Erosion-resistant cold-box foundry binder systems

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#(1) Field of the Invention

#While the invention has been described with reference to a preferred embodiment, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. In this application, all units are in the metric system and all amounts and percentages are by weight, unless otherwise expressly indicated.

#The components of the Part I and Part II of the binder were blended for 3 minutes using a Hobart sand mixer. Test wedge cores, weighing 4 pounds, were prepared by adding 1.0 weight percent of the binder (the Part I was added first) to 2000 grams of Manley 1L5W, such that the ratio of Part I/Part II was 1:1, blowing the mixture into a metal wedge pattern, gassing it 50% sulfur dioxide in nitrogen for 1.5 seconds, and then purging with air for 10 seconds.

#The shape of the erosion wedge and a diagram of the test method are shown in FIG. 7 of “Test Casting Evaluation of Chemical Binder Systems”, W L Tordoff et al, AFS Transactions, 80-74, (pages 152-153), developed by the British Steel Casting Research Association. According to this test, molten iron (1480° C.) is poured through a pouring cup into a 1″ diameter×16 ″ height sprue, where it ran down the sprue, impinged upon the wedge-shaped test mold at an angle of 60°, and ran into a sand vented reservoir.