US20010022999A1 - Exothermic sleeve mixes containing fine aluminum - Google Patents
Exothermic sleeve mixes containing fine aluminum Download PDFInfo
- Publication number
- US20010022999A1 US20010022999A1 US09/761,543 US76154301A US2001022999A1 US 20010022999 A1 US20010022999 A1 US 20010022999A1 US 76154301 A US76154301 A US 76154301A US 2001022999 A1 US2001022999 A1 US 2001022999A1
- Authority
- US
- United States
- Prior art keywords
- sleeve
- composition
- weight percent
- casting
- exothermic
- 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.)
- Abandoned
Links
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 41
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 38
- 239000000203 mixture Substances 0.000 claims abstract description 62
- 229910052751 metal Inorganic materials 0.000 claims abstract description 37
- 239000002184 metal Substances 0.000 claims abstract description 37
- 239000007800 oxidant agent Substances 0.000 claims abstract description 11
- 238000005266 casting Methods 0.000 claims description 60
- 239000011230 binding agent Substances 0.000 claims description 30
- 238000000034 method Methods 0.000 claims description 18
- 239000003054 catalyst Substances 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 9
- 238000009826 distribution Methods 0.000 claims description 8
- 238000012360 testing method Methods 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- 239000004005 microsphere Substances 0.000 claims description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 6
- 229920005822 acrylic binder Polymers 0.000 claims description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 238000005058 metal casting Methods 0.000 abstract description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 description 8
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 6
- 229910000323 aluminium silicate Inorganic materials 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- 229910001610 cryolite Inorganic materials 0.000 description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 4
- FGIUAXJPYTZDNR-UHFFFAOYSA-N potassium nitrate Chemical compound [K+].[O-][N+]([O-])=O FGIUAXJPYTZDNR-UHFFFAOYSA-N 0.000 description 4
- 229910001141 Ductile iron Inorganic materials 0.000 description 3
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 3
- 150000001412 amines Chemical class 0.000 description 3
- 239000001569 carbon dioxide Substances 0.000 description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 239000011810 insulating material Substances 0.000 description 3
- 229920001568 phenolic resin Polymers 0.000 description 3
- 239000005011 phenolic resin Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 239000011819 refractory material Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 150000003512 tertiary amines Chemical group 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- VQGHOUODWALEFC-UHFFFAOYSA-N 2-phenylpyridine Chemical compound C1=CC=CC=C1C1=CC=CC=N1 VQGHOUODWALEFC-UHFFFAOYSA-N 0.000 description 2
- YLQBMQCUIZJEEH-UHFFFAOYSA-N Furan Chemical compound C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 2
- JUJWROOIHBZHMG-UHFFFAOYSA-N Pyridine Chemical compound C1=CC=NC=C1 JUJWROOIHBZHMG-UHFFFAOYSA-N 0.000 description 2
- SMWDFEZZVXVKRB-UHFFFAOYSA-N Quinoline Chemical compound N1=CC=CC2=CC=CC=C21 SMWDFEZZVXVKRB-UHFFFAOYSA-N 0.000 description 2
- DZBUGLKDJFMEHC-UHFFFAOYSA-N acridine Chemical compound C1=CC=CC2=CC3=CC=CC=C3N=C21 DZBUGLKDJFMEHC-UHFFFAOYSA-N 0.000 description 2
- 125000001931 aliphatic group Chemical group 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- SZVJSHCCFOBDDC-UHFFFAOYSA-N ferrosoferric oxide Chemical compound O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 2
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- AWJUIBRHMBBTKR-UHFFFAOYSA-N isoquinoline Chemical compound C1=NC=CC2=CC=CC=C21 AWJUIBRHMBBTKR-UHFFFAOYSA-N 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- TZIHFWKZFHZASV-UHFFFAOYSA-N methyl formate Chemical compound COC=O TZIHFWKZFHZASV-UHFFFAOYSA-N 0.000 description 2
- 150000002823 nitrates Chemical class 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229920001228 polyisocyanate Polymers 0.000 description 2
- 239000005056 polyisocyanate Substances 0.000 description 2
- 239000004323 potassium nitrate Substances 0.000 description 2
- 235000010333 potassium nitrate Nutrition 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920003987 resole Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- IWDFHWZHHOSSGR-UHFFFAOYSA-N 1-ethylimidazole Chemical compound CCN1C=CN=C1 IWDFHWZHHOSSGR-UHFFFAOYSA-N 0.000 description 1
- MCTWTZJPVLRJOU-UHFFFAOYSA-N 1-methyl-1H-imidazole Chemical compound CN1C=CN=C1 MCTWTZJPVLRJOU-UHFFFAOYSA-N 0.000 description 1
- FGYADSCZTQOAFK-UHFFFAOYSA-N 1-methylbenzimidazole Chemical compound C1=CC=C2N(C)C=NC2=C1 FGYADSCZTQOAFK-UHFFFAOYSA-N 0.000 description 1
- IWTFOFMTUOBLHG-UHFFFAOYSA-N 2-methoxypyridine Chemical compound COC1=CC=CC=N1 IWTFOFMTUOBLHG-UHFFFAOYSA-N 0.000 description 1
- ZAISDHPZTZIFQF-UHFFFAOYSA-N 2h-1,4-thiazine Chemical compound C1SC=CN=C1 ZAISDHPZTZIFQF-UHFFFAOYSA-N 0.000 description 1
- PWRBCZZQRRPXAB-UHFFFAOYSA-N 3-chloropyridine Chemical compound ClC1=CC=CN=C1 PWRBCZZQRRPXAB-UHFFFAOYSA-N 0.000 description 1
- MWVTWFVJZLCBMC-UHFFFAOYSA-N 4,4'-bipyridine Chemical compound C1=NC=CC(C=2C=CN=CC=2)=C1 MWVTWFVJZLCBMC-UHFFFAOYSA-N 0.000 description 1
