US2487207A - Core material composition, mold core, and process for making mold cores - Google Patents
Core material composition, mold core, and process for making mold cores Download PDFInfo
- Publication number
- US2487207A US2487207A US660419A US66041946A US2487207A US 2487207 A US2487207 A US 2487207A US 660419 A US660419 A US 660419A US 66041946 A US66041946 A US 66041946A US 2487207 A US2487207 A US 2487207A
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- core
- mold
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- cores
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Classifications
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- 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
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
-
- 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
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/04—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for protection of the casting, e.g. against decarbonisation
-
- 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
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S71/00—Chemistry: fertilizers
- Y10S71/903—Soil conditioner
Definitions
- This invention pertains to mold cores used in casting aluminum and magnesium, to the process of making such cores, and to a composition from which such cores may be made.
- one of the objects of my invention is to provide a composition of materials which can be easily and quickly mixed with a small amount of water to form a moldable core material which can be hardened and dehydrated by baking at a low, temperature for a short time;
- a second object is to provide a composition of materials, as above stated which, after baking, will provide core which will absorb and con-. duct away all gases ordinarily released when pouring molds with light metal such as aluminum or magnesium, and at the same time have a surface which will resist pressure of the melted metal and keep its shape at all times during pourin and
- a third object is to provide a core made, as above mentioned, which is readily friable after the casting has cooled.
- these ingredients are mixed in the proportion of 95 to 97 percent perlite and 5 to 3 percent binder.
- binder can be added up to percent by volume.
- the ordinary silicious clay as above referred to is clay containing approximately thirty-four (34) percent S102 and varying quantitles of iron oxide, aluminum, lime and magnesia, approximately 66 percent.
- This core may be surfaced in the usual manner to obtain a smoother finish, if desired, but
- expanded perlite which is a new product, is such that gases produced when and as the metals, above mentioned, fill the mould are readily absorbed directly into the core body, or conveyed thru the core to a. place of disposal. Core venting is not necessary, and castings made show no tendency toward the pockets.
- binder specified is best suited to the use here contemplated, and while the amount mixed in with the perlite is not critical, it should not ordinarily exceed ten (10) percent. Any greater amount is wasteful and unnecessary.'
- resin or natural resin as used herein is intended to mean the dry sap of pine trees, or the like, whether in a fresh state or after treatment by heat, such as rosin. The expression is used to distinguish this substance from artificial or synthetic resin.
- a core forming composition for aluminum casting molds consisting of to percent classified expanded perlite and 10-5 percent of a binder composed of approximately 11 parts rosin, 40 parts synthetic urea-formaldehyde resin, .and 49 parts siliceous clay, by weight.
- a core form for molds for casting aluminum and the like composed of expanded perlite 90-95 percent and a carbonizable organic binder to maintain the shape of the core -5 percent, said binder being composed of natural resin 11 parts, synthetic urea-formaldehyde resin parts. and clay 49 parts, by weight.
- a core forming composition for aluminum mold cores consisting of to percent classifled expanded perlite, together with 10 to '5 percent of a binder composed 01' 11 parts pine resin, 40 parts synthetic urea-formaldehyde resin, and 49 parts silicious 0188. by weight.
Description
Patented Nov. 8, 1949 CORE, AND MOLD CODES PROCESS FOR MAKING some s. Adams, Phoenix, Aria.
No Drawing. Application April 8, 1946, Serial No. 660.419
1 This invention pertains to mold cores used in casting aluminum and magnesium, to the process of making such cores, and to a composition from which such cores may be made.
vIn casting the light metals, aluminum and magnesium, it is necessary to provide adequate venting for gases formed as the metal is poured. Where cores are necessary as a part of the mould venting -by the usual means is impractical in some cases and impossible in others. It is highly desirable to dispose of the gases formed as the mold is filled so that the casting will be free from blow holes and will fully conform to'the mold. While the core material must be sufficiently porous to absorb ortransmit gases for venting, it must also be of a texture which will resist the flow of melted metal and present a mold wall impervious to the melt. In addition the core must be friable, and easily broken down for removal after casting.
