presented above, but without chrome oxide.
[0014] Obviously, numerous modifications and variations of the present invention are possible. It is, therefore, to be understood that within the scope of the following claims, the invention may be practiced otherwise than as specifically described. While the invention has been described with respect to certain embodiments, different variations, modifications, and additions to the invention will become evident to persons of ordinary skill in the art. AU such modifications, variations, and additions are intended to be encompassed within the scope of this patent, which is limited only by the claims appended hereto.

Claims

What is claimed:
1. A method of forming a ceramic mold comprising impregnating ceramic cloth with slurry, wrapping the cloth around a form, and allowing the slurry to harden.
2. The method of claim 1 , further comprising removing the form from the mold.
3. The method of claim 1, wherein the slurry comprises cement.
4. The method of claim 1 , wherein the slurry comprises alumina.
5. The method of claim 1, wherein the slurry comprises chrome oxide.
6. The method of claim 1, wherein the slurry comprises silica fiber.
7. The method of claim 1 , wherein the form comprises polystyrene foam.
8. The method of claim 1, wherein the form is removed from the mold by heating.
9. The method of claim 1, wherein the slurry comprises a refractory calcine, cement, clay, micronized silica, a deflocculant, colloidal silica, chrome oxide, kyanite, water, and silica fiber.
10. The method of claim 1, wherein the ceramic cloth comprises silica.
11. The method of claim 1, wherein the ceramic cloth comprises chrome oxide.
12. A method of forming a ceramic mold comprising impregnating ceramic cloth with slurry, placing the cloth upon a form, and allowing the slurry to harden.
13. The method of claim 12, further comprising removing the form from the mold.
14. The method of claim 12, wherein the form comprises a panel with a flat surface.
EP20070754241 2006-03-28 2007-03-27 Manufacture of ceramic molds Withdrawn EP2010464A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US78666706P 2006-03-28 2006-03-28
PCT/US2007/007689 WO2007126895A1 (en) 2006-03-28 2007-03-27 Manufacture of ceramic molds

Publications (1)

Publication Number Publication Date
EP2010464A1 true EP2010464A1 (en) 2009-01-07

Family

ID=38421725

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20070754241 Withdrawn EP2010464A1 (en) 2006-03-28 2007-03-27 Manufacture of ceramic molds

Country Status (7)

Country Link
EP (1) EP2010464A1 (en)
JP (1) JP2009531271A (en)
AR (1) AR060146A1 (en)
EA (1) EA013188B1 (en)
TW (1) TW200740579A (en)
WO (1) WO2007126895A1 (en)
ZA (1) ZA200808408B (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8033320B2 (en) * 2008-07-25 2011-10-11 General Electric Company High emittance shell molds for directional casting
GB2492781B (en) * 2011-07-11 2015-10-07 Richard Dudley Shaw Improvements in and relating to investment casting
EP2792655B1 (en) * 2013-04-18 2015-05-06 Refractory Intellectual Property GmbH & Co. KG Wear indicator in a composite system of refractory ceramic bricks
CN107234213A (en) * 2017-07-25 2017-10-10 苏州市鑫渭阀门有限公司 The ceramic precision casting method of the high pressure stainless steel pump housing

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5041321A (en) * 1984-11-02 1991-08-20 The Boeing Company Fiberformed ceramic insulation and method
US4615935A (en) * 1985-04-29 1986-10-07 The Boeing Company Glass fiber reinforced ceramic preform and method of casting it
US5753570A (en) * 1989-07-18 1998-05-19 The Boeing Company Reinforced ceramic microform composite
DE69607056T2 (en) * 1995-05-10 2000-11-09 Toshiba Kawasaki Kk Fiber reinforced ceramic composite material and method for its production
US6364000B2 (en) * 1997-09-23 2002-04-02 Howmet Research Corporation Reinforced ceramic shell mold and method of making same

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2007126895A1 *

Also Published As

Publication number Publication date
TW200740579A (en) 2007-11-01
EA013188B1 (en) 2010-02-26
ZA200808408B (en) 2010-02-24
WO2007126895A1 (en) 2007-11-08
AR060146A1 (en) 2008-05-28
EA200802048A1 (en) 2009-04-28
JP2009531271A (en) 2009-09-03

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