GB1602122A - Foundry binder - Google Patents

Foundry binder Download PDF

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Publication number
GB1602122A
GB1602122A GB18454/77A GB1845477A GB1602122A GB 1602122 A GB1602122 A GB 1602122A GB 18454/77 A GB18454/77 A GB 18454/77A GB 1845477 A GB1845477 A GB 1845477A GB 1602122 A GB1602122 A GB 1602122A
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GB
United Kingdom
Prior art keywords
silicate
binder
molar ratio
sio2
potassium
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.)
Expired
Application number
GB18454/77A
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.)
Unilever PLC
Original Assignee
Unilever PLC
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 Unilever PLC filed Critical Unilever PLC
Priority to GB18454/77A priority Critical patent/GB1602122A/en
Priority to BE187288A priority patent/BE866580A/en
Priority to BR7802687A priority patent/BR7802687A/en
Priority to CA302,458A priority patent/CA1109896A/en
Priority to JP5324978A priority patent/JPS53144421A/en
Priority to AU35668/78A priority patent/AU521140B2/en
Priority to IT68005/78A priority patent/IT1147755B/en
Priority to FR7812978A priority patent/FR2389432B1/fr
Priority to ZA00782513A priority patent/ZA782513B/en
Priority to NL7804734A priority patent/NL7804734A/en
Priority to SE7805139A priority patent/SE438456B/en
Priority to ES469437A priority patent/ES469437A1/en
Priority to DE19782819456 priority patent/DE2819456A1/en
Publication of GB1602122A publication Critical patent/GB1602122A/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C1/00Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/186Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
    • B22C1/188Alkali metal silicates
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B12/00Cements not provided for in groups C04B7/00 - C04B11/00
    • C04B12/04Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303Inorganic additives
    • C04B35/6316Binders based on silicon compounds

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Silicates, Zeolites, And Molecular Sieves (AREA)
  • Detergent Compositions (AREA)

