US2847741A - Method of making washed shell mold - Google Patents

Method of making washed shell mold Download PDF

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US2847741A
US2847741A US471930A US47193054A US2847741A US 2847741 A US2847741 A US 2847741A US 471930 A US471930 A US 471930A US 47193054 A US47193054 A US 47193054A US 2847741 A US2847741 A US 2847741A
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mold
shell
shell mold
particles
casting
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US471930A
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Donald E Meves
William D Lawther
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American Steel Foundries
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American Steel Foundries
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C3/00Selection of compositions for coating the surfaces of moulds, cores, or patterns

Definitions

  • This invention relates to shell molding and more particularly to the elimination of characteristic surface defects in low carbon, low alloy steel castings produced in conventional shell molds.
  • such molds are generally formed of a mixture of silica or zirconite sand and a thermo-setting phenolic resin, either in powder form or in a solvent to achieve uniform coating of the grains of sand.
  • dust suppressants are used for health purposes and sometimes a release agent is incorporated in the mixture to prevent the shell from sticking to the pattern which is heated during forming of the shell mold to set the resin.
  • the characteristic surface defects of such low carbon, low alloy steel castings results from a reaction between the molten steel and the mold, and between components of the mold. It is believed that this reaction is at least partially caused by the gases produced in the formation of silicon carbide by combination of carbon in the phenolic resin with the sand, and it is further believed that the molten steel participates in this reaction by developing high temperatures sufficient to cause the production of such gas, and possibly the carbon in the steel accentuates the formation of such gas by participating in the reaction. It has also been discovered that the molten steel tends to pick up carbon from the mold when this reaction occurs, thereby resulting in undesirable carbon fluctuation in portions of the surface of the steel castings.
  • the tion is to eliminate the characteristic surface defects of low carbon, low alloy steel castings formed in conventional shell molds, without the necessity of altering the conventional shell mold mixture and Without the necessity of burning the phenolic resin from the mold after formation thereof.
  • a more Specific object of the invention is to wash the casting contacting surfaces of a conventional shell mold Without destroying the dimensional accuracy thereof.
  • Another object of the invention is to wash the casting contacting surfaces of a shell mold with a material which penetrates the surfaces and is preferably inert with respect to the molten steel and with respect to the phenolic resin and the sand in the presence of molten steel, to prevent the formation of gases or other phenomena causing the characteristic surface defect of low carbon, low alloy steel castings produced in conventional shell molds.
  • a further object of the invention is to devise a mold wash in the form of a slurry of water, and a wetting agent, such as, for example, alcohol and finely divided material such as titanium dioxide, manganese dioxide and cerium oxide in a particle size capable of penetrating the casting surface of a shell mold to a sutficient depth to prevent the reaction which causes the characteristic surface defects of low carbon, low alloy steel castings.
  • a wetting agent such as, for example, alcohol and finely divided material such as titanium dioxide, manganese dioxide and cerium oxide in a particle size capable of penetrating the casting surface of a shell mold to a sutficient depth to prevent the reaction which causes the characteristic surface defects of low carbon, low alloy steel castings.
  • the maximum efiiective particle size of such powders when used on conventional shell molds is about one micron, although it will be understood that the size of the pores in the shell mold determines the effective size of the wash particles which must penetrate the pores to be effective for the purposes above set forth. The penetration is necessary to provide a barrier to reaction of the shell components beneath the casting contacting surfaces thereof without developing a layer on the casting contacting surfaces substantially thicker than 20 microns.
  • wash particles are most effective when the casting surface of the shell mold has been penetrated by such particles to a depth of at least of an inch and preferably of an inch.
  • the casting contacting surfaces of the mold which define the casting cavity in which the casting is to be formed by molten steel poured in the usual manner are washed, as for example, by brushing, spraying, or flushing with a slurry of particles, such as titanium dioxide, manganese dioxide, or cerium oxide and. a wetting agent in water.
  • the wash is applied until it has penetrated the casting surfaces of the mold, but has not built up a layer on such surfaces in excess of 20 microns.
  • the washed shell is then dried by the application of heat as, for example, by heating in an oven, or by infra red drying, or by application of a torch primary object of the present invenflame to the layer. It has been discovered that this prevents the reaction which causes the characteristic surface defects of low carbon, low alloy steel castings without destroying the dimensional accuracy of the mold.
  • the shell mold is then filled in the usual manner with molten low carbon, low alloy steel herein defined as a steel having a carboncontent not substantially in excess of about 1.5 percent by weight and a content of chromium, manganese, nickel, molybdenum, copper, vanadium, titanium and aluminum, singly or in any combination thereof within a range of about nil to 15 percent by weight. It has been found that steel castings produced in this manner are substantially free from the characteristic surface defects of low carbon, low alloy steel castings formed in shell molds according to conventional practices.
  • a method of producing low carbon, low alloy steel castings comprising making a shell mold having sand particles bonded together by a thermo-setting resin, said mold having. a porous surface. defining a contour of a' casting tially in excess of 1 micron and then filling saidmold with said molten steel.