- AQIIVEISJBBUCR-UHFFFAOYSA-N 4-(3-phenylpropyl)pyridine Chemical compound C=1C=NC=CC=1CCCC1=CC=CC=C1 AQIIVEISJBBUCR-UHFFFAOYSA-N 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920000538 Poly[(phenyl isocyanate)-co-formaldehyde] Polymers 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- NNDGIEARKHXAEO-UHFFFAOYSA-J [F-].[F-].[F-].[F-].F.F.[Al+3].[K+] Chemical compound [F-].[F-].[F-].[F-].F.F.[Al+3].[K+] NNDGIEARKHXAEO-UHFFFAOYSA-J 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 239000003849 aromatic solvent Substances 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- -1 chromite Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000002529 flux (metallurgy) Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- JVZRCNQLWOELDU-UHFFFAOYSA-N gamma-Phenylpyridine Natural products C1=CC=CC=C1C1=CC=NC=C1 JVZRCNQLWOELDU-UHFFFAOYSA-N 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910001960 metal nitrate Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 150000004702 methyl esters Chemical class 0.000 description 1
- 239000003110 molding sand Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052609 olivine Inorganic materials 0.000 description 1
- 239000010450 olivine Substances 0.000 description 1
- 239000012286 potassium permanganate Substances 0.000 description 1
- SKFYTVYMYJCRET-UHFFFAOYSA-J potassium;tetrafluoroalumanuide Chemical compound [F-].[F-].[F-].[F-].[Al+3].[K+] SKFYTVYMYJCRET-UHFFFAOYSA-J 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- PBMFSQRYOILNGV-UHFFFAOYSA-N pyridazine Chemical compound C1=CC=NN=C1 PBMFSQRYOILNGV-UHFFFAOYSA-N 0.000 description 1
- UMJSCPRVCHMLSP-UHFFFAOYSA-N pyridine Natural products COC1=CC=CN=C1 UMJSCPRVCHMLSP-UHFFFAOYSA-N 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
-
- 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
- B22D7/104—Hot tops therefor from exothermic material only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/131—Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
- Y10T428/1317—Multilayer [continuous layer]
Definitions
- the invention relates to an exothermic sleeve composition
- an exothermic sleeve composition comprising (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and (b) an oxidizing agent capable of generating an exothermic reaction.
- the invention also relates to the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions, and the use of the sleeves to prepare metal castings.
- a casting assembly typically consists of a pouring cup, a gating system (including downsprue, choke, and runner), riser, sleeve, mold, core, and other components.
- a gating system including downsprue, choke, and runner
- riser including downsprue, choke, and runner
- sleeve sleeve
- Risers or feeders are reservoirs that contain excess molten metal.
- the excess molten metal is needed to compensate for contractions or voids of metal that occur during the casting process.
- Metal from the riser fills such voids in the casting when the casting metal contracts.
- Sleeves are used to surround or encapsulate the riser and other parts of the casting assembly in order to keep the molten metal in the riser hot and maintain it in the liquid state for a longer time.
- sleeves In order to serve their function, sleeves have exothermic and/or insulating properties. Exothermic sleeves function by liberating heat. This liberated heat satisfies some or all of the specific heat requirements of the riser and limits the temperature loss of the molten metal in the riser, thereby keeping the metal hotter and liquid longer. Insulating sleeves, on the other hand, maintain the heat of the molten metal in the riser by insulating it from the surrounding mold assembly.
- sleeves were produced by “ramming”, “vacuuming”, and “blowing or shooting”, methods well known in the art. More recently, it was discovered that sleeves could be made by chemically curing a shaped sleeve mix with a curing catalyst by the no-bake and cold-box process. See published application WO 97/35677, which hereby incorporated by reference. These processes provide sleeves with improved dimensional accuracy.
- Typical exothermic sleeve formulations contain aluminum as a fuel, metal oxides and nitrates as oxidizers, and fluoride containing compounds as fluxing agents.
- the aluminum is typically used is granular and/or a powder, having a broad particle size distribution, and is considered “coarse” in nature.
- the exothermic sleeves prepared with this coarse aluminum produce an acceptable exothermic reaction in most cases, but the surface finish of the casting metal against the sleeve material is often “rough” because the massive heat produced by the exotherm of the sleeve. This is a concern to foundries because a rough casting surface finish requires extra cleaning time and machining before the casting can be used effectively. In some cases the surface finish is so rough that the casting is defective and scrapped.
- One method used to prevent the exotherm from the sleeve from causing a poor surface finish is to move the riser sleeve away from the casting assembly. By doing this, the casting is exposed to less heat, and the risk of a poor surface finish is decreased.
- the disadvantage of this remedy is that it increases the amount of riser metal used, which lowers the casting yield.
- the spring thorn is a “spring-loaded locator” that creates a gap between the riser sleeve and the casting that allows sand to build-up between the riser sleeve and the surface of the casting.
- This molding sand acts as a barrier between the sleeve and the surface casting and keeps the exotherm created by the riser away from the casting surface.
- the spring thorn is particularly useful for mounting riser sleeves used with high pressure, green sand molding equipment to cast metals.