Description

(54) FOUNDRY BINDER (71) We, UNILEVER LIMITED, a British Company, of Unilever House, Blackfriars, London EC4, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to core binders and particularly to an improved carbon dioxide silicate process for making moulds and cores for the foundry industry. For some years a process has been used in industry in whicb a moulding sand is mixed with, as a binder, a sodium silicate solution to form a core or mould -- herein- after referred to as a core - which is treated with carbon dioxide gas to set the core by reacting with the sodium silicate.
In production of these CO2 silicate cores it is necessary to gas the core for a sufficient time to obtain adequate strength for handling purposes. Cores produced by this process should have a reasonable shelf life and then it is desirable that the core, after it has been used in a metal casting operation, should be readily disintegrated and removed from the metal casting. The disintegration or breakdown of the core can be assisted by the inclusion of starch, sugar or dextrin and like materials with the sodium silicate solution. It is common practice in commercial sodium silicates designed for foundry industry to include a breakdown agent.
In British Specification No. 874,117 a process for binding particulate refractory material has been disclosed in which the binder is a solution of potassium and sodium silicates in which the weight ratio SiO2: (K2O + Na2O) is at least 3:1 and the weight ratio K2O:Na2O is from 2:1 to 4:1. The mixture of silicates and binder can be hardened using carbon dioxide gas. The lowest molar ratio SiO2:K2O disclosed in this specifica tion is 3.3:1 and this is a commonly available form of potassium silicate.
It has now been found that if particularly fast gassing times are desired and if improved core breakdown is required, such benefits can be achieved by using particular potassium silicates in the binder, having selected ratios of potassium oxide and silicon dioxide.
Accordingly, the present invention provides a process for the production of foundry cores using the CO2-silicate process in which process the silicate binder comprises a potassium silicate having a molar ratio SiO2:K2O in the range 1.6 to 2.2:1.
The preferred molar ratio of SiO2:K2O is in the range 1.8 to 2.2:1. Potassium silicates at molar ratios above 2.3 and at solids of 50% by weight are too viscous to handle satisfactorily in the foundry environment.
It has also been found that even when significant proportions of sodium silicates are present in the silicate binder a surprising decrease in gassing times can still be obtained. The preferred sodium silicates have a molar ratio SiO2:Na2O in the range 1.65 to 2.8:1, more preferably 2 to 2.4.
The proportion of sodium silicate in the silicate binder should not exceed 75% by weight if significant improvements are to be achieved.
From the viewpoint of production of CO2 silicate cores, any reduction in gassing time gives a two4old benefit. First of all it means that from any equipment a signifi cantly greater output can be obtained and, secondly, it means a significant reduction in the amount of carbon dioxide gas required to produce a specified number of cores.
It has also been found that the effect of breakdown agents, such as sucrose, is en hanced when the silicate component comprises or consists of potassium silicates as earlier specified.
In addition, when reusing reclaimed foundry sands, the use of potassium silicates has a further benefit in that the potassium silicates have a less harmful effect on the refractory nature of the reclaimed sand than do the normallv used sodium silirates.
Furthermore, in the range of potassium silicates used in this invention it has been found that the potassium silicates have a lower viscosity than the normally used sodium sili- cates, thus assisting in the ease of mixing of the silicate and sand.
In characterising cores prepared using the CO, silicate process it is normal to determine the compressive strength of the core immediately after the CO2 gassing stage followed by compression strength after 24 hours and 48 hours in controlled conditions.
A further test is carried out on the cores after casting to determine breakdown characteristics of the heat-treated core.
The breakdown test involves applying an impact load through a spring loaded plunger to the core to determine the number of impacts necessary to penetrate one centimetre into the core. The impact load is applied to a probe having a 30 conical head giving a load of up to 31 kilograms. This test and the other tests used in this specification are described in detail in the book " The CO2-Silicate Process in Foundries ", written by K. E. L. Nicholas and published by the British Cast Iron Research Association, Alvechurch, Birmingham, in 1972.
Comparative tests were made using a standard sodium silicate binder having a 2.0 to 1 SiO2:Na2O molar ratio at 45% solids, together with various potassium silicates.
The cores were prepared using 3.5% by weight of the alkaline silicate solution mixed with a suitable Chelford sand. Cylindrical specimens were prepared of 2 inches diameter and 2 inches height and these were rammed in the usual fashion and gassed with carbon dioxide at flow rates 2.5, 10 and 20 litres per minute at 68.95 kilo-Newtons per square metre pressure. The compression strengths of the samples were determined immediately as gassed and after periods of 24 and 48 hours. The specimens were stored at temperatures in the range 20 to 270C and relative humidities of the order of 50%. The core breakdown properties were determined after incorporation in a grey iron casting weighing 25 kilograms poured at 14000C.
The results of these experiments are set out in Table I below.
The binders used are indicated in Table I by letters A to E and compositions were as set out below: Binder A is a sodium silicate having a 2.0 to 1 SiO2:Na20 molar ratio at 45% solids.
Binder B is a potassium silicate having a 2.0 to 1 SiO2:K2O molar ratio at 45% solids.
Binder C is a potassium silicate having a 1.8 to 1 SiO2:K2O molar ratio at 45% solids.
Binder D is a potassium silicate having a 1.6 to 1 SiO2:K2O molar ratio at 45% solids.
