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

1、Aluminosilicate hydrogel bonded granular compositions and method of preparing sameAbstractGranular compositions are disclosed for use in preparing hard, water and erosion-resistant, shapes such as foundry molds and cores, that are self-setting under ambient atmospheric conditions to allow such shape

2、s to be stripped from patterns on which they are formed, such pattern stripping being possible immediately after forming in the case of foundry cores and the like, and within controllable pattern strip times as low as 60 seconds for foundry molds. The shapes may be used without baking and, in the ca

3、se of foundry molds and cores, are ready for casting molten metal within as little as one hour. Molds and/or cores free of organic materials can be formed with the novel compositions, providing essentially carbon-free surfaces at the mold-metal interface, as well as being free of other deleterious e

4、lements such as sulfur, phosphorus and boron, thereby avoiding alloy composition alteration at the interface due to migration during casting. The refractory compositions of the invention incorporate unique aluminosilicate hydrogels of alkali metals as binders, are compatible in use with existing ind

5、ustrial foundry mold/core-forming equipment and procedures, and are eminently free of environmental (toxicity) problems in the foundry atmosphere. Inventors: Helferich; Richard L. (Clayton, OH), Shook; William B. (Columbus, OH) Assignee:The Duriron Company (Dayton, OH) Appl. No.: 06/217,203Filed: De

6、cember 16, 1980Related U.S. Patent DocumentsApplication NumberFiling DatePatent NumberIssue DateTD 958802Nov., 1978TD Current U.S. Class:106/38.3 ; 106/38.9; 501/106; 501/122; 501/127; 501/130; 501/133Current International Class: C04B 28/00(20060101); C04B 28/26(20060101); B22C 1/18(20060101); B22C

7、1/16(20060101); B28B 007/34()Field of Search: 106/38.3,38.9,84 501/106,122,127,130,133 References Cited Referenced ByU.S. Patent Documents2131338September 1938Vail2277704March 1942Kinzie et al.2378927June 1945Jewett2493693January 1950Parkinson2502418April 1950Callis2842444July 1958Emblem et al.29113

8、11November 1959Feagin et al.3017677January 1962Greenwald3203057August 1965Hunt et al.3218683November 1965Nishiyama et al.3306758February 1967Miller3423216January 1969Somers3600203August 1971Aldera3804641April 1974Lyass et al.3804643April 1974Arita et al.3874885April 1975Lyass et al.3881947May 1975Pa

9、lmer3892579July 1975Mabie3923525December 1975Toeniskoetter et al.3930872January 1976Toeniskoetter et al.4056937November 1977Suzuki4070195January 1978Toeniskoetter et al.Other ReferencesDavis et al., Jour. of AFS, Steel Molding Sands Bonded with Sod. Silicate and Sod. Aluminate, pp. 11-14, Apr. 1964.

10、 Primary Examiner: Hayes; Lorenzo B. Attorney, Agent or Firm: St. Onge, Steward, Johnston & Reens Parent Case TextThis is a continuation of application Ser. No. 958,802, filed Nov. 8, 1978, now abandoned. ClaimsWhat is claimed is:1. Formed shapes of refractory material which are composed of a moldab

11、le mix that is self-setting without baking at ambient atmospheric conditions, said mix comprising at least 90% by weight of refractory granular particles, and an aluminosilicate hydrogel binder having a mole ratio of alumina to silica of about 0.33 to 2.0 for retaining said particles in said formed

12、shapes, said binder consisting of an alkaline mixture of aqueous solutions containing, respectively, a water soluble source of silica and a water soluble source of alumina, said solutions being combined in said granular mix in proportion to produce said aluminosilicate hydrogel binder under said amb

13、ient atmospheric conditions, said aluminosilicate hydrogel producing in said formed shapes a minimum compressive strength of about 12 psi within 60-65 minutes at 50.degree. F. or within 10-12 minutes at 80.degree. F. ambient temperature, 50% humidity, and forming a substantially water-resistant rigi

14、d bond between the particles of the mix after molding said mix into said shapes. 2. Formed shapes as defined in claim 1, wherein said solutions of water soluble sources of silica and alumina are proportioned to produce said substantially water-resistant rigid bond in not more than 30 minutes. 3. For

15、med shapes as defined in claim 1, wherein said particles are refractory granules of siliceous or metal oxide type selected from the group consisting of quartz, zircon, kaolin, mullite, olivine, chromite, aluminosilicate and mixtures thereof. 4. Formed shapes as defined in claim 3 which are totally inorganic in composition. 5. A totally inorganic formed shape according to claim 1, comprising a foundry sand mold for casting metal, said mold being composed of a moldabl