A method of casting an article from a molten metal including: admitting molten metal to a mould formed from a foundry sand comprising a blend of silica sand and a zircon aggregate, the zircon aggregate exhibiting a sharp rise in linear thermal expansion coefficient in a temperature band above 1200 C. and up to 1600 C.; and cooling the mould and molten metal to solidify the molten metal and form a cast article, wherein one or more surfaces of the mould, or of a portion of the mould, in contact with the molten metal are uncoated.

A sand mold-forming additive capable of making a sand mold-forming composition having excellent forming property and a sand mold having excellent moisture resistance is provided. The sand mold-forming additive contains 0.01-2.00 parts by weight of an inorganic alkali metal compound (B) per 100 parts by weight of anionic surfactant (A). The inorganic alkali metal compound (B) is at least one selected from sodium chloride and sodium sulfate. The ionic surfactant (A) is preferably at least one selected from alkyl sulfonic acid metal salts (A1), alkyl sulfuric acid metal salts (A2), and polyoxyalkylene alkyl ether sulfuric acid ester metal salts (A3).

A sand mold-forming additive capable of making a sand mold-forming composition having excellent forming property and a sand mold having excellent moisture resistance is provided. The sand mold-forming additive contains 0.01-2.00 parts by weight of an inorganic alkali metal compound (B) per 100 parts by weight of anionic surfactant (A). The inorganic alkali metal compound (B) is at least one selected from sodium chloride and sodium sulfate. The ionic surfactant (A) is preferably at least one selected from alkyl sulfonic acid metal salts (A1), alkyl sulfuric acid metal salts (A2), and polyoxyalkylene alkyl ether sulfuric acid ester metal salts (A3).

Various embodiments of a slurry composition for investment casting and a method of forming such composition are disclosed. The slurry composition can include a refractory material, a binder, a solvent, and a thixotropic agent that includes fibrillated fibers. The slurry composition can also include a filler that includes glass bubbles.

Various embodiments of a slurry composition for investment casting and a method of forming such composition are disclosed. The slurry composition can include a refractory material, a binder, a solvent, and a thixotropic agent that includes fibrillated fibers. The slurry composition can also include a filler that includes glass bubbles.

A method for manufacturing a structure from a granular material, called sand, in particular a mold. A layer of sand is deposited. The layer of sand is selectively agglomerated by spraying, using a spray nozzle, an inorganic binder having an M2SiO3 type (meta)silicate dissolved in a solvent. Prior to the spraying, the inorganic binder is heated to a temperature to confer on it a viscosity less than 0.2 Pa.Math.s. A device for implementing the method is provided.

A method for manufacturing a structure from a granular material, called sand, in particular a mold. A layer of sand is deposited. The layer of sand is selectively agglomerated by spraying, using a spray nozzle, an inorganic binder having an M2SiO3 type (meta)silicate dissolved in a solvent. Prior to the spraying, the inorganic binder is heated to a temperature to confer on it a viscosity less than 0.2 Pa.Math.s. A device for implementing the method is provided.

A release agent is disclosed for use with an organic binder system used in metal casting. The binder system has a Part I component including an epoxy resin and a free radical initiator and a Part II component having an epoxy resin and an acrylate, where the Part I and Part II components are kept separate until the time of use. The release agent will typically have a molecular weight in the range of 150 to 160, with eight to ten carbon atoms. Two examples of the epoxide are pinene oxide and decene-1 oxide, each of which is effective as an internal release agent when present in the binder for a cold box process in the range of about 0.15% to about 1% of the total weight of the Part I and Part II components.

A casting mould comprising: an inorganic or refractory mould, wherein the mould is configured to receive feedstock; wherein the feedstock is configured to be heated in situ. A reusable mould, reusable susceptor, and/or release agent may be incorporated. Method of manufacturing a mould, and casting a part employing 5 in situ heating, are also provided.

What is described is the use of a particulate material comprising, as its sole constituent or as one of multiple constituents, a particulate synthetic amorphous silicon dioxide having a particle size distribution with a median in the range from 0.1 to 0.4 ?m, determined by means of laser scattering, as additive for a molding material mixture at least comprising: a refractory mold base material having an AFS grain fineness number in the range from 30 to 100, particulate amorphous silicon dioxide having a particle size distribution with a median in the range from 0.7 to 1.5 ?m, determined by means of laser scattering, and water glass, for increasing the moisture resistance of a molding producible by hot curing of the molding material mixture. Also described are corresponding processes, mixtures and kits.