Binder E is a potassium silicate having a 2.2 to 1 SiO2:K2O molar ratio at 53% solids.
The lower impact breakdown figures in brackets indicate the effect of the addition of 20% by weight of binder of sucrose.
TABLE I
Compression Strength (kilo-Newtons per square metre) (kN/m2) Impact Breakdown Co2 (average number Flow Rate Gassing As Gassed 24 Hours 48 Hours to enter 1 cm.
(litres Time per min.) (secs.) A B C D E A B C D E A B C D E A B C D 2.5 10 476 4688 4592 15 627 4737 4881 18.7 20 814 634 4144 4985 3503 5178 (1.8) 19.8 30 76 903 7398 4344 4344 (3.4) 23.1 40 993 903 3359 5033 2910 5178 (5.6) 45 910 3503 3751 60 414 945 4640 4047 3896 4640 19.3 90 786 2910 4592 10 10 600 882 5033 7743 4833 5626 15 703 4489 4392 20 848 752 1262 3999 3999 4833 4640 5033 5378 30 110 772 7798 2813 8584 3110 40 876 731 1324 2517 3847 3703 3454 4344 3503 45 586 3206 2717 60 462 855 5674 2765 4537 3110 90 779 4144 3110 TABLE I CONTD.
Compression Strength (kilo-Newtons per square metre) Impact Breakdown Co2 (average number Flow Rate Gassing As Gassed 24 Hours 48 Hours to enter 1 cm.) (litres Time per min.) (secs.) A B C D E A B C D E A B C D E A B C D 20 10 586 3799 3702 15 614 4095 4592 20 896 648 3061 4640 2910 3944 30 117 752 7398 3503 6019 3406 40 848 820 2813 3406 2468 3406 45 848 3158 3013 60 359 683 5033 2075 4392 1682 90 586 5081 4392 It will be seen from Table I that the immediate "As Gassed" compression strength of the samples is achieved at a significantly shorter time using potassium silicate than the commercially used sodium silicate. This means that greater production rates can be achieved from a plant and significantly less carbon dioxide is required for any set number of cores.
The 24 and 48 hours strengths, using potassium silicate, did not reach the often unnecessarily high compression strengths frequently met with using known sodium silicates. This factor probably contributed to the better breakdown achieved using potassium silicates.
The impact strength indicates that the breakdown of the cores bound with potassium silicate is slightly better than that of standard sodium silicate. When breakdown aids such as sugar are incorporated into potassium silicate binders, there is even more significant improvement of properties.
It will be appreciated that, while the potassium silicates specified in this specification give a significant improvement in gassing time, they are more expensive than the corresponding sodium silicates. A commercial balance can frequently be struck between the outstandingly short gassing times obtained using only potassium silicates at a hither cost and the significant improvements which can be achieved by using a blend of the potassium and sodium silicates.
Tables II and III give further details of further test samples using mixtures of potassium and sodium silicates. Gassing times were selected to achieve comparable compressive strengths in the experimental cores. The cores were stored at 20 C and 60% relative humidity.
The binders used in Tables II and III were: Binder F - potassium silicate 53% solids (SiO2:K2O - 2.0:1 molar) and 25% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder G - potassium silicate 53% solids (SiO2:K2O - 2.0:1 molar) and 50% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder H - potassium silicate 53% solids (SiO2:K2O - 2.0:1 molar) and 75% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder J - 100% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder K -- potassium silicate 53% solids (SiO2:K2O - 2.2:1 molar) and 25% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder L - potassium silicate 53% solids (SiO2:K2O - 2.2:1 molar) and 50% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
Binder M - potassium silicate 53% solids (SiO2:K2O - 2.2:1 molar) and 75% by weight sodium silicate 46% solids (SiO2:Na2O - 2.0:1 molar).
TABLE II
Binder F Binder G Binder H Binder J 75:25 50:50 25:75 0:100 Co2 Flow Rate Gassing Compression Gassing Compression Gassing Compression Gassing Compression (litres Test Time Strength Time Strength Time Strength Time Strength per min.) Time (secs.) (kN/m2) (secs.) (kN/m2) (secs.) (kN/m2) (secs.) (kN/m2) 10 As gassed 12 359 19 365 30 372 45 345 20 710 30 696 50 717 72 683 30 1034 45 1014 68 1055 100 1014 24 hours 12 2489 19 2420 30 2765 45 4392 20 2172 30 2365 50 3751 72 3254 30 1482 45 2172 68 2764 100 1675 48 hours 12 3110 19 4537 30 4881 45 4537 20 2317 30 4785 58 4344 72 3799 30 1434 45 4144 68 3847 100 2958 TABLE III
Binder K Binder L Binder M 75:25 50:50 25::75 CO2 Flow Rate Gassing Compression Gassing Compression Gassing Compression (litres Test Time Strength Time Strength Time Strength per min.) Time (secs.) (kN/m2) (secs.) (kN/m2) (secs.) (kN/m2) 10 As gassed 8.5 365 16 372 30 372 15 717 25 689 45 710 23 1034 34 1007 72 1048 24 hours 8.5 2517 16 3061 30 2910 15 2172 25 2910 45 2420 23 1779 34 3110 72 2365 48 hours 8.5 2344 16 4881 30 3847 15 2365 25 3896 45 4785 23 1627 34 4192 72 3358 WHAT WE CLAIM IS: 1. A process for the production of foundry cores using the CO2-silicate process in which process the silicate binder comprises a potassium silicate having a molar ratio SiO2:K2O in the range 1.6 to 2.2:1.
2. A process as claimed in Claim 1 in which the molar ratio SiO2:K2O of the potassium silicate is in the range 1.8 to 2.2:1.
3. A process as claimed in Claim 1 or Claim 2 in which the potassium silicate binder comprises up to 75% by weight of sodium silicate having a molar ratio SiO2:Na2O in the range 1.65 to 2.8:1.
4. A process as claimed in Claim 3 in which the molar ratio SiO2:Na20 of the sodium silicate is in the range 2 to 2 A:1.
5. An aqueous silicate binder solution comprising at least 25% by weight of potas sium silicate having a molar ratio SiO2:K2O in the range 1.6 to 2.2:1 and sodium silicate.
6. A bindary solution as claimed in Claim 5 in which the molar ratio SiO2:K2O of the potassium silicate is in the range 1.8 to 2.2:1.
7. A potassium silicate binder substantially as described herein with reference to the Examples.
8. A process for the production of foundry cores as described herein with reference to the Examples.
9. Foundry cores produced by a process as claimed in any one of the Claims 1 to 5 or 8.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (9)

