A method for forming a monolithic bypass includes pouring a molten metal into a monolithic bypass mold cavity of a mold, the monolithic bypass mold cavity shaped complimentary to a shape of the monolithic bypass; forming the monolithic bypass, the monolithic bypass comprising a bypass valve body disposed between an upstream conduit and a downstream conduit, an inlet opening defined by the upstream conduit, an outlet opening defined by the downstream conduit, a bypass bore extending through the upstream conduit, the bypass valve body, and the downstream conduit from the inlet opening to the outlet opening, the inlet opening and the outlet opening configured to attach to a primary valve body, the monolithic bypass defining a U-shape, the monolithic bypass and the bypass bore each being seamless; and removing the monolithic bypass from the mold.

A method for forming a monolithic bypass includes pouring a molten metal into a monolithic bypass mold cavity of a mold, the monolithic bypass mold cavity shaped complimentary to a shape of the monolithic bypass; forming the monolithic bypass, the monolithic bypass comprising a bypass valve body disposed between an upstream conduit and a downstream conduit, an inlet opening defined by the upstream conduit, an outlet opening defined by the downstream conduit, a bypass bore extending through the upstream conduit, the bypass valve body, and the downstream conduit from the inlet opening to the outlet opening, the inlet opening and the outlet opening configured to attach to a primary valve body, the monolithic bypass defining a U-shape, the monolithic bypass and the bypass bore each being seamless; and removing the monolithic bypass from the mold.

A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

The subject matter of the invention is mold material mixtures for producing molds or cores for metal casting, consisting of at least one refractory base mold material, a binder and an additive based on factice. The invention also relates to a component system, a method for producing molds and cores using the mold material mixtures or the component system respectively, and to molds and cores produced by said method.

A post-treatment process for increasing the hot strength of a formed part (100) made of particulate material and binder is disclosed, wherein the formed part (100) is formed a part manufactured by 3D printing (S72) and after its manufacture is heated (S30) using a heating device (40), and the heated formed part (100) is exposed (S50) to an atmosphere enriched with gaseous water generated by supplying water.

The foundry sand binder supply apparatus of the present invention comprises a hopper for storing a binder therein, a binder transfer device for transferring the binder, a binder measuring and discharging device disposed beneath a distal end of the binder transfer device, and a binder supply amount control device. The binder measuring and discharging device comprises a measuring container for receiving the binder therein, a load cell for measuring the weight of the binder inside the measuring container, and a discharge device for discharging the binder from the measuring container. The binder supply amount control device is operable to control the discharge device to discharge the binder from the measuring container by a predetermined amount less than the whole amount of the binder inside the measuring container, and control the binder transfer device to supply the binder into the measuring container by the predetermined amount of the discharged binder.

A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

The present invention relates to a phenolic resin for use in the phenolic resin component of a two-component binder system for the polyurethane cold box process, to a two-component binder system for use in the polyurethane cold box process, to a molding material mixture for curing by contacting with a tertiary amine, to the use of a corresponding phenolic resin, of a corresponding phenol component, of a corresponding two-component binder system or of a corresponding molding material mixture. The present invention relates, moreover, to an article from the group consisting of feeders, foundry molds and foundry cores, producible from a corresponding molding material mixture, to a process for preparing a phenolic resin, and to a process for producing an article from the group consisting of feeders, foundry molds and foundry cores.