- the invention relates to an exothermic sleeve mix comprising:
- the surface finish of the casting that is in contact with the heat produced by the burning of the exothermic sleeve is improved, if fine aluminum is used in the exothermic sleeve mix. Smoother castings are made, similar to or better than that of cores and molds made with sand.
- the sleeve compositions are used to make castings from metals, e.g iron, duticle iron, steel, aluminum, etc.
- a smoother finish reduces the need for cleaning and machining the casting.
- the exothermic riser sleeve can be placed directly in contact with the surface of the casting.
- Special mounting techniques such as the so-called “spring thorn locator” that increase the cost of making the casting, are not required.
- Casting assembly - assembly of casting components such as pouring cup, gating system (downsprue, runner, choke), molds, core, riser, sleeve, etc., which are used to make a metal casting.
- ISOCURE® cold-box binder a two part polyurethane-forming cold-box binder where the Part I is a phenolic resin similar to that described in U.S. Pat. No. 3,485,797. The resin is dissolved in a blend of aromatic, ester, and aliphatic solvents, and a silane.
- Part II is the polyisocyanate component, and comprises a polymethylene polyphenyl isocyanate, a solvent blend consisting primarily of aromatic solvents and a minor amount of aliphatic solvents, and a benchlife extender. The weight ratio of Part I to Part II is about 55:45.
- Exothermic sleeve - a sleeve that has exothermic properties compared to the mold/core assembly in which it is used.
- Gating system - system through which metal is directed from the pouring cup to the mold and/or core assembly.
- Components of the gating system include the downsprue, runners, choke, etc.
- Handleable the ability of a sleeve to be transported from one place to another without sagging or breaking.
- Microspheres - alumino-silicate hollow spheres such as those described in WO 97/35677.
- Mold assembly an assembly of molds and/or cores made from a foundry aggregate (typically sand) and a foundry binder, which is placed in a casting assembly to provide a shape for the casting.
- a foundry aggregate typically sand
- a foundry binder typically sand
- Sleeve - any moldable shape having exothermic and/or insulating properties made from a sleeve composition that covers, in whole or part, any component of the casting assembly.
- the exothermic sleeve composition comprises (a) fine aluminum and (b) an oxidizing agent.
- the sleeve compositions are used to make sleeve mixes that contain (1) an exothermic sleeve composition, and (2) an effective amount of a chemically reactive inorganic or organic binder.
- the sleeve mix is shaped and cured by contacting the sleeve with an effective amount of a curing catalyst.
- the fine aluminum typically a powder, is defined as aluminum having a particle distribution such that 95 weight percent of the aluminum passes through 1 00 mesh as determined by the US Standard Screen Test, preferably a particle distribution such that more than 95 percent of the aluminum passes through the 140 mesh.
- Aluminum can be used as a pure metal, as an alloy with magnesium, silicon, copper, or possibly a component of a waste material. Although not preferred for achieving the best surface finish, minor amounts of coarse aluminum can be mixed with the fine aluminum to reduce the cost of the sleeve composition 1 , for instance up to 15 weight percent based on the amount of aluminum, preferably less than 5 weight percent.
- Coarse aluminum is aluminum having a particle distribution outside the definition stipulated for fine aluminum.
- the oxidizing agent used for the exothermic sleeve includes iron oxide, manganese oxide, nitrates, potassium permanganate, etc. Oxides do not need to be present at stoichiometric levels to satisfy the metal aluminum fuel component since the riser sleeves and molds in which they are contained are permeable. Thus oxygen from the oxidizing agents is supplemented by atmospheric oxygen when the aluminum fuel is burned. Typically the weight ratio of aluminum to oxidizing agent is from about 10:1 to about 1:1, preferably about 5:1 to about 1.5:1.
- the amount of fine aluminum in the sleeve composition will range from 5 weight percent to 45 weight percent, typically 20 weight percent to 35 weight percent, based upon the weight of the sleeve composition.
- Insulating materials can be added to the sleeve composition.
- Such materials include refractory materials (e.g. magnesia, alumina, sand, and aluminosilicate), hollow microspheres, and fibers.
- the amount of insulating material in the sleeve composition ranges from 30 weight percent to 85 weight percent, typically 30 weight percent to 70 weight percent, where the weight percent is based upon the weight of the sleeve composition.
- Preferably used as the insulating material are hollow aluminosilicate microspheres such as those described in WO 97/35677, which is hereby incorporated by reference.
- the sleeve mixes can also contain refractories such as silica, sand, magnesia, alumina, olivine, chromite, aluminosilicate, and silicon carbide among others. These refractories are preferably used in amounts less than 60 weight percent based upon the weight of the sleeve composition, more preferably less than 25 weight percent based upon the weight of the sleeve composition.
- the sleeve composition may contain fillers, additives, and fluxes, such as cryolite (Na 3 AlF 6 ), potassium aluminum tetrafluoride, potassium aluminum hexafluoride.
- cryolite Na 3 AlF 6
- potassium aluminum tetrafluoride potassium aluminum hexafluoride
- the sleeve compositions are mixed with chemical binders to form a sleeve mix.
- Any inorganic or organic foundry binder that sufficiently holds the sleeve mix together in the shape of a sleeve and polymerizes in the presence of a curing catalyst, will work.
- examples of such binders include inorganic binders such as sodium silicate binders cured with carbon dioxide (see U.S. Pat. No. 4,985,489 which is hereby incorporated into this disclosure by reference), and organic binders such as phenolic resins, phenolic urethane binders, furan binders, alkaline phenolic resole binders (see U.S. Pat. No.
