Aluminosilicate hydrogel bonded granular compositions and method of preparing same.docx

Aluminosilicate hydrogel bonded granular compositions and method of preparing same.docx

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Aluminosilicatehydrogelbondedgranularcompositionsandmethodofpreparingsame

Abstract

Granularcompositionsaredisclosedforuseinpreparinghard,wateranderosion-resistant,shapessuchasfoundrymoldsandcores,thatareself-settingunderambientatmosphericconditionstoallowsuchshapestobestrippedfrompatternsonwhichtheyareformed,suchpatternstrippingbeingpossibleimmediatelyafterforminginthecaseoffoundrycoresandthelike,andwithincontrollablepatternstriptimesaslowas60secondsforfoundrymolds.Theshapesmaybeusedwithoutbakingand,inthecaseoffoundrymoldsandcores,arereadyforcastingmoltenmetalwithinaslittleasonehour.Moldsand/orcoresfreeoforganicmaterialscanbeformedwiththenovelcompositions,providingessentiallycarbon-freesurfacesatthemold-metalinterface,aswellasbeingfreeofotherdeleteriouselementssuchassulfur,phosphorusandboron,therebyavoidingalloycompositionalterationattheinterfaceduetomigrationduringcasting.Therefractorycompositionsoftheinventionincorporateuniquealuminosilicatehydrogelsofalkalimetalsasbinders,arecompatibleinusewithexistingindustrialfoundrymold/core-formingequipmentandprocedures,andareeminentlyfreeofenvironmental（toxicity）problemsinthefoundryatmosphere.

Inventors:

Helferich;RichardL.（Clayton,OH）,Shook;WilliamB.（Columbus,OH）

Assignee:

TheDurironCompany（Dayton,OH）

Appl.No.:

06/217,203

Filed:

December16,1980

RelatedU.S.PatentDocuments

ApplicationNumber

FilingDate

PatentNumber

IssueDate

958802

Nov.,1978

CurrentU.S.Class:

106/38.3;106/38.9;501/106;501/122;501/127;501/130;501/133

CurrentInternationalClass:

C04B28/00 （20060101）;C04B28/26 （20060101）;B22C1/18 （20060101）;B22C1/16 （20060101）;B28B007/34 （）

FieldofSearch:

106/38.3,38.9,84501/106,122,127,130,133

ReferencesCited[ReferencedBy]

U.S.PatentDocuments

2131338

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Vail

2277704

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2378927

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Jewett

2493693

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Parkinson

2502418

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Callis

2842444

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Emblemetal.

2911311

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Feaginetal.

3017677

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Greenwald

3203057

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Huntetal.

3218683

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Nishiyamaetal.

3306758

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Miller

3423216

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Somers

3600203

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Aldera

3804641

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Lyassetal.

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3874885

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Lyassetal.

3881947

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3923525

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Toeniskoetteretal.

3930872

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4056937

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Toeniskoetteretal.

OtherReferences

Davisetal.,Jour.ofAFS,"SteelMoldingSandsBondedwithSod.SilicateandSod.Aluminate,"pp.11-14,Apr.1964..

PrimaryExaminer:

Hayes;LorenzoB.

Attorney,AgentorFirm:

St.Onge,Steward,Johnston&Reens

ParentCaseText

ThisisacontinuationofapplicationSer.No.958,802,filedNov.8,1978,nowabandoned.

Claims

Whatisclaimedis:

1.Formedshapesofrefractorymaterialwhicharecomposedofamoldablemixthatisself-settingwithoutbakingatambientatmosphericconditions,saidmixcomprisingatleast90%byweightofrefractorygranularparticles,andanaluminosilicatehydrogelbinderhavingamoleratioofaluminatosilicaofabout0.33to2.0forretainingsaidparticlesinsaidformedshapes,saidbinderconsistingofanalkalinemixtureofaqueoussolutionscontaining,respectively,awatersolublesourceofsilicaandawatersolublesourceofalumina,saidsolutionsbeingcombinedinsaidgranularmixinproportiontoproducesaidaluminosilicatehydrogelbinderundersaidambientatmosphericconditions,saidaluminosilicatehydrogelproducinginsaidformedshapesaminimumcompressivestrengthofabout12psiwithin60-65minutesat50.degree.F.orwithin10-12minutesat80.degree.F.ambienttemperature,50%humidity,andformingasubstantiallywater-resistantrigidbondbetweentheparticlesofthemixaftermoldingsaidmixintosaidshapes.

2.Formedshapesasdefinedinclaim1,whereinsaidsolutionsofwatersolublesourcesofsilicaandaluminaareproportionedtoproducesaidsubstantiallywater-resistantrigidbondinnotmorethan30minutes.

3.Formedshapesasdefinedinclaim1,whereinsaidparticlesarerefractorygranulesofsiliceousormetaloxidetypeselectedfromthegroupconsistingofquartz,zircon,kaolin,mullite,olivine,chromite,aluminosilicateandmixturesthereof.

4.Formedshapesasdefinedinclaim3whicharetotallyinorganicincomposition.

5.Atotallyinorganicformedshapeaccordingtoclaim1,comprisingafoundrysandmoldforcastingmetal,saidmoldbeingcomposedofamoldabl