4 cu (on. era- 1x8) it is baked at a temperature of about 600 degrees In view of the foregoing one of the objects of my invention is to provide a composition of materials which can be easily and quickly mixed with a small amount of water to form a moldable core material which can be hardened and dehydrated by baking at a low, temperature for a short time;
A second object is to provide a composition of materials, as above stated which, after baking, will provide core which will absorb and con-. duct away all gases ordinarily released when pouring molds with light metal such as aluminum or magnesium, and at the same time have a surface which will resist pressure of the melted metal and keep its shape at all times during pourin and A third object is to provide a core made, as above mentioned, which is readily friable after the casting has cooled.
Other objects will appear, hereinafter,
I attain the foregoing objects by the methods and in the manner, hereinafter explained.
First, I make a uniform mixture of expanded Perlite, screened to a uniform size and a binder of natural powdered rosin 11 parts, synthetic urea-formaldehyde resin parts, and ordinary siliceous clay 49 parts, by weight. Preferably these ingredients are mixed in the proportion of 95 to 97 percent perlite and 5 to 3 percent binder. However binder can be added up to percent by volume. The ordinary silicious clay as above referred to is clay containing approximately thirty-four (34) percent S102 and varying quantitles of iron oxide, aluminum, lime and magnesia, approximately 66 percent.
- formation of blow holes or gas Fahrenheit until dehydrated and carbonized. This takes from one half hour to one and onehalf hours, depending on the size of the core. Due to the nature of the perlite no shrinkage takes place.
This core may be surfaced in the usual manner to obtain a smoother finish, if desired, but
is ordinarily ready for use without further finishing when cooled.
After being installed in a mold, and after casting a core made as above described, it may be broken by a few sharp blows and will readily disintegrate so that it can easily be blown out of the casting.
The nature of expanded perlite, which is a new product, is such that gases produced when and as the metals, above mentioned, fill the mould are readily absorbed directly into the core body, or conveyed thru the core to a. place of disposal. Core venting is not necessary, and castings made show no tendency toward the pockets.
The binder specified, however, is best suited to the use here contemplated, and while the amount mixed in with the perlite is not critical, it should not ordinarily exceed ten (10) percent. Any greater amount is wasteful and unnecessary.'
The term resin" or natural resin as used herein is intended to mean the dry sap of pine trees, or the like, whether in a fresh state or after treatment by heat, such as rosin. The expression is used to distinguish this substance from artificial or synthetic resin.
In view of the foregoing, I wish to be limited only by the following claims:
I, claim:
1. A core forming composition for aluminum casting molds consisting of to percent classified expanded perlite and 10-5 percent of a binder composed of approximately 11 parts rosin, 40 parts synthetic urea-formaldehyde resin, .and 49 parts siliceous clay, by weight.
emo:
2. The method or making a mold core for casting aluminum. and the like, consistin: in
mixing about 95 percent expanded periite granules with percent binder composed of natural resin 11 parts, synthetic urea-formaldehyde resin 40 parts, and siliceous clay 49 parts, and adding sufilclent :water to make a clinging mix; then baking the resultant composition until dehydrated and until the binder has carbonized.
3. A core form for molds for casting aluminum and the like, composed of expanded perlite 90-95 percent and a carbonizable organic binder to maintain the shape of the core -5 percent, said binder being composed of natural resin 11 parts, synthetic urea-formaldehyde resin parts. and clay 49 parts, by weight.
4. A core forming composition for aluminum mold cores consisting of to percent classifled expanded perlite, together with 10 to '5 percent of a binder composed 01' 11 parts pine resin, 40 parts synthetic urea-formaldehyde resin, and 49 parts silicious 0188. by weight.
