US3776992A - Method for producing sleeves or sheets for feeder heads formed in metal casting and an apparatus therefor - Google Patents

Method for producing sleeves or sheets for feeder heads formed in metal casting and an apparatus therefor Download PDF

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Publication number
US3776992A
US3776992A US00129778A US3776992DA US3776992A US 3776992 A US3776992 A US 3776992A US 00129778 A US00129778 A US 00129778A US 3776992D A US3776992D A US 3776992DA US 3776992 A US3776992 A US 3776992A
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Prior art keywords
mixture
materials
water
sleeves
sheets
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US00129778A
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English (en)
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M Miki
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Individual
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Individual
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Priority claimed from JP7794970A external-priority patent/JPS4937609B1/ja
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/06—Ingot moulds or their manufacture
    • B22D7/10—Hot tops therefor
    • B22D7/108—Devices for making or fixing hot tops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
    • B22C15/23—Compacting by gas pressure or vacuum
    • B22C15/24—Compacting by gas pressure or vacuum involving blowing devices in which the mould material is supplied in the form of loose particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
    • B22C5/04—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by grinding, blending, mixing, kneading, or stirring
    • B22C5/0409—Blending, mixing, kneading or stirring; Methods therefor
    • B22C5/0463—Plants
    • B22C5/0468—Plants having feeding moulds, e.g. using gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/06—Ingot moulds or their manufacture
    • B22D7/10—Hot tops therefor
    • B22D7/102—Hot tops therefor from refractorial material only