Description

United States Patent Ofltice 2,847,741 Patented Aug. 19, 1958 2,847,741 METHOD OF MAKING WASHED SHELL MOLD Application November 29, 1954 Serial N 0. 471,930
4 Claims. (Cl. 22-193) No Drawing.
This invention relates to shell molding and more particularly to the elimination of characteristic surface defects in low carbon, low alloy steel castings produced in conventional shell molds.
As is known in the art, such molds are generally formed of a mixture of silica or zirconite sand and a thermo-setting phenolic resin, either in powder form or in a solvent to achieve uniform coating of the grains of sand.
In some mixtures dust suppressants are used for health purposes and sometimes a release agent is incorporated in the mixture to prevent the shell from sticking to the pattern which is heated during forming of the shell mold to set the resin.
Although such shell molds ordinarily produce commercially acceptable iron castings and stainless steel castings, it is Well known in the art that low carbon, low alloy steel castings, such as those formed, for example of grade 8" steel, are subject to characteristic surface defects when formed in such molds. It is also known that this and other difficulties exist with respect to certain grades of stainless steel and malleable iron. Prior art efforts to solve this problem have largely been directed in one of two channels. One approach to the problem has been to discover a substitute for the sand, such as, for example, olivine, which is a relatively expensive magnesium silicate within the range of forsterite to fayalite. Although such sand substitutes improve the qualities of low carbon, low alloy steel castings, they are expensive and have not completely solved the difficulty.
Another prior art approach to this problem has been the incorporation of ceramic powder in the shell mold mixture. After formation of the shell mold, the phenolic resin has been burned out either by heating the entire mold or by burning the casting surfaces of the mold with a torch. Although such expediencies have eliminated the characteristic surface defects of low carbon, low alloy steel castings produced in shell molds, the expense of such processes is prohibitive, and it has been found that they tend to destroy the dimensional accuracy of the molds.
According to the present invention, it has been discovered that the characteristic surface defects of such low carbon, low alloy steel castings results from a reaction between the molten steel and the mold, and between components of the mold. It is believed that this reaction is at least partially caused by the gases produced in the formation of silicon carbide by combination of carbon in the phenolic resin with the sand, and it is further believed that the molten steel participates in this reaction by developing high temperatures sufficient to cause the production of such gas, and possibly the carbon in the steel accentuates the formation of such gas by participating in the reaction. It has also been discovered that the molten steel tends to pick up carbon from the mold when this reaction occurs, thereby resulting in undesirable carbon fluctuation in portions of the surface of the steel castings.
The use of mold washes to prevent the steel from contacting the shell mold has generally been regarded as impractical due to the fact that such washes destroy the dimensional accuracy of the mold which is produced to very close tolerances.
Accordingly, the tion is to eliminate the characteristic surface defects of low carbon, low alloy steel castings formed in conventional shell molds, without the necessity of altering the conventional shell mold mixture and Without the necessity of burning the phenolic resin from the mold after formation thereof.
A more Specific object of the invention is to wash the casting contacting surfaces of a conventional shell mold Without destroying the dimensional accuracy thereof.
Another object of the invention is to wash the casting contacting surfaces of a shell mold with a material which penetrates the surfaces and is preferably inert with respect to the molten steel and with respect to the phenolic resin and the sand in the presence of molten steel, to prevent the formation of gases or other phenomena causing the characteristic surface defect of low carbon, low alloy steel castings produced in conventional shell molds.