- binders include epoxy-acrylic binders sold by Ashland Inc. under the ISOSET® trademark.
- the epoxy-acrylic binders, cured with sulfur dioxide in the presence of an oxidizing agent, are described in U.S. Pat. No. 4,526,219, which is hereby incorporated into this disclosure by reference.
- Most preferred as the binder are amine curable phenolic urethane binders, are described in U.S. Pat. No. 3,485,497, U.S. Pat. Nos. 3,409,579, and 3,676,3923, which are hereby incorporated into this disclosure by reference.
- These binders are based on a two-part system, one part being a phenolic resin component and the other part being a polyisocyanate component.
- the amount of binder needed is an effective amount to maintain the shape of the sleeve and allow for effective curing, i.e. which will produce a sleeve which can be handled or self-supported after curing.
- An effective amount of binder is greater than about 4 weight percent, based upon the weight of the sleeve composition.
- the amount of binder ranges from about 5 weight percent to about 15 weight percent, more preferably from about 6 weight percent to about 12 weight percent.
- Curing the sleeve by the no-bake process takes place by mixing a liquid curing catalyst with the sleeve mix, shaping the sleeve mix containing the catalyst, and allowing the sleeve shape to cure, typically at ambient temperature without the addition of heat.
- the preferred liquid curing catalyst is a tertiary amine and the preferred no-bake curing process is described in U.S. Pat. No. 3,485,797, which is hereby incorporated by reference into this disclosure.
- liquid curing catalysts include 4-alkyl pyridines wherein the alkyl group has from one to four carbon atoms, isoquinoline, arylpyridines such as phenyl pyridine, pyridine, acridine, 2-methoxypyridine, pyridazine, 3-chloro pyridine, quinoline, N-methyl imidazole, N-ethyl imidazole, 4,4′-dipyridine, 4-phenylpropylpyridine, 1-methylbenzimidazole, and 1,4-thiazine.
- arylpyridines such as phenyl pyridine, pyridine, acridine, 2-methoxypyridine, pyridazine, 3-chloro pyridine, quinoline, N-methyl imidazole, N-ethyl imidazole, 4,4′-dipyridine, 4-phenylpropylpyridine, 1-methylbenzimidazole, and 1,4-thiazine.
- Curing the sleeve by the cold-box process takes place by blowing or ramming the sleeve mix into a pattern and contacting the sleeve with a vaporous or gaseous catalyst.
- Various vapor or vapor/gas mixtures or gases such as tertiary amines, carbon dioxide, methyl formate, and sulfur dioxide can be used depending on the chemical binder chosen.
- gaseous curing agent is appropriate for the binder used.
- an amine vapor/gas mixture is used with phenolic-urethane resins.
- Sulfur dioxide in conjunction with an oxidizing agent
- Carbon dioxide see U.S. Pat. No. 4,985,489, which is hereby incorporated by reference
- methyl esters see U.S. Pat. No. 4,750,716 which is hereby incorporated into this disclosure by reference
- alkaline phenolic resole resins are used with alkaline phenolic resole resins.
- Preferably sleeves are prepared by a cold-box process with a phenolic urethane binder by passing a tertiary amine gas, such a triethylamine, through the molded sleeve mix in the manner as described in U.S. Pat. No. 3,409,579; or with an epoxy-acrylic binder cured with sulfur dioxide in the presence of an oxidizing agent as described in U.S. Pat. No. 4,526,219.
- Typical gassing times are from 0.5 to 3.0 seconds, preferably from 0.5 to 2.0 seconds.
- Purge times are from 1.0 to 60 seconds, preferably from 1.0 to 10 seconds.
- the exothermic sleeves were prepared with phenolic-urethane binder using cold-box technology.
- the exothermic composition contained aluminosilicate microspheres, aluminum powder, iron oxide, manganese dioxide, potassium nitrate and cryolite. Those components were mixed with an ISOCURE® Part I and Part II binder and then cured with an amine catalyst using conventional cold box technology.
- the sleeves were then tested for casting performance in a ductile iron test casting. Evaluation of the resulting castings included the safety margin of the riser and an analysis of the surface finish of casting. All parts are by weight and all percentages are weight percentages based upon the weight of the sleeve composition unless otherwise specified.
- Sleeve compositions were prepared by mixing the following components with the aluminum powder described in Table I.
- the “fine aluminum” and “coarse aluminum” used in the examples are described in Table II.
- TABLE I Exothermic sleeve composition
- Component Amount (pbw) 2 Microspheres 51 Potassium nitrate 8 Cryolite 3 MnO 2 5 Fe 3 O 4 5 Aluminum powder (Table II) 28
- Sleeves (C, D, 3, and 4) were prepared by mixing the aluminum compositions (A, B, 1, and 2) with 8.8 parts of ISOCURE® cold-box binder. Test sleeves (2′′ ⁇ 3′′) were prepared by the ISOCURE® cold-box process along the lines described in WO 97/35677, which is hereby incorporated by reference.
- Ductile iron castings were prepared from casting assemblies where sleeves C, D, 3, and 4 were used to surround the top riser of the casting assembly respectively.
- the test casting made is an impeller casting having a weight of about 5.5 kg. and uses a 2′′ ⁇ 3′′ riser to feed the casting.
- the metal is poured down the sprue from the side, filling the casting cavity first and then the riser.
- the pouring temperature was 1400° C.