Definitions

  • FUR FEEDER HEADS MHTHOI FOR PRODUCING SLEEVES OR SHEETS FORMED 1N METAL Filed March 31, 1971 CASTTNG AND AN APPARATUS THERFOR 2 Sheets-Sheet 2 OO 0m 0m 0% A25 mic. 0m
  • a method of producing sleeves or sheets for feeder heads formed in metal casting which comprises optionally blending a raw material mixture of refractory materials with large quantities of inorganic and organic fibrous materials and a binding agent; cotton-opening and mixing the inorganic and organic fibrous materials blended in the raw materials through agitation in the dry state without adding water; kneading the resultant mixture with less than 150% by weight of water so as to hold the mixture in the solid form with minimal fluidity; molding the kneaded mixture into a desired shape by pressing in molds; and drying to solidify the molded mixture at a temperature of about 180 C.
  • the present invention relates generally to a method of producing sleeves or sheets for feeder heads formed in metal casting and to an apparatus therefor. More particularly, this invention relates to a method of continuously producing exothermic or heat-insulating sleeves or sheets for feeder heads formed in metal castings in which large quantities of fibrous materials are added, and to an apparatus therefor.
  • any method using a vacuum water-removal system is unsuitable for the mass production of sleeves or sheets. Therefore, a special mold had to be developed for pressing in the sleeve molding step of the conventional methods. This enabled the production of sleeves of higher strength, but eflicient mass production of such sleeves was still unattainable.
  • Another object of the present invention is to provide a method for the continuous production of feeder head sleeves formed in metal casting of sheets or slabs, such as for framing feeder heads formed in molds for steel ingot-making, from a mixture of refractory materials of powder or granular form with large quantities of inorganic and organic fibrous materials in which the molding of such sleeves, sheets or slabs is carried out through pressing by using a core shooter for metal casting, a coreproducing machine, or the like, and to provide an apparatus therefor.
  • the present invention is constructed, as follows:
  • the present invention is so characterized that a refractory material, in powder or granular form, such as silica or brick powder, with or without the addition of an exothermic material and an oxidizing agent, is admixed with at least 15% by weight of inorganic fibrous materials, such as asbestos or ore flakes, and at least 5% by weight of organic fibers such as wood chips or fiber.
  • a binding agent such as a synthetic resin, without the addition of water and the entire mixture, is subjected to thorough cotton-opening by using a cotton-opening mixer, and then mixed with other materials in powder or granular form.
  • the so cotton-opened mixture is added less than 150%, preferably between and water and this mixture is kneaded by a kneader or the like, so as to yield a nonfluid non-slurry or non-paste or muddy, like mixture, i.e., the mixture remains'in the powder, granular or solid form.
  • the so kneaded mixture is then placed into molds to be molded into desired shapes; and the molded mix 3 ture is then dried and solidified at about 180 C. in a. drier or the like.
  • FIG. 1 shows an operation flow-sheet describing the method and apparatus of the present invention
  • FIG. 2A shows a diagrammatic sectional view of the molding step in the method of the present invention
  • FIG. 2B shows an enlarged view of area IIB in FIG. 2A
  • FIG. 3 shows a perspective view of a sleeve and sheet made by the method of the present invention
  • FIG. 4 is a curve comparing the heat insulation property of sleeves produced by the method of the present invention with sleeves produced by the conventional methods;
  • FIG. 5 shows comparative sectional views of feeder heads formed by using sleeves produced by the method of the present invention and feeder heads formed by conventional methods.
  • the method of the present invention is explained, as follows, using an operation flow-sheet of a continuous production apparatus shown in FIG. 1. It is noted that practice of the method of the present invention is not limited to the use of such a continuous production apparatus.
  • the whole process of the method of the present invention is divided into four or five steps: the first step for blending raw materials (if not required, this step may be omitted); the second step for cotton-opening; the third step for kneading; the fourth step for molding; and the fifth step for drying.
  • Binding agent 5-30 Percent by weight (a) Refractory materials -50 (b) Inorganic fibrous material -60 (c) Organic fibrous material 5-30 (d) Binding agent 5-30 Note: In the above case, the total of inorganic fibrous materials (b) and organic fibrous materials (0) should be greater than For producing exothermic and heatinsulating sleeves, the refractory materials should contain an exothermic material and its oxidizing agent.
  • the above-mentioned materials in the above-mentioned ratios are charged to a hopper 2 using a charging bucket 1.
  • the materials are then continuously sliced out of the hopper by a slicer 3 into a lot of the desired amount, and delivered into a cotton-opening mixer 4 at the second step.
  • the first step may be omitted so that the raw materials are charged directly into cotton-opening mixer 4, as shown by the dotted lines.
  • Cotton-opening mixer 4 is equipped, on its inside, with a screw 5 having blades to cut or cotton-open fibrous materials, and with an agitating bar 6.
  • the cotton-opening mixer rotated by a motor 7 set above it, minces and well cotton-opens the charged mixture of raw materials, particularly fibrous materials (b) and (c), in the dry state, and well mixes the so-cotton-opened materials with other materials of powder or granular form, such as refractory materials.
  • Cotton-opening at the second step is novel and has not been adopted by any known methods other than the method of the present invention. Then, a mixture containing the so-cotton-opened materials is sent from the bottom of the cotton-opening mixer 4 into an aqueduct shaped hopper 9 set at one end of a kneader 8.
  • the mixture has been cotton-opened and well mixed in the second step, it can be kneaded in the kneader 8 by using a small amount of water, such as about so that even though it is kneaded with water, such kneading does not need a great quantity of water, and the kneaded mixture keeps in the original powder or granular form, which is quite different from that obtained according to conventional methods.
  • the mixture of powder or granular form which has been put into said alternating hopper 1-3 is sent to the fourth step, where it is charged by an alternating dumper 14 alternately into a hopper 17 and a hopper 18 set respectively on molding machines 19 and 20. Molding by the molding machines 19 and 20 at the fourth step is carried out as shown in FIG. 2A. As the two molding series follow the same operation process, only one series is described in the following explanation.
  • the mixture of powder or granular form 25 in one of the hoppers 18 is charged into molds 22. and 23 as the volume of one lot which has been sliced out from dumper 26. As the molds are filled with the mixture 25, the dumper 26 is shut, and the so charged mixture is pressed from up to down under a pressure of 5 or 6 kg./cm. by compressed air 27.