A further object of the invention is to devise a mold wash in the form of a slurry of water, and a wetting agent, such as, for example, alcohol and finely divided material such as titanium dioxide, manganese dioxide and cerium oxide in a particle size capable of penetrating the casting surface of a shell mold to a sutficient depth to prevent the reaction which causes the characteristic surface defects of low carbon, low alloy steel castings.
it has been discovered, in this connection, that grades of cerium oxide, manganese dioxide and titanium dioxide powders are ineffective for the purpose above described when the particles range in size from about 7 to 15 microns or greater. However, it has been found that manganese dioxide, titanium dioxide and cerium oxide powders, having a. particle size of from about .2 to about .75 micron, substantially eliminate such characteristic defects of low carbon, low alloy steel castings produced in shell molds, the casting contacting surfaces of which have been sealed with a slurry of such powder and a wetting agent in water. In this connection, it has been found that the maximum efiiective particle size of such powders when used on conventional shell molds is about one micron, although it will be understood that the size of the pores in the shell mold determines the effective size of the wash particles which must penetrate the pores to be effective for the purposes above set forth. The penetration is necessary to provide a barrier to reaction of the shell components beneath the casting contacting surfaces thereof without developing a layer on the casting contacting surfaces substantially thicker than 20 microns.
It has been found that the wash particles are most effective when the casting surface of the shell mold has been penetrated by such particles to a depth of at least of an inch and preferably of an inch.
According to the invention, after a conventional shell mold has been produced in the usual manner, as above described, the casting contacting surfaces of the mold which define the casting cavity in which the casting is to be formed by molten steel poured in the usual manner are washed, as for example, by brushing, spraying, or flushing with a slurry of particles, such as titanium dioxide, manganese dioxide, or cerium oxide and. a wetting agent in water. The wash is applied until it has penetrated the casting surfaces of the mold, but has not built up a layer on such surfaces in excess of 20 microns. The washed shell is then dried by the application of heat as, for example, by heating in an oven, or by infra red drying, or by application of a torch primary object of the present invenflame to the layer. It has been discovered that this prevents the reaction which causes the characteristic surface defects of low carbon, low alloy steel castings without destroying the dimensional accuracy of the mold.
The shell mold is then filled in the usual manner with molten low carbon, low alloy steel herein defined as a steel having a carboncontent not substantially in excess of about 1.5 percent by weight and a content of chromium, manganese, nickel, molybdenum, copper, vanadium, titanium and aluminum, singly or in any combination thereof within a range of about nil to 15 percent by weight. It has been found that steel castings produced in this manner are substantially free from the characteristic surface defects of low carbon, low alloy steel castings formed in shell molds according to conventional practices.
A Wash which has been particularly effective for the purposes above described has been devised in accordance with the following formulation:
150 parts by weight of water 100 parts by weight of titanium dioxide, particle size about..4 micron of a part by weight of cellulose gum 7 /2 parts by weight of a phenolic resin core binder.
What is claimed is:
1. A method of producing low carbon, low alloy steel castings comprising making a shell mold having sand particles bonded together by a thermo-setting resin, said mold having. a porous surface. defining a contour of a' casting tially in excess of 1 micron and then filling saidmold with said molten steel.
2. A method according to claim 1, wherein the layer particles are titanium dioxide.
3. A method according to claim 1, wherein the layer particles are manganese dioxide.
4. A method according to claim 1, wherein the layer particles are cerium oxide.
References Cited in the file of this patent UNITED STATES PATENTS 2,169,386 Hall Aug. 15, 1939 2,491,096 Feagin Dec. 13, 1949 2,544,598 Kalina Mar. 6, 1951 2,592,337 Robertson et al. Apr. 8, 1952 OTHER REFERENCES The Iron Age, Oct. 30, 1952, pages 8892.