- the surface finish of the castings in contact with the sleeve was compared.
- the results of the casting experiments are summarized in Table III below. The safety margin of all the sleeved risers was measured and was more than adequate. TABLE III (CASTING RESULTS) CASTING EXAMPLE SLEEVE Al RESULTS/SURFACE FINISH G C Coarse (A) Poor H D Mix (B) Poor 6 3 Fine (1) Excellent 7 4 Fine (2) Excellent
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Abstract
The invention relates to an exothermic sleeve composition comprising (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and (b) an oxidizing agent capable of generating an exothermic reaction. The invention also relates to the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions, and the use of the sleeves to prepare metal castings.
Description
- The invention relates to an exothermic sleeve composition comprising (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and (b) an oxidizing agent capable of generating an exothermic reaction. The invention also relates to the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions, and the use of the sleeves to prepare metal castings.
- A casting assembly typically consists of a pouring cup, a gating system (including downsprue, choke, and runner), riser, sleeve, mold, core, and other components. To produce a metal casting, metal is poured into the pouring cup of the casting assembly and passes through the gating system to the mold and/or core assembly where it cools and solidifies. The metal part is then removed by separating it from the core and/or mold assembly.
- Risers or feeders are reservoirs that contain excess molten metal. The excess molten metal is needed to compensate for contractions or voids of metal that occur during the casting process. Metal from the riser fills such voids in the casting when the casting metal contracts. Thus the metal from the riser needs to remain in a liquid state for a longer period of time, so it can provide metal to the casting as it cools and solidifies. Sleeves are used to surround or encapsulate the riser and other parts of the casting assembly in order to keep the molten metal in the riser hot and maintain it in the liquid state for a longer time.
- In order to serve their function, sleeves have exothermic and/or insulating properties. Exothermic sleeves function by liberating heat. This liberated heat satisfies some or all of the specific heat requirements of the riser and limits the temperature loss of the molten metal in the riser, thereby keeping the metal hotter and liquid longer. Insulating sleeves, on the other hand, maintain the heat of the molten metal in the riser by insulating it from the surrounding mold assembly.
- For years sleeves were produced by “ramming”, “vacuuming”, and “blowing or shooting”, methods well known in the art. More recently, it was discovered that sleeves could be made by chemically curing a shaped sleeve mix with a curing catalyst by the no-bake and cold-box process. See published application WO 97/35677, which hereby incorporated by reference. These processes provide sleeves with improved dimensional accuracy.
- Typical exothermic sleeve formulations contain aluminum as a fuel, metal oxides and nitrates as oxidizers, and fluoride containing compounds as fluxing agents. The aluminum is typically used is granular and/or a powder, having a broad particle size distribution, and is considered “coarse” in nature. The exothermic sleeves prepared with this coarse aluminum produce an acceptable exothermic reaction in most cases, but the surface finish of the casting metal against the sleeve material is often “rough” because the massive heat produced by the exotherm of the sleeve. This is a concern to foundries because a rough casting surface finish requires extra cleaning time and machining before the casting can be used effectively. In some cases the surface finish is so rough that the casting is defective and scrapped.
- One method used to prevent the exotherm from the sleeve from causing a poor surface finish is to move the riser sleeve away from the casting assembly. By doing this, the casting is exposed to less heat, and the risk of a poor surface finish is decreased. The disadvantage of this remedy is that it increases the amount of riser metal used, which lowers the casting yield.
- An example of a method used to move the sleeve away from the riser sleeve is the so-called “spring thorn”. The spring thorn is a “spring-loaded locator” that creates a gap between the riser sleeve and the casting that allows sand to build-up between the riser sleeve and the surface of the casting. This molding sand acts as a barrier between the sleeve and the surface casting and keeps the exotherm created by the riser away from the casting surface. The spring thorn is particularly useful for mounting riser sleeves used with high pressure, green sand molding equipment to cast metals. Another way to reduce the negative impact of the sleeve's exotherm on the surface finish of the casting is by adding a protective layer of metal (a riser “pad”) between the riser sleeve and the casting assembly. After the casting is made and the riser is removed from the casting, this additional pad of metal must be removed from the casting. The disadvantage of this technique is that it adds processing steps, which increases the cost of the casting.
- The invention relates to an exothermic sleeve mix comprising:
- (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and
- (b) an oxidizing agent capable of generating an exothermic reaction.
- The surface finish of the casting that is in contact with the heat produced by the burning of the exothermic sleeve is improved, if fine aluminum is used in the exothermic sleeve mix. Smoother castings are made, similar to or better than that of cores and molds made with sand. The sleeve compositions are used to make castings from metals, e.g iron, duticle iron, steel, aluminum, etc.
- A smoother finish reduces the need for cleaning and machining the casting. As a result, the exothermic riser sleeve can be placed directly in contact with the surface of the casting. Special mounting techniques, such as the so-called “spring thorn locator” that increase the cost of making the casting, are not required.
- The following definitions and abbreviations are stipulated:
- μm - microns.
- Casting assembly - assembly of casting components such as pouring cup, gating system (downsprue, runner, choke), molds, core, riser, sleeve, etc., which are used to make a metal casting.
- ISOCURE® cold-box binder - a two part polyurethane-forming cold-box binder where the Part I is a phenolic resin similar to that described in U.S. Pat. No. 3,485,797. The resin is dissolved in a blend of aromatic, ester, and aliphatic solvents, and a silane. Part II is the polyisocyanate component, and comprises a polymethylene polyphenyl isocyanate, a solvent blend consisting primarily of aromatic solvents and a minor amount of aliphatic solvents, and a benchlife extender. The weight ratio of Part I to Part II is about 55:45.
