Method for curing cold-box foundry shape with gaseous catalyst

An apparatus for forming a cured foundry shape from a foundry mix comprising a foundry aggregate and a binder, by way of a “cold box” process, the apparatus comprising:

• a core box for containing the foundry shape being formed, the core box having an inlet and a outlet, the inlet and outlet arranged relative to each other to facilitate contact between the binder and a vaporous curing catalyst;
• an apparatus for providing a first and a second curing catalyst in a vaporous state, the apparatus comprising:
• a first chamber for vaporizing the first catalyst, the first chamber connected to the core box inlet;
• a second chamber for vaporizing the second catalyst, connected to the core box through the first chamber;
• and
• a source of a catalytically-inert carrier gas, directly connected to each of the first and second chambers, to propel the respective vaporous curing catalysts through the core box.

A “cold box” process for forming a foundry shape, comprising the steps of:

• introducing a foundry mix into a pattern to form the foundry shape, the foundry mix comprising a major amount of a foundry aggregate and an uncured binder;
• contacting, in a sequential manner, the formed foundry shape with a first and at least a second vaporous curing catalyst, each vaporous curing catalyst being a tertiary amine with between three and six carbon atoms and capable of curing the formed foundry shape, until the formed foundry shape is sufficiently cured to be handleable;
• and
• removing the formed and cured foundry shape from the pattern.