Claims (1)

1. A METHOD OF PRODUCING LOW CARBON, LOW ALLOY STEEL CASTINGS COMPRISING MAKING A SHELL MOLD HAVING SAND PARTICLES BONDED TOGETHER BY A THERMO-SETTING RESIN, SAID MOLD HAVING A POROUS SURFACE DEFINIGN A CONTROUR OF A CASTING TO BE FORMED IN SAID MOLD, THEN FORMING A LAYER ON SAID SURFACE PENETRATING THE PORES THEREOF TO A DEPTH OF AT LEAST 1/04 OF AN INCH AND DEFINING A COATING ON SAID SURFACE NOT SUBSTANTIALLY IN EXCESS OF 20 MICRONS, SAID LAYER BEING FORMED OF PARTICLES CONSISTING OF ONE OR MORE OF THE GROUP OF TITANIUM DIOXIDE, MANGANESE DIOXIDE AND CERIUM OXIDE, SAID PARTICLES BEING CHEMICALLY INACTIVE WITH RESPECT TO SAID SURFACE IN THE PRESENCE OF SAID STEEL IN THE MOLTEN STATE AND HAVING A PARTICLE SIZE NOT SUBSTANTIALLY IN EXCESS OF 1 MICRON AND THEN FILLING SAID MOLD WITH SAID MOLTEN STEEL.
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3116522A (en) * 1958-07-16 1964-01-07 Howard F Taylor Shell mold compositions
US3121269A (en) * 1960-11-25 1964-02-18 Amsted Ind Inc Mold wash
US3180632A (en) * 1961-10-02 1965-04-27 North American Aviation Inc Coated crucible and crucible and mold coating method
US3216074A (en) * 1964-02-26 1965-11-09 Edward N Harrison Method for making shaped foundry articles
US3216073A (en) * 1964-02-26 1965-11-09 Edward N Harrison Method and device for accurately aligning shaped foundry articles
US3243397A (en) * 1961-08-18 1966-03-29 Gen Motors Corp Mold and core coating composition from calcined hydrated aluminum silicate, mica, and bentonite
DE1508720B1 (en) * 1965-07-09 1970-06-04 Combustible Nucleaire Refractory coating, resistant to molten uranium, for crucibles, casting molds, their accessories and equipment
US3529654A (en) * 1968-02-15 1970-09-22 Crane Co Improving the surface of ferrous articles by complexing agents

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2169386A (en) * 1938-11-05 1939-08-15 Birdsboro Steel Foundry & Mach Manufacture of foundry molds
US2491096A (en) * 1945-08-31 1949-12-13 Austenal Lab Inc Casting mold
US2544598A (en) * 1948-02-28 1951-03-06 Wetherill Engineering Company Metal casting mold
US2592337A (en) * 1949-07-23 1952-04-08 Non Ferrous Die Casting Compan Method of chill casting brass and other copper alloys containing zinc

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2169386A (en) * 1938-11-05 1939-08-15 Birdsboro Steel Foundry & Mach Manufacture of foundry molds
US2491096A (en) * 1945-08-31 1949-12-13 Austenal Lab Inc Casting mold
US2544598A (en) * 1948-02-28 1951-03-06 Wetherill Engineering Company Metal casting mold
US2592337A (en) * 1949-07-23 1952-04-08 Non Ferrous Die Casting Compan Method of chill casting brass and other copper alloys containing zinc

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3116522A (en) * 1958-07-16 1964-01-07 Howard F Taylor Shell mold compositions
US3121269A (en) * 1960-11-25 1964-02-18 Amsted Ind Inc Mold wash
US3243397A (en) * 1961-08-18 1966-03-29 Gen Motors Corp Mold and core coating composition from calcined hydrated aluminum silicate, mica, and bentonite
US3180632A (en) * 1961-10-02 1965-04-27 North American Aviation Inc Coated crucible and crucible and mold coating method
US3216074A (en) * 1964-02-26 1965-11-09 Edward N Harrison Method for making shaped foundry articles
US3216073A (en) * 1964-02-26 1965-11-09 Edward N Harrison Method and device for accurately aligning shaped foundry articles
DE1508720B1 (en) * 1965-07-09 1970-06-04 Combustible Nucleaire Refractory coating, resistant to molten uranium, for crucibles, casting molds, their accessories and equipment
US3529654A (en) * 1968-02-15 1970-09-22 Crane Co Improving the surface of ferrous articles by complexing agents

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