  1. **WARNING** start of CLMS field may overlap end of DESC **.
    TABLE III
    Binder K Binder L Binder M 75:25 50:50 25:75 CO2 Flow Rate Gassing Compression Gassing Compression Gassing Compression (litres Test Time Strength Time Strength Time Strength per min.) Time (secs.) (kN/m2) (secs.) (kN/m2) (secs.) (kN/m2) 10 As gassed 8.5 365 16 372 30 372 15 717 25 689 45 710 23 1034 34 1007 72 1048 24 hours 8.5 2517 16 3061 30 2910
    15 2172 25 2910 45 2420 23 1779 34 3110 72 2365 48 hours 8.5 2344 16 4881 30 3847 15 2365 25 3896 45 4785 23 1627 34 4192 72 3358 WHAT WE CLAIM IS: 1. A process for the production of foundry cores using the CO2-silicate process in which process the silicate binder comprises a potassium silicate having a molar ratio SiO2:K2O in the range 1.6 to 2.2:1.
  2. 2. A process as claimed in Claim 1 in which the molar ratio SiO2:K2O of the potassium silicate is in the range 1.8 to 2.2:1.
  3. 3. A process as claimed in Claim 1 or Claim 2 in which the potassium silicate binder comprises up to 75% by weight of sodium silicate having a molar ratio SiO2:Na2O in the range 1.65 to 2.8:1.
  4. 4. A process as claimed in Claim 3 in which the molar ratio SiO2:Na20 of the sodium silicate is in the range 2 to 2 A:1.
  5. 5. An aqueous silicate binder solution comprising at least 25% by weight of potas sium silicate having a molar ratio SiO2:K2O in the range 1.6 to 2.2:1 and sodium silicate.
  6. 6. A bindary solution as claimed in Claim 5 in which the molar ratio SiO2:K2O of the potassium silicate is in the range 1.8 to 2.2:1.
  7. 7. A potassium silicate binder substantially as described herein with reference to the Examples.
  8. 8. A process for the production of foundry cores as described herein with reference to the Examples.
  9. 9. Foundry cores produced by a process as claimed in any one of the Claims 1 to 5 or 8.
GB18454/77A 1977-05-03 1977-05-03 Foundry binder Expired GB1602122A (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
GB18454/77A GB1602122A (en) 1977-05-03 1977-05-03 Foundry binder
BE187288A BE866580A (en) 1977-05-03 1978-04-28 BINDER FOR MOLDING SAND AND CORE SAND
BR7802687A BR7802687A (en) 1977-05-03 1978-04-28 PROCESS FOR THE PRODUCTION OF CASTING MACHINES AND Aqueous Solution of Silicate Agglutinant
CA302,458A CA1109896A (en) 1977-05-03 1978-05-02 Foundry binder
JP5324978A JPS53144421A (en) 1977-05-03 1978-05-02 Bond for casting
AU35668/78A AU521140B2 (en) 1977-05-03 1978-05-02 Foundry binder
IT68005/78A IT1147755B (en) 1977-05-03 1978-05-02 BINDER AND PROCEDURE FOR THE PRODUCTION OF SOULS FOR FOUNDRY
FR7812978A FR2389432B1 (en) 1977-05-03 1978-05-02
ZA00782513A ZA782513B (en) 1977-05-03 1978-05-02 Foundry binder
NL7804734A NL7804734A (en) 1977-05-03 1978-05-03 SILICATE SOLUTION AND THE MANUFACTURE OF FOUNDERS WITH THEIR USE.
SE7805139A SE438456B (en) 1977-05-03 1978-05-03 PROCEDURE FOR PREPARING CAST CORNES USING A CO? 712 SILICATE PROCEDURE AND Aqueous SILICATE BINDING SOLUTION
ES469437A ES469437A1 (en) 1977-05-03 1978-05-03 Foundry binder
DE19782819456 DE2819456A1 (en) 1977-05-03 1978-05-03 METHOD AND BINDING SOLUTION FOR PRODUCING CASTING CORES

