U.S. patent number 3,874,885 [Application Number 05/248,380] was granted by the patent office on 1975-04-01 for method of making foundry moulds and cores.
Invention is credited to Pavel Afanasievich Borsuk, Viktor Georgievich Kuznetsov, Abram Moiseevich Lyass, Zokhrab Gamid Ogly Usubov.
United States Patent |
3,874,885 |
Lyass , et al. |
April 1, 1975 |
METHOD OF MAKING FOUNDRY MOULDS AND CORES
Abstract
A process of producing foundry moulds and cores from a moulding
sand or sand mixture, containing moulding sand, hydraulic cement as
a binder, an alkali-metal aluminate, an alkali-metal carbonate and
a surface-active material.
Inventors: |
Lyass; Abram Moiseevich
(Moscow, SU), Borsuk; Pavel Afanasievich (Moscow,
SU), Usubov; Zokhrab Gamid Ogly (Moscow,
SU), Kuznetsov; Viktor Georgievich (Moscow,
SU) |
Family
ID: |
20464524 |
Appl.
No.: |
05/248,380 |
Filed: |
April 28, 1972 |
Foreign Application Priority Data
|
|
|
|
|
Feb 11, 1971 [SU] |
|
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1615586 |
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Current U.S.
Class: |
106/38.35;
106/726; 164/23; 106/38.9; 106/809 |
Current CPC
Class: |
B22C
1/18 (20130101) |
Current International
Class: |
B22C
1/18 (20060101); B22C 1/16 (20060101); B28b
007/34 () |
Field of
Search: |
;106/38.3,38.35,38.9,89,97 ;164/23 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Hayes; Lorenzo B.
Attorney, Agent or Firm: Holman & Stern
Claims
What is claimed is:
1. A process of making foundry molds and cores from a fluid
self-hardening sand or sand mixture with controllable properties
comprising the steps of preparing (1) a mixture consisting
essentially of 100 parts by weight of molding sand, from 8 to 15
parts by weight of hydraulic cement as a binder, (2) a mixture of
from 0.25 to 1.5 parts by weight of an alkali-metal aluminate and
from 0.5 to 2.0 parts by weight of an alkali-metal carbonate as the
hardening accelerator, from 0.05 to 0.2 parts by weight of a
surface-active material with a foaming action; and water; mixing
(1) and (2) to form a fluid mass; forming the foundry mold and
cores from said mass and hardening said molds and cores in air.
2. The process as claimed in claim 1, in which the alkali-metal
aluminate is sodium aluminate.
3. The process as claimed in claim 1 in which the alkali-metal
carbonate is potassium carbonate.
4. The process as claimed in claim 1 in which the surface-active
material is sodium alkyl aryl sulfonate.
5. In a liquid self-hardening mold or core mixture consisting
essentially of 100 parts by weight of molding sand, from 8 to 15
parts by weight of hydraulic cement as a binder and from 0.05 to
0.2 part by weight of a surface-active substance with a foaming
action and a self-hardening accelerating additive, the improvement
consisting of, as said additive 0.5 to 2.0 parts by weight of
potassium carbonate and from 0.25 to 1.5 parts by weight of sodium
aluminate.
6. The liquid self-hardening mold or core mixture as claimed in
claim 5, wherein sodium alkyl aryl sulfonate is the self-active
substance with a foaming action.
Description
BACKGROUND OF THE INVENTION
The present invention relates to foundry work and more particularly
to a process of making foundry moulds and cores from a fluid
self-hardening moulding sand or sand mixture.
By using the above mixtures such operations as the compacting of
the moulding sand and drying of the moulds and cores produced
thereof can be avoided, dimensional accuracy of castings and
efficiency of the process are enhanced.
Well known are the processes of manufacturing foundry moulds and
cores based on the use of fluid self-hardening sand mixtures
containing a small amount of a surface-active material which
ensures the conversion of the mixture to a fluid state.
One of these sand mixtures contains a moulding sand, an
alkali-metal silicate as a binding agent, dicalcium silicate as a
hardener and a surface-active material (see, for example, French
Pat. No. 1,342,529).
The above sand mixture proved successful, though the hardening rate
and strength control is rather difficult to predict because the
dicalcium-silicate-containing material is a waste product varying
in dicalcium silicate content and, hence, perties are unique to
this sand mixture. Moreover, the knockout of the cores made from
the above sand mixtures presents a serious problem.
Attempts also have been made to provide a fluid self-hardening sand
mixture containing cement as a binder (see, for instance, English
Pat. No. 1,085,651, French Additional Pat. No. 87,456).
The sand mixture features stable properties, though typical of the
moulds and cores manufactured of the above mixture is a low
hardening rate and inadequate strength. The compression strength of
the sand mixture within 1 hr after manufacture does not exceed, as
a rule, 1 kg/cm.sup.2 which precludes the possibility of using the
mixture for the production of heavy cores of intricate shape.
It is an object of the present invention to overcome or at least to
diminish the above difficulties.
SUMMARY OF THE INVENTION
The present invention has the principal object to provide a process
of making foundry moulds and cores from a fluid self-hardening sand
or sand mixture with controllable properties, such as: hardening
rate and strength.