- Exothermic sleeve - a sleeve that has exothermic properties compared to the mold/core assembly in which it is used.
- Gating system - system through which metal is directed from the pouring cup to the mold and/or core assembly. Components of the gating system include the downsprue, runners, choke, etc.
- Handleable - the ability of a sleeve to be transported from one place to another without sagging or breaking.
- Microspheres - alumino-silicate hollow spheres such as those described in WO 97/35677.
- Mold assembly - an assembly of molds and/or cores made from a foundry aggregate (typically sand) and a foundry binder, which is placed in a casting assembly to provide a shape for the casting.
- Riser - cavity connected to a mold or casting cavity of the casting assembly which acts as a reservoir for excess molten metal to prevent cavities in the casting as it contracts on solidification.
- Sleeve - any moldable shape having exothermic and/or insulating properties made from a sleeve composition that covers, in whole or part, any component of the casting assembly.
- US Standard Screen Test 8″- test to determine particle size distribution using set of sieves diameter and aperture sizes from 4 inches to 500 mesh.
- The exothermic sleeve composition comprises (a) fine aluminum and (b) an oxidizing agent. The sleeve compositions are used to make sleeve mixes that contain (1) an exothermic sleeve composition, and (2) an effective amount of a chemically reactive inorganic or organic binder. The sleeve mix is shaped and cured by contacting the sleeve with an effective amount of a curing catalyst.
- The fine aluminum, typically a powder, is defined as aluminum having a particle distribution such that 95 weight percent of the aluminum passes through 1 00 mesh as determined by the US Standard Screen Test, preferably a particle distribution such that more than 95 percent of the aluminum passes through the 140 mesh.
- Aluminum can be used as a pure metal, as an alloy with magnesium, silicon, copper, or possibly a component of a waste material. Although not preferred for achieving the best surface finish, minor amounts of coarse aluminum can be mixed with the fine aluminum to reduce the cost of the sleeve composition1, for instance up to 15 weight percent based on the amount of aluminum, preferably less than 5 weight percent. Coarse aluminum is aluminum having a particle distribution outside the definition stipulated for fine aluminum.
- The oxidizing agent used for the exothermic sleeve includes iron oxide, manganese oxide, nitrates, potassium permanganate, etc. Oxides do not need to be present at stoichiometric levels to satisfy the metal aluminum fuel component since the riser sleeves and molds in which they are contained are permeable. Thus oxygen from the oxidizing agents is supplemented by atmospheric oxygen when the aluminum fuel is burned. Typically the weight ratio of aluminum to oxidizing agent is from about 10:1 to about 1:1, preferably about 5:1 to about 1.5:1.
- Depending upon the degree of exothermic properties wanted in the sleeve, the amount of fine aluminum in the sleeve composition will range from 5 weight percent to 45 weight percent, typically 20 weight percent to 35 weight percent, based upon the weight of the sleeve composition.
- Insulating materials can be added to the sleeve composition. Such materials include refractory materials (e.g. magnesia, alumina, sand, and aluminosilicate), hollow microspheres, and fibers. The amount of insulating material in the sleeve composition ranges from 30 weight percent to 85 weight percent, typically 30 weight percent to 70 weight percent, where the weight percent is based upon the weight of the sleeve composition. Preferably used as the insulating material are hollow aluminosilicate microspheres such as those described in WO 97/35677, which is hereby incorporated by reference.
- The sleeve mixes can also contain refractories such as silica, sand, magnesia, alumina, olivine, chromite, aluminosilicate, and silicon carbide among others. These refractories are preferably used in amounts less than 60 weight percent based upon the weight of the sleeve composition, more preferably less than 25 weight percent based upon the weight of the sleeve composition.
- In addition, the sleeve composition may contain fillers, additives, and fluxes, such as cryolite (Na3AlF6), potassium aluminum tetrafluoride, potassium aluminum hexafluoride.
- The sleeve compositions are mixed with chemical binders to form a sleeve mix. Any inorganic or organic foundry binder, that sufficiently holds the sleeve mix together in the shape of a sleeve and polymerizes in the presence of a curing catalyst, will work. Examples of such binders include inorganic binders such as sodium silicate binders cured with carbon dioxide (see U.S. Pat. No. 4,985,489 which is hereby incorporated into this disclosure by reference), and organic binders such as phenolic resins, phenolic urethane binders, furan binders, alkaline phenolic resole binders (see U.S. Pat. No. 4,750,716 which is hereby incorporated by reference), and epoxy-acrylic binders among others. Preferred binders include epoxy-acrylic binders sold by Ashland Inc. under the ISOSET® trademark. The epoxy-acrylic binders, cured with sulfur dioxide in the presence of an oxidizing agent, are described in U.S. Pat. No. 4,526,219, which is hereby incorporated into this disclosure by reference. Most preferred as the binder are amine curable phenolic urethane binders, are described in U.S. Pat. No. 3,485,497, U.S. Pat. Nos. 3,409,579, and 3,676,3923, which are hereby incorporated into this disclosure by reference. These binders are based on a two-part system, one part being a phenolic resin component and the other part being a polyisocyanate component.
- The amount of binder needed is an effective amount to maintain the shape of the sleeve and allow for effective curing, i.e. which will produce a sleeve which can be handled or self-supported after curing. An effective amount of binder is greater than about 4 weight percent, based upon the weight of the sleeve composition. Preferably the amount of binder ranges from about 5 weight percent to about 15 weight percent, more preferably from about 6 weight percent to about 12 weight percent.