  • each of said vent holes 24 is constructed as a cluster of a great number of minute holes 24, so as to prevent passage of the mixture of powder or granular form.
  • Such molding is also possible with a light pressing, either manually or with a machine, instead of using compressed air. Also, instead of the abovementioned type slicer B, cotton-opening mixer 4, and kneader 8, any types will meet the purposes of the present invention.
  • Sleeves which have been molded as mentioned above are dried at about C. in a drier 21 in the fifth step.
  • the mixed blending agent e.g., phenol resin
  • a cover with the binding agent makes the product sleeve also water-repellant, that is, highly moisture-repellant.
  • the method of the present invention can be more easily applied to the production of sheets which can be molded without difiiculty by using a device for producing molds for sheets, such as the sheets of FIG. 3 (II).
  • refractory materials (a) of granular form contained in the abovementioned mixture are used silica stone, alumina, chamot, brick powder, fly-ash, silica, etc. If necessary, such exothermic materials such as aluminum and its oxidizing agent are added thereto.
  • the granular size of any of these materials should be between 0.2 and 1 mm.
  • inorganic fibrous materials (b) are used rock wool, glass wool, ore flakes, asbestos, etc., any of which is sized about 3 to 5 mm. in the longitudinal direction.
  • organic fibrous materials (c) are used wood chips, pulp, fiber, paper, etc., any of which is sized about 0.5 to 5 mm. in the longitudinal direction.
  • a binding agent (d) is used a water-insoluble synthetic resin such as phenol resin.
  • the purposes of mixing the abovementioned raw materials are:
  • the refractory materials (a) such as silica and brick powder make the product fireproof and keep its form stable when used; inorganic fibrous materials (b) such as asbestos and ore flakes makes the product strong and light; and organic fibrous materials (e) such as wood powder and pulp make the product light and porous.
  • a binding agent (d) such as phenol resin is added to melt in the molding step and cover the above-mentioned mixture so as to bind the materials of granular form and make the product water-repellent and moisture-proof.
  • the present invention large quantities of inorganic and organic fibrous materials are mixed, thereby making the apparent specific gravity of product below 1 (that is, lighter than water), and also making it strong. Because of such lightweight, the product has high heat-insulation, and because of the use of a binding agent, it exhibits good moisture prevention, as mentioned above, thereby not only greatly raising feeder head efiects of the product, but also reducing production costs.
  • a mixture of raw materials is cotton-opened and well mixed in the dry state before being kneaded with water, thus holding itself in nearly the same condition as of a mixture containing only refractory materials according to the conventional methods, that is, in the original powder or granular form of no fluidity, with the addition of less than water, preferably between 75 and 100% when kneaded.
  • This makes it possible to carry out molding without any special process to remove superfluous water, and to use a pressing method for such molding, thereby again making it possible to mass-produce sleeves by using a core producing machine or the like in the molding step, and, moreover, to make such sleeves strong and heat-insulatmg.
  • the method of the present invention is not limitedly applied to the product of such sleeves or sheets, but is applicable also to the production of sleeves or sheets of an apparent specific gravity of about 1, even with large quantities of fibrous materials added to refractory materials, etc.
  • the method of the present invention functions in cotton-opening the added fibrous materials to be well mixed in the mixing step with other materials, such as refractory materials, so that the so made mixture may be subjected to molding without the need of removing water in the molding step, though it has been kneaded in the previous kneading step with some water added.
  • a pressing method as well as making them stronger than those made otherwise.
  • Phenol resin 6% of the above mixture Water 100% of the above mixture.
  • a sleeve I shown in FIG. 3 having an outside diameter of mm., an inside diameter of 120 mm. and a height of 120 mm. was produced.
  • the added volume of water for use in kneading at the third step was 75-100%, and the molding at the fourth step could be carried out by using a core producing machine at the same rate as in the production of cores of conventional type using the same machine.
  • a heat-insulating sleeve (A) and an exothermic, heat-insulating sleeve (B) were produced with sufiicient solidness.
  • Table I compares the apparent specific gravity of these materials, calculated by using a formula:
  • Sleeve (C) made by a conventional method contained no added fibrous materials, but was heat-insulating, exothermic, and of nearly the same size as the sleeve of the present invention.
  • Sleeve (D) was also devoid of fibrous materials, and was heat-insulating, exothermic, and of nearly the same size as the sleeve of the present invention.
  • Table 2 presents data comparing moisture resistance of these materials.
  • test pieces (A) and (B) of the present invention had much slower rise of temperature than the test pieces (C) and (D) of the conventional methods, proving that the sleeve of the present invention has good heat insulation.
  • the curves at the upper part indicate respectively the temperature of the heated side of test pieces, and those at the lower part indicate respectively the temperature rise on the other side.
  • sleeves or sheets of the present invention are poorly water-absorbent, thus requiring no cover for moisture prevention. They canbe used as molds as they are, or stocked for a long time. Besides, because of their light weight, they can be handled or transported without difficulty. Because of good heat insulation due to such light weight, a feeder head can maintain its temperature for a long period of time. Also, because of the very low heat absorption, they may be very slow in heat generation, making it possible to obtain an almost smokeless mixture, which is very effective in preventing air pollution.
  • the present invention is characterized by such a great advantage as continuous and automatic production of sleeves for great reduction of production costs.
  • sheets for feeder heads is intended to encompass such sheets in either slab or sleeve form.
  • a method of producing sheets for feeder heads formed in metal casting which consists essentially of (a) blending a raw material mixture comprising (i) from 10 to 50% by weight of at least one refractory material in granular or powder form of a particle size of 0.2-1 mm. and being selected from the group consisting of silica, alumina, chamot, brick powder, fly ash, silica stone, and mixtures thereof; (ii) 15 %-60% by weight of at least one inorganic fibrous material being selected from the group consisting of asbestos, rock wool, glass wool, ore flakes and mixtures thereof;

