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US 12,285,797 B2Granted
Casting elements and methods of making the same using low temperature solidification
AssigneeRutgers, The State University of New Jersey
InventorsRichard E. Riman, Kevin Blinn
Life of this patent
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Abstract
Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.
Claims12
A method of forming a foundry casting element, the method comprising:
- forming an aqueous slurry comprising a solid inorganic binder material or a precursor thereof;
- packing the slurry against a pattern to form a shaped slurry;
- curing the shaped slurry at a temperature of less than 350° C. to form a casting element;
- removing the pattern from the casting element,
- wherein the solid inorganic binder material comprises at least one component selected from the group consisting of magnesium oxide, magnesium hydroxide, magnesium carbonate, magnesium carbonate hydrate, calcium oxide, calcium hydroxide, calcium carbonate, mono-calcium silicate, di-calcium silicate, tri-calcium silicate, calcium aluminate, calcium aluminosilicate, and a rare earth oxide,
- wherein the curing comprises infiltrating the shaped slurry with CO2 at a temperature ranging from about 15° C. to about 350° C. and at a pressure ranging from about 0.5 psig to about 5,000 psig, and
- wherein the slurry optionally comprises an inert component selected from the group consisting of oxide sands, diamond, graphite, carbon black, graphene, graphene oxide, metal carbides, silicon carbide, boron carbide, tungsten carbide, niobium carbide, titanium boride, zirconium boride, zirconia, titania, alumina, olivine, diopside, garnet, spinel, quartz, cristobalite, tridymite, calcium carbonate and dolomite, wherein the inert component does not react with the binder material or the precursor thereof.
4 more elements
A method of forming a foundry casting element, the method comprising:
- forming an aqueous first slurry comprising a refractory sand, colloidal silica and a binding polymer;
- forming an aqueous second slurry comprising a solid inorganic binder material and a thermoreversible additive;
- applying the first slurry to a pattern to form a first coating;
- heating the second slurry to a temperature ranging from about 40° C. to about 250° C.;
- dipping the pattern into the heated second slurry to form a second coating on the first coating;
- gelating the second coating by allowing the second coating to cool to a temperature below about 40° C.;
- and
- infiltrating the first coating and the second coating with CO2 to cure the first coating and the second coating to form a casting element with two coating layers;
- wherein the first slurry and/or second slurry optionally comprises an inert component selected from the group consisting of oxide sands, diamond, graphite, carbon black, graphene, graphene oxide, metal carbides, silicon carbide, boron carbide, tungsten carbide, niobium carbide, titanium boride, zirconium boride, zirconia, titania, alumina, olivine, diopside, garnet, spinel, quartz, cristobalite, tridymite, calcium carbonate and dolomite, wherein the inert component does not react with the binder material or the binding polymer.
6 more elements
A method of forming a foundry casting element, the method comprising:
- forming an aqueous slurry comprising a solid inorganic oxide material;
- and
- infiltrating the slurry with CO2 to at least partially convert the solid inorganic oxide material to a solid inorganic carbonate material and to form a refractory element for bricks, or castable, gunning, or ramming mixes;
- wherein the foundry casting element optionally comprises an inert component selected from the group consisting of oxide sands, diamond, graphite, carbon black, graphene, graphene oxide, metal carbides, silicon carbide, boron carbide, tungsten carbide, niobium carbide, titanium boride, zirconium boride, zirconia, titania, alumina, olivine, diopside, garnet, spinel, quartz, cristobalite, tridymite, calcium carbonate and dolomite, wherein the inert component does not react with the inorganic oxide material,
- wherein the CO2 is infiltrated at a temperature ranging from about 15° C. to about 350° C. and at a pressure ranging from about 0.5 psig to about 5,000 psig.
2 more elements
Dependencies are inferred from the claim text.