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US 4,127,157 AGranted
Aluminum phosphate binder composition cured with ammonia and amines
AssigneeAshland Oil, Inc.
InventorsJohn J. Gardikes, Richard H. Toeniskoetter
Life of this patent
Estimating the term…
Abstract
Disclosed are foundry binder compositions comprising boronated aluminum phosphate and water, cured by contacting them with gaseous ammonia or an amine. Optionally the composition may also include alkaline earth metals and oxides, and solid polyhydric alcohols or solid organic carboxylic acids.
Claims34
A process for the fabrication of foundry shapes which comprises:
- (a) mixing foundry aggregate with a bonding amount of up to about 10% by weight based upon the weight of aggregate of a composition which comprises in admixture;
- (i) boronated hydrogen aluminum phosphate containing a mole ratio of phosphorus to aluminum of about 2:1 to about 5:1 and from about 3 to about 40 mole percent of boron based on the moles of aluminum, and
- (ii) water;
- wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and water, the amount of water is from about 5 to about 50% by weight based upon the total weight of aluminum phosphate and water, and the quantity and particle size of said aggregate are such to provide sufficient porosity in the foundry shape to permit escape of volatiles from the shape during casting;
- (b) introducing the foundry mix obtained from step (a) into a pattern;
- (c) flowing a curing gas selected from the group consisting of ammonia and amine gases through said foundry mix for a time at least sufficient for the mix to become self-supporting;
- and
- (d) thereafter removing the shaped foundry mix of step (c) from the pattern.
5 more elements
A process for casting of relatively low melting point non-ferrous type metal which comprises:
- (a) fabricating a shape from a composition which comprises a major amount of aggregate and an effective bonding amount up to about 40% by weight of the aggregate of a binder composition which comprises in admixture;
- (i) boronated hydrogen aluminum phosphate containing a mole ratio of phosphorus to aluminum of about 2:1 to about 5:1 and from about 3 to about 40 mole percent of boron based on the moles of aluminum,
- (ii) water;
- and
- (iii) curing agent comprising ammonia or an amine, wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and water, and the amount of water is from about 5 to about 50% by weight based upon the total weight of aluminum phosphate and water;
- (b) pouring said relatively low melting point non-ferrous type metal while in the liquid state into or around said shape;
- (c) allowing said non-ferrous type metal to cool and solidify;
- and
- (d) then separating the molded article.
6 more elements
A process for casting of ferrous-type metal which comprises:
- (a) fabricating a shape from a composition which comprises a major amount of aggregate and an effective bonding amount up to about 40% by weight of the aggregate of a binder composition which comprises in admixture:
- (i) boronated hydrogen aluminum phosphate containing a mole ratio of phosphorus to aluminum of about 2:1 to about 5:1 and from about 3 to about 40 mole percent of boron based on the moles of aluminum,
- (ii) water;
- and
- (iii) curing agent comprising ammonia or an amine, wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and water, and the amount of water is from about 5 to about 50% by weight based upon the total weight of aluminum phosphate and water.
- (b) pouring said ferrous-type metal while in the liquid state into said shape;
- (c) allowing said ferrous-type metal to cool and solidify;
- and
- (d) then separating the molded article.
6 more elements
In the die casting process the improvement which comprises:
- (a) fabricating a core from a composition which comprises a major amount of aggregate and an effective bonding amount up to about 40% by weight of the aggregate of a binder composition which comprises in admixture:
- (i) boronated hydrogen aluminum phosphate containing a mole ratio of phosphorus to aluminum of about 2:1 to about 5:1 and from about 3 to about 40 mole percent of boron based on the moles of aluminum;
- (ii) water;
- and
- (iii) curing agent comprising ammonia or an amine, wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and water, and the amount of water is from about 5 to about 50% by weight based upon the total weight of aluminum phosphate and water.
- (b) positioning said core in a die;
- (c) injecting a molten die-casting metal into said die and around said core;
- (d) allowing said die-casting metal to cool and solidify;
- and
- (e) then separating a molded article.
7 more elements
Binder composition which comprises in admixture;
- (a) boronated hydrogen aluminum phosphate containing a mole ratio of phosphorus to aluminum of about 2:1 to about 5:1 and from about 3 to about 40 mole percent of boron based on the moles of aluminum,
- (b) water;
- and
- (c) curing agent comprising ammonia or an amine, wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and water, and the amount of water is from about 5 to about 50% by weight based upon the total weight of aluminum phosphate and water.
1 more element
Dependencies are inferred from the claim text.