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
US00129778A 1970-09-07 1971-03-31 Method for producing sleeves or sheets for feeder heads formed in metal casting and an apparatus therefor Expired - Lifetime US3776992A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP7794870 1970-09-07
JP7794970A JPS4937609B1 (enrdf_load_stackoverflow) 1970-09-07 1970-09-07

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US3776992A true US3776992A (en) 1973-12-04

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US (1) US3776992A (enrdf_load_stackoverflow)
DE (1) DE2138481C3 (enrdf_load_stackoverflow)
FR (1) FR2106342B1 (enrdf_load_stackoverflow)
GB (1) GB1339483A (enrdf_load_stackoverflow)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4087285A (en) * 1973-06-01 1978-05-02 Kurz Fredrik W A Method for strengthening vitreous products and composition boards
US4605057A (en) * 1982-08-06 1986-08-12 Hitachi, Ltd. Process for producing core for casting
US20110027741A1 (en) * 2008-03-28 2011-02-03 Bloom Engineering Company, Inc. Vacuum-formed refractory member and method of making

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1410043A (en) * 1972-10-19 1975-10-15 Foseco Trading Ag Refractory heat insulating materials
GB2202218B (en) * 1987-02-19 1991-02-06 De Beers Ind Diamond Method of making an article from pyrophyllite
DE102010054513A1 (de) * 2010-12-15 2012-06-21 Claas Guss Gmbh Gusskern und Verfahren zur Beeinflussung des Erstarrungsverhaltens eines Gussteils

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3456914A (en) * 1965-10-23 1969-07-22 Johns Manville Inorganic fiber riser sleeves
DE1646508B2 (de) * 1966-01-10 1973-08-23 Foseco Trading AG, Chur, Graubunden (Schweiz) Verfahren zur herstellung einer feuerfesten faserhaltigen, waermeisolierenden masse

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4087285A (en) * 1973-06-01 1978-05-02 Kurz Fredrik W A Method for strengthening vitreous products and composition boards
US4605057A (en) * 1982-08-06 1986-08-12 Hitachi, Ltd. Process for producing core for casting
US20110027741A1 (en) * 2008-03-28 2011-02-03 Bloom Engineering Company, Inc. Vacuum-formed refractory member and method of making

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Publication number Publication date
GB1339483A (en) 1973-12-05
FR2106342B1 (enrdf_load_stackoverflow) 1974-08-19
DE2138481B2 (de) 1973-12-13
DE2138481C3 (de) 1974-07-18
FR2106342A1 (enrdf_load_stackoverflow) 1972-05-05
DE2138481A1 (de) 1972-03-16

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