- Curing the sleeve by the no-bake process takes place by mixing a liquid curing catalyst with the sleeve mix, shaping the sleeve mix containing the catalyst, and allowing the sleeve shape to cure, typically at ambient temperature without the addition of heat. The preferred liquid curing catalyst is a tertiary amine and the preferred no-bake curing process is described in U.S. Pat. No. 3,485,797, which is hereby incorporated by reference into this disclosure. Specific examples of such liquid curing catalysts include 4-alkyl pyridines wherein the alkyl group has from one to four carbon atoms, isoquinoline, arylpyridines such as phenyl pyridine, pyridine, acridine, 2-methoxypyridine, pyridazine, 3-chloro pyridine, quinoline, N-methyl imidazole, N-ethyl imidazole, 4,4′-dipyridine, 4-phenylpropylpyridine, 1-methylbenzimidazole, and 1,4-thiazine.
- Curing the sleeve by the cold-box process takes place by blowing or ramming the sleeve mix into a pattern and contacting the sleeve with a vaporous or gaseous catalyst. Various vapor or vapor/gas mixtures or gases such as tertiary amines, carbon dioxide, methyl formate, and sulfur dioxide can be used depending on the chemical binder chosen. Those skilled in the art will know which gaseous curing agent is appropriate for the binder used. For example, an amine vapor/gas mixture is used with phenolic-urethane resins. Sulfur dioxide (in conjunction with an oxidizing agent) is used with an epoxy-acrylic resin. Carbon dioxide (see U.S. Pat. No. 4,985,489, which is hereby incorporated by reference) or methyl esters (see U.S. Pat. No. 4,750,716 which is hereby incorporated into this disclosure by reference) are used with alkaline phenolic resole resins.
- Preferably sleeves are prepared by a cold-box process with a phenolic urethane binder by passing a tertiary amine gas, such a triethylamine, through the molded sleeve mix in the manner as described in U.S. Pat. No. 3,409,579; or with an epoxy-acrylic binder cured with sulfur dioxide in the presence of an oxidizing agent as described in U.S. Pat. No. 4,526,219. Typical gassing times are from 0.5 to 3.0 seconds, preferably from 0.5 to 2.0 seconds. Purge times are from 1.0 to 60 seconds, preferably from 1.0 to 10 seconds.
- The exothermic sleeves were prepared with phenolic-urethane binder using cold-box technology. The exothermic composition contained aluminosilicate microspheres, aluminum powder, iron oxide, manganese dioxide, potassium nitrate and cryolite. Those components were mixed with an ISOCURE® Part I and Part II binder and then cured with an amine catalyst using conventional cold box technology. The sleeves were then tested for casting performance in a ductile iron test casting. Evaluation of the resulting castings included the safety margin of the riser and an analysis of the surface finish of casting. All parts are by weight and all percentages are weight percentages based upon the weight of the sleeve composition unless otherwise specified.
- Sleeve compositions were prepared by mixing the following components with the aluminum powder described in Table I. The “fine aluminum” and “coarse aluminum” used in the examples are described in Table II.
TABLE I (Exothermic sleeve composition) Component Amount (pbw)2 Microspheres 51 Potassium nitrate 8 Cryolite 3 MnO2 5 Fe3O4 5 Aluminum powder (Table II) 28 -
TABLE II PARTICLE SIZE DISTRIBUTION OF THE COARSE AND FINE ALUMINUM USED IN THE SLEEVE COMPOSITION Weight % particle retained on Mesh Aluminum Composition A 1 2 B3 Mesh no. μm Coarse Fine Fine Mixture 40 425 0 0 0 0 70 212 26 0 0 13 100 150 34 0 0 17 140 106 33 0 2 16.5 200 75 6 7 7 6.5 325 45 1 20 21 10.5 Pan <45 0 73 70 36.5 - Sleeves (C, D, 3, and 4) were prepared by mixing the aluminum compositions (A, B, 1, and 2) with 8.8 parts of ISOCURE® cold-box binder. Test sleeves (2″×3″) were prepared by the ISOCURE® cold-box process along the lines described in WO 97/35677, which is hereby incorporated by reference.
- Ductile iron castings were prepared from casting assemblies where sleeves C, D, 3, and 4 were used to surround the top riser of the casting assembly respectively. The test casting made is an impeller casting having a weight of about 5.5 kg. and uses a 2″×3″ riser to feed the casting. The metal is poured down the sprue from the side, filling the casting cavity first and then the riser. The pouring temperature was 1400° C. The surface finish of the castings in contact with the sleeve was compared. The results of the casting experiments are summarized in Table III below. The safety margin of all the sleeved risers was measured and was more than adequate.
TABLE III (CASTING RESULTS) CASTING EXAMPLE SLEEVE Al RESULTS/SURFACE FINISH G C Coarse (A) Poor H D Mix (B) Poor 6 3 Fine (1) Excellent 7 4 Fine (2) Excellent - The observations recorded in Table III indicate that the ductile iron castings made with the sleeves that contained the fine aluminum had excellent surface finish, while the castings prepared with the sleeves that contained the coarse aluminum had poor surface finish.
Claims (13)
1. An exothermic sleeve composition comprising:
(a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and
(b) an effective amount of an oxidizing agent capable of generating an exothermic reaction.