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB18454/77A GB1602122A (en) 1977-05-03 1977-05-03 Foundry binder

Publications (1)

Publication Number Publication Date
GB1602122A true GB1602122A (en) 1981-11-04

Family

ID=10112722

Family Applications (1)

Application Number Title Priority Date Filing Date
GB18454/77A Expired GB1602122A (en) 1977-05-03 1977-05-03 Foundry binder

Country Status (13)

Country Link
JP (1) JPS53144421A (en)
AU (1) AU521140B2 (en)
BE (1) BE866580A (en)
BR (1) BR7802687A (en)
CA (1) CA1109896A (en)
DE (1) DE2819456A1 (en)
ES (1) ES469437A1 (en)
FR (1) FR2389432B1 (en)
GB (1) GB1602122A (en)
IT (1) IT1147755B (en)
NL (1) NL7804734A (en)
SE (1) SE438456B (en)
ZA (1) ZA782513B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3373465D1 (en) * 1982-12-16 1987-10-15 Dynamit Nobel Ag Water-containing hardenable shaped masses based on inorganic components, and method of producing shaped bodies
DE19951622A1 (en) 1999-10-26 2001-05-23 Vaw Ver Aluminium Werke Ag Binder system based on water glass

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2829060A (en) * 1954-10-25 1958-04-01 Rolls Royce Mould and method of making the same
GB874117A (en) * 1959-06-19 1961-08-02 Unilever Ltd Processes for binding particulate solid materials and binders for use in such processes
US3442665A (en) * 1966-06-13 1969-05-06 Mueller Arno Process for preparing sand cores using co2 cured silicate binders
JPS52124418A (en) * 1976-04-14 1977-10-19 Kato Tomomichi Mold manufacturing
JPS5224122A (en) * 1975-08-20 1977-02-23 Kato Asamichi Method of making mold of good disintegrating property

Also Published As

Publication number Publication date
BE866580A (en) 1978-10-30
AU521140B2 (en) 1982-03-18
AU3566878A (en) 1979-11-08
SE438456B (en) 1985-04-22
JPS53144421A (en) 1978-12-15
FR2389432A1 (en) 1978-12-01
IT7868005A0 (en) 1978-05-02
CA1109896A (en) 1981-09-29
FR2389432B1 (en) 1982-11-05
DE2819456A1 (en) 1978-11-09
SE7805139L (en) 1978-11-04
ES469437A1 (en) 1979-10-01
NL7804734A (en) 1978-11-07
BR7802687A (en) 1978-12-19
IT1147755B (en) 1986-11-26
ZA782513B (en) 1979-12-27

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PS Patent sealed [section 19, patents act 1949]
PCNP Patent ceased through non-payment of renewal fee