This is achieved by the fact that in a sand mixture containing
moulding sand, hydraulic cement as a binder and a surface-active
material, according to the invention, an alkali-metal aluminate and
an alkali-metal carbonate are introduced during production.
The alkali-metal aluminate enables more rapid hardening of the
fluid sand mixture.
Most advantageous is the addition of the alkali-metal aluminate in
an amount ranging between 0.25-1.5 percent of the weight of the
moulding sand. Usually sodium aluminate is employed being among the
compounds most widespread in the industry. According to the present
invention, sodium aluminate is introduced into the fluid sand
mixture in a liquid state. It would be expedient to employ sodium
aluminate of a specific gravity of 1.48-1.68 g/cm.sup.3 with a
molar ratio of Na.sub.2 O: Al.sub.2 O.sub.3 of between 1.1:1 and
1.5:1. Sodium aluminate is an active hardening accelerator,
therefore its addition even in small amounts substantially reduces
the flowability of the sand. As the contents of sodium aluminate in
the fluid sand mixture increases, a moment might occur when the
mixture completely loses its flowability by hardening during the
preparation cycle.
According to the present invention an alkali-metal carbonate is
also added to the fluid sand mixture. Most effective is potassium
carbonate.
Potassium carbonate assists in increasing the bench life of the
sand mixture, decelerates the sand hardening at the initial stage
and enhances its strength at the late hardening stage. Fluidizing
capacity of potassium carbonate offers a two-fold reduction in the
amount of foaming agent, preserving meanwhile high flowability of
the sand mixture which enhances its strength. Preferably, the
content of the alkali-metal carbonate in the sand mixture shall
amount to 0.5-2 percent of the weight of the moulding sand.
According to a preferred embodiment of the present invention a
fluid self-hardening sand might contain 100 parts by weight of
moulding sand, for example, quartz, 10 parts by weight of Portland
cement, 6 parts by weight of water, 0.1 part by weight of a
surface-active material. The amounts of sodium aluminate and
potassium carbonate are given in Table 1. The sand and Portland
cement are mixed for 1-2 min. Then a liquid composition is prepared
by dissolving potassium carbonate in water and adding the
surface-active material and sodium aluminate to the solution. Next
the liquid composition produced thereby is introduced into the
sand-Portland cement mixture and stirred until the mixture is
converted to a fluid state.
In the accompanying graph the x-axis indicates the hardening time
or holding time of the foundry moulds and cores in air in hours and
the y-axis -- shows compression strength in kg/cm.sup.2.
Variation of compression strengths of the foundry moulds and cores
manufactured of sand mixtures of 1, 2 and 3 of Table 1 respectively
with their air hardening time is illustrated by curves A, B and
C.
As shown by the graph and Table 1, the higher the potassium
carbonate content of a sand mixture, the greater amount of sodium
aluminate can be introduced into the mixture and the higher will be
the hardening rate of the sand mixture (curve C).
According to the present invention the binder is cement, such as
Portland cement, alumina cement, their mixtures or neat
cements.
Conforming to this invention, a specific surface area of a cement
exerts an appreciable influence upon the hardening rate of a fluid
sand mixture. The larger the specific surface area of cement, the
higher the hardening rate and strength which can be attained for a
given fluid sand mixture. By changing the specific surface area of
cement it is possible to control the mixture hardening rate. The
properties of sand mixture 1, containing Portland cement with a
different specific surface area, are compared in Table 2.
Table 2 gives the specific surface area of Portland cement measured
by filtration of air through a layer of a
Table 1 ______________________________________ Parts by weight Sand
mixture ingredients Sand Sand Sand mixture 1 mixture 2 mixture 3
______________________________________ Quartz sand 100 100 100
Portland cement 10 10 10 Surface-active material 0.1 0.1 0.1 Water
7 7 7 Sodium aluminate, spec. gr. 1.60, molar ratio of Na.sub.2
O:Al.sub.2 O.sub.3 = 1.1:1 0.9 1.2 1.5 Potassium carbonate 1.0 1.5
2.0 ______________________________________
Table 2 ______________________________________ Specific surface
Flowability Compression strength, kg/cm.sup.2 area of Portland
preserva- cement, cm.sup.2 /g tion time, 1 hour 3 hours 24 hours
min ______________________________________ 2500 20 2.0 2.5 9.5 4500
7 3.0 4.5 14.0 ______________________________________
ground material and calculated by the Causenie-Carmand method.
For the objects specified in the present invention several types of
surface-active materials can be advantageously used, such as:
anion, cation, nonionogenic materials and/or a mixture of these.
Such materials are alkyl aryl sulfonates, alkyl sulfonates, primary
and secondary alkyl sulfonates, products of oxyethylation of fatty
acids, alcohols, alkyl phenols, fatty amines, alkyl nephtols and
mercaptans, quaternary ammonium compounds. The proportion of the
surface-active material shall be within 0.05-0.2 percent by weight
of the moulding sand.
Any ground refractory material commonly employed in foundry work
for the production of moulds and cores, such as quartz sand,
olivine, chromo-magnesite, grog or chamotte, etc. can be used as a
moulding sand.
* * * * *