2. The composition of wherein the fine aluminum comprises a particle distribution such that 95 weight percent of the aluminum passes through a 100 mesh as determined by the US Standard Screen Test.
claim 1
3. The sleeve composition of wherein the fine aluminum comprises a particle distribution such that 95 weight percent passes through a 140 mesh as determined by the US Standard Screen Test.
claim 2
4. The composition of wherein the fine aluminum comprises at least 5 to 45 weight percent of the sleeve composition.
claim 3
5. The sleeve composition of wherein the sleeve composition contains from 30 weight percent to 80 weight percent of hollow alumina microspheres, where said weight is based upon the total weight of the sleeve composition.
claim 4
6. The sleeve composition of wherein the sleeve composition contains sand as a refractory in an amount of 30 weight percent to 70 weight percent based upon the total weight of the sleeve composition.
claim 4
7. A sleeve mix comprising the sleeve composition of , , 3, 4, 5, or 6 and an effective binding amount of an organic foundry binder.
claim 1
2
8. A cold-box process for making an exothermic sleeve comprising:
(A) introducing the sleeve mix of into a sleeve pattern to prepare an uncured sleeve;
claim 7
(B) contacting said uncured sleeve prepared by (A) with a vaporous curing catalyst;
(C) allowing said sleeve resulting from (B) to cure until said sleeve becomes handleable; and
(E) removing said sleeve from the pattern.
9. The process of wherein the binder is selected from the group consisting of phenolic urethane binders and epoxy-acrylic binders.
claim 8
10. The process of wherein the binder level is from about 4 weight percent to about 12 weight percent based upon the weight of the sleeve composition.
claim 9
11. A sleeve prepared by the process of .
claim 10
12. A process for casting a metal part which comprises:
(1) using an exothermic sleeve of in a mold assembly of a casting assembly;
claim 11
(2) pouring metal, while in the liquid state, into said casting assembly;
(3) allowing said metal to cool and solidify; and
(4) then separating the cast metal part from the casting assembly.
13. A metal part prepared in accordance with .
claim 12
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US09/761,543 US20010022999A1 (en) | 1999-08-31 | 2001-01-16 | Exothermic sleeve mixes containing fine aluminum |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US38688499A | 1999-08-31 | 1999-08-31 | |
US09/761,543 US20010022999A1 (en) | 1999-08-31 | 2001-01-16 | Exothermic sleeve mixes containing fine aluminum |
Related Parent Applications (1)
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US38688499A Continuation-In-Part | 1999-08-31 | 1999-08-31 |
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US20010022999A1 true US20010022999A1 (en) | 2001-09-20 |
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US09/761,543 Abandoned US20010022999A1 (en) | 1999-08-31 | 2001-01-16 | Exothermic sleeve mixes containing fine aluminum |
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US (1) | US20010022999A1 (en) |
AU (1) | AU7092700A (en) |
WO (1) | WO2001015833A2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080099180A1 (en) * | 2004-09-02 | 2008-05-01 | Gunter Weicker | Moulding Mixture For Producing Casting Moulds For Metalworing |
US20110220314A1 (en) * | 2008-11-20 | 2011-09-15 | Ask Chemicals Feeding Systems Gmbh | Molding material mixture and feeder for casting aluminum |
US20180345356A1 (en) * | 2015-12-01 | 2018-12-06 | Hüttenes-Albertus Chemische Werke Gesellsche Werke Gesellschaft Mit Beschränkter Haftung | Method for producing refractory composite particles and feeder elements for the foundry industry, corresponding feeder elements and uses |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN115582516B (en) * | 2022-11-21 | 2023-03-28 | 优铸科技(北京)有限公司 | Pouring system structure and casting process method |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5915450A (en) * | 1997-06-13 | 1999-06-29 | Ashland Inc. | Riser sleeves for custom sizing and firm gripping |
-
2000
- 2000-08-30 WO PCT/US2000/023857 patent/WO2001015833A2/en active Application Filing
- 2000-08-30 AU AU70927/00A patent/AU7092700A/en not_active Abandoned
-
2001
- 2001-01-16 US US09/761,543 patent/US20010022999A1/en not_active Abandoned
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080099180A1 (en) * | 2004-09-02 | 2008-05-01 | Gunter Weicker | Moulding Mixture For Producing Casting Moulds For Metalworing |
US7770629B2 (en) * | 2004-09-02 | 2010-08-10 | As Lungen Gmbh | Moulding mixture for producing casting moulds for metalworking |
US20110220314A1 (en) * | 2008-11-20 | 2011-09-15 | Ask Chemicals Feeding Systems Gmbh | Molding material mixture and feeder for casting aluminum |
US20180345356A1 (en) * | 2015-12-01 | 2018-12-06 | Hüttenes-Albertus Chemische Werke Gesellsche Werke Gesellschaft Mit Beschränkter Haftung | Method for producing refractory composite particles and feeder elements for the foundry industry, corresponding feeder elements and uses |
US10919086B2 (en) * | 2015-12-01 | 2021-02-16 | HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung | Method for producing refractory composite particles and feeder elements for the foundry industry, corresponding feeder elements and uses |
TWI731002B (en) * | 2015-12-01 | 2021-06-21 | 德商哈登斯 雅伯特斯化學威基有限公司 | Methods for producing refractory composite particles and feeder elements for the foundry industry and such feeder elements |
Also Published As
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WO2001015833A2 (en) | 2001-03-08 |
AU7092700A (en) | 2001-03-26 |
WO2001015833A3 (en) | 2008-02-28 |
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