EDWARD S. ADAMS.
nmnnncns crrnn The following references are oi record in the tile 01 this patent:
UNITED STATES PATENTS Number Name Date 2,183,424 Clark Dec. 12, 1939 2,203,471 Ray June 4, 1940 2,322,638 Kleeman June 22, 1943 2,381,735 Gantz Aug. 7, 1945 1 2,388,060 Hicks Oct. 30, 1945 2,401,760 Heyroth June 11, 1946 2,431,884 Neuschotz Dec. 2, 1947 I FOREIGN PATENTS I Number Country Date 1 303,858 Great Britain Nov. 21, 1929 OTHER REFERENCES "Thermal Insulation i'rom Pei-lite, Chem. b Metallurgical Ens. vol. 52, July 1945, pp. 140, 142.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US660419A US2487207A (en) | 1946-04-08 | 1946-04-08 | Core material composition, mold core, and process for making mold cores |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US660419A US2487207A (en) | 1946-04-08 | 1946-04-08 | Core material composition, mold core, and process for making mold cores |
Publications (1)
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US2487207A true US2487207A (en) | 1949-11-08 |
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US660419A Expired - Lifetime US2487207A (en) | 1946-04-08 | 1946-04-08 | Core material composition, mold core, and process for making mold cores |
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Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2626872A (en) * | 1948-06-02 | 1953-01-27 | Great Lakes Carbon Corp | Asphalt building board |
US2690594A (en) * | 1952-03-17 | 1954-10-05 | Dant & Russell | Acoustical tile and method of manufacture |
US2705197A (en) * | 1950-04-19 | 1955-03-29 | Hermann G Seybold | Wallboard composition and method of making same |
US2728733A (en) * | 1950-09-26 | 1955-12-27 | Res Counsel Inc | Light-weight aggregates of perlite fines and clay |
US2734812A (en) * | 1956-02-14 | robie | ||
US2784085A (en) * | 1948-09-03 | 1957-03-05 | F E Schundler & Co Inc | Manufacture of high temperature insulating materials |
US2802747A (en) * | 1955-10-26 | 1957-08-13 | Aluminum Co Of America | Plaster mold for casting readily oxidizable metals |
US2806772A (en) * | 1954-09-15 | 1957-09-17 | Electro Refractories & Abrasiv | Abrasive bodies |
US2956893A (en) * | 1957-10-28 | 1960-10-18 | Int Minerals & Chem Corp | Perlite insulation material |
US2971878A (en) * | 1953-08-21 | 1961-02-14 | Carey Philip Mfg Co | Insulation material and method of making same |
US2988525A (en) * | 1957-07-09 | 1961-06-13 | American Colloid Co | Foundry mold composition |
US3042578A (en) * | 1955-09-19 | 1962-07-03 | Johns Manville Perlite Corp | Insulating product and its manufacture |
US3386223A (en) * | 1966-02-01 | 1968-06-04 | Minnesota Mining & Mfg | Method of joining drywall panels |
DE2716168A1 (en) * | 1976-04-12 | 1977-10-27 | Nynaes Petroleum Ab | PROCESS FOR MANUFACTURING CASTING FORMS OR CASTING FORM CORES AND MOLDED MATERIAL FOR USE IN THIS PROCESS FROM AN AQUATIC MIXTURE OF MOLDING SAND, BINDING AGENT, AND CARBON MATERIAL |
US4146526A (en) * | 1976-03-15 | 1979-03-27 | Zlobinsky Boris A | Cold-setting mixture for the production of casting moulds and cores |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB303858A (en) * | 1928-01-11 | 1929-11-21 | Albert Stahn | Binder for foundry cores |
US2183424A (en) * | 1938-08-05 | 1939-12-12 | George C Clark | Mold material for casting metals |
US2203471A (en) * | 1938-04-05 | 1940-06-04 | Hercules Powder Co Ltd | Binding agent for foundry cores and method of manufacture thereof |
