A mold wash is used in a casting method using a lost foam to make a casting having a hole with a diameter of 12 mm or less. The casting method includes determining a thermal decomposition amount C(,t) [wt %] of a resin binder when the mold wash is exposed at a temperature [ C.] for a time t [sec], and determining a room temperature transverse rupture strength .sub.b(,t) [MPa] of the mold wash after receiving thermal loads, and performing casting with the mold wash having the room temperature transverse rupture strength .sub.b(,t) after receiving thermal loads being equal to or larger than a threshold value .sub.cr [MPa].

A mullite shell mold for casting includes a facecoat layer containing ceramic flour. The mullite shell mold also includes a first layer disposed on the facecoat layer. The first layer can contain sintered ceramic media. The facecoat layer and the first layer can each contain less than 1 wt % crystalline silica.

A mullite shell mold for casting includes a facecoat layer containing ceramic flour. The mullite shell mold also includes a first layer disposed on the facecoat layer. The first layer can contain sintered ceramic media. The facecoat layer and the first layer can each contain less than 1 wt % crystalline silica.

A mold release agent monitoring system includes a molding tool and a supply of mold release agent is provided along with a spray device for applying the mold release agent to the molding tool. A monitoring system monitors an amount of mold release agent applied to the molding tool during a discrete spray cycle. The mold release agent monitoring system provides an output signal to an indicator system for indicating an amount of mold release agent applied during the prior discrete spray cycle. The monitoring system also monitors a total consumption of mold release agent over a determined time period and provides a warning to a consumer of a need to reorder more mold release agent when a remaining mold release agent level falls below a predetermined level.

A mold release agent monitoring system includes a molding tool and a supply of mold release agent is provided along with a spray device for applying the mold release agent to the molding tool. A monitoring system monitors an amount of mold release agent applied to the molding tool during a discrete spray cycle. The mold release agent monitoring system provides an output signal to an indicator system for indicating an amount of mold release agent applied during the prior discrete spray cycle. The monitoring system also monitors a total consumption of mold release agent over a determined time period and provides a warning to a consumer of a need to reorder more mold release agent when a remaining mold release agent level falls below a predetermined level.

The use of a cementitious composition is described, as a coating for disposable foundry cores, said cementitious composition comprising at least one binder or hydraulic cement in a quantity ranging from 40% to 99.9% by weight with respect to the total weight of the cementitious composition; possibly one or more fillers in a quantity ranging from 0.1% to 60% by weight, with respect to the total weight of the cementitious composition, said filler preferably having a D99<100 m; at least one rheology modifying agent selected from cellulose, derivatives of cellulose such as methylhydroxyethylcellulose, vinyl acetate/versatate copolymers, polycarboxylate ether polymer, or a mixture thereof, in a quantity ranging from 0.1% to 5% by weight with respect to the total weight of the cementitious composition. A disposable foundry core is also described, having at least one coating layer based on said cementitious composition.

The use of a cementitious composition is described, as a coating for disposable foundry cores, said cementitious composition comprising at least one binder or hydraulic cement in a quantity ranging from 40% to 99.9% by weight with respect to the total weight of the cementitious composition; possibly one or more fillers in a quantity ranging from 0.1% to 60% by weight, with respect to the total weight of the cementitious composition, said filler preferably having a D99<100 m; at least one rheology modifying agent selected from cellulose, derivatives of cellulose such as methylhydroxyethylcellulose, vinyl acetate/versatate copolymers, polycarboxylate ether polymer, or a mixture thereof, in a quantity ranging from 0.1% to 5% by weight with respect to the total weight of the cementitious composition. A disposable foundry core is also described, having at least one coating layer based on said cementitious composition.

A mold for casting a titanium-containing article includes calcium aluminate and silicon carbide, and the silicon carbide is graded in the mold such that it is in different portions of the mold in different amounts, with the highest concentration of silicon carbide being located between a bulk of the mold and a surface of the mold that opens to a mold cavity.

A mold for casting a titanium-containing article includes calcium aluminate and silicon carbide, and the silicon carbide is graded in the mold such that it is in different portions of the mold in different amounts, with the highest concentration of silicon carbide being located between a bulk of the mold and a surface of the mold that opens to a mold cavity.

A low-pressure sand-casting system includes a sand-casting mold receiving a molten casting material to cast an automobile vehicle cylinder head. A port is created in the automobile vehicle cylinder head. A manifold port metal core assembly includes a metal core. A compressible material coating is applied on the manifold port core metal core.