US2322638A (en) * | 1942-07-31 | 1943-06-22 | Westinghouse Electric & Mfg Co | Mold and mold composition |
US2381735A (en) * | 1942-03-31 | 1945-08-07 | Aluminum Co Of America | Mold chill |
US2388060A (en) * | 1943-06-19 | 1945-10-30 | John E Gallois | Ceramic composition |
US2401760A (en) * | 1943-01-12 | 1946-06-11 | Carborundum Co | Method of making molds |
US2431884A (en) * | 1943-08-31 | 1947-12-02 | Neuschotz Robert | Method of expanding pearlite |
-
1946
- 1946-04-08 US US660419A patent/US2487207A/en not_active Expired - Lifetime
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB303858A (en) * | 1928-01-11 | 1929-11-21 | Albert Stahn | Binder for foundry cores |
US2203471A (en) * | 1938-04-05 | 1940-06-04 | Hercules Powder Co Ltd | Binding agent for foundry cores and method of manufacture thereof |
US2183424A (en) * | 1938-08-05 | 1939-12-12 | George C Clark | Mold material for casting metals |
US2381735A (en) * | 1942-03-31 | 1945-08-07 | Aluminum Co Of America | Mold chill |
US2322638A (en) * | 1942-07-31 | 1943-06-22 | Westinghouse Electric & Mfg Co | Mold and mold composition |
US2401760A (en) * | 1943-01-12 | 1946-06-11 | Carborundum Co | Method of making molds |
US2388060A (en) * | 1943-06-19 | 1945-10-30 | John E Gallois | Ceramic composition |
US2431884A (en) * | 1943-08-31 | 1947-12-02 | Neuschotz Robert | Method of expanding pearlite |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2734812A (en) * | 1956-02-14 | robie | ||
US2626872A (en) * | 1948-06-02 | 1953-01-27 | Great Lakes Carbon Corp | Asphalt building board |
US2784085A (en) * | 1948-09-03 | 1957-03-05 | F E Schundler & Co Inc | Manufacture of high temperature insulating materials |
US2705197A (en) * | 1950-04-19 | 1955-03-29 | Hermann G Seybold | Wallboard composition and method of making same |
US2728733A (en) * | 1950-09-26 | 1955-12-27 | Res Counsel Inc | Light-weight aggregates of perlite fines and clay |
US2690594A (en) * | 1952-03-17 | 1954-10-05 | Dant & Russell | Acoustical tile and method of manufacture |
US2971878A (en) * | 1953-08-21 | 1961-02-14 | Carey Philip Mfg Co | Insulation material and method of making same |
US2806772A (en) * | 1954-09-15 | 1957-09-17 | Electro Refractories & Abrasiv | Abrasive bodies |
US3042578A (en) * | 1955-09-19 | 1962-07-03 | Johns Manville Perlite Corp | Insulating product and its manufacture |
US2802747A (en) * | 1955-10-26 | 1957-08-13 | Aluminum Co Of America | Plaster mold for casting readily oxidizable metals |
US2988525A (en) * | 1957-07-09 | 1961-06-13 | American Colloid Co | Foundry mold composition |
US2956893A (en) * | 1957-10-28 | 1960-10-18 | Int Minerals & Chem Corp | Perlite insulation material |
US3386223A (en) * | 1966-02-01 | 1968-06-04 | Minnesota Mining & Mfg | Method of joining drywall panels |
US4146526A (en) * | 1976-03-15 | 1979-03-27 | Zlobinsky Boris A | Cold-setting mixture for the production of casting moulds and cores |
DE2716168A1 (en) * | 1976-04-12 | 1977-10-27 | Nynaes Petroleum Ab | PROCESS FOR MANUFACTURING CASTING FORMS OR CASTING FORM CORES AND MOLDED MATERIAL FOR USE IN THIS PROCESS FROM AN AQUATIC MIXTURE OF MOLDING SAND, BINDING AGENT, AND CARBON MATERIAL |
US4174225A (en) * | 1976-04-12 | 1979-11-13 | Ab Nynas-Petroleum | Manufacturing moulds or mould cores |
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