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.

The present invention relates to the use of closed-pore microspheres of expanded perlite as a filler for producing moldings for the foundry industry, to a composition for producing moldings for the foundry industry, comprising closed-pore microspheres of expanded perlite as a filler, and a binder, the binder being selected from the group consisting of water glass, phenol-formaldehyde resins, two-component systems comprising as reactants a polyisocyanate and a polyol component containing free hydroxyl groups (OH groups), and starch, and also to moldings for the foundry industry and to a process for producing a molding for the foundry industry.

The invention relates to a mold material mixture for producing casting molds for metal processing, a process for producing casting molds, casting molds which can be obtained by the process and their use. The production of the casting molds is carried out using a refractory base molding material and a binder based on water glass. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminium oxide, titanium oxide and zinc oxide is added to the binder, with particular preference being given to using synthetic amorphous silicon dioxide. The mold material mixture contains a surface-active material as further significant constituent. The addition of the surface-active material enables the flowability of the mold material mixture to be improved, which makes it possible to produce casting molds having a very complicated geometry.

A core discharge device is provided for discharging a sand core from a cast material in which the sand core contains a binder having water glass. The core discharge device includes a humidified gas supply device that supplies humidified gas to the sand core inside the cast molded article. The humidified gas is a gas to which humidity has been added and from which droplets have been removed.

The invention relates to a method for producing a part using a deposition technique. A layered composite is built up in layers, the individual layers each containing particulate material and binding material as well as optionally, a treatment agent. The layers maintain a predetermined porosity. The layer composite is built up in the absence of hardening agent. Once construction is complete, the layer composite is hardened.

A method of forming a dry molding sand additive may include recovering a non-sand fraction from a foundry waste material and adding the non-sand fraction to a dry molding sand additive formulation to form a dry molding sand additive. Adding the non-sand fraction to the dry molding sand additive formulation may reduce the amount of fresh clay and carbon to produce the dry molding sand additive. A method of forming a molding sand additive may include recovering a waste molding sand additive composition having a clay or carbon content differing from a desired clay and carbon content, recycling the waste molding sand additive as a raw material in production of a fresh molding sand additive, and adjusting the amount of fresh clay or carbon added during production of the fresh molding sand additive to achieve the desired clay and carbon content.

The present invention provides a nanoparticle based sand conditioner composition a method of synthesizing the same. The composition comprises the raw material compound RM 1, RM 2, RM 3 and RM 4. The RM1 comprises of carbonaceous material, hydrocarbons, ultrafine metal/metal oxide and ceramic oxide nanoparticles and metallic wires. The RM 2 comprises natural carbon source. The RM 3 comprises synthetic/non-renewable carbon source. The RM 4 comprises hydrocarbons. The method of synthesizing nanoparticle based sand conditioner comprises mixing RM 2 and RM 4 in a mixer for 10 minutes for coating RM 2 with RM 4 to obtain an intermediate product. The RM 1 and RM 3 are added to intermediate product in a mixer and mixed for 10 minutes to get a uniform/homogeneous mixture which is cooled to obtain a sand conditioner composition impregnated with nanoparticles into carbon.

The present invention provides a nanoparticle based sand conditioner composition a method of synthesizing the same. The composition comprises the raw material compound RM 1, RM 2, RM 3 and RM 4. The RM1 comprises of carbonaceous material, hydrocarbons, ultrafine metal/metal oxide and ceramic oxide nanoparticles and metallic wires. The RM 2 comprises natural carbon source. The RM 3 comprises synthetic/non-renewable carbon source. The RM 4 comprises hydrocarbons. The method of synthesizing nanoparticle based sand conditioner comprises mixing RM 2 and RM 4 in a mixer for 10 minutes for coating RM 2 with RM 4 to obtain an intermediate product. The RM 1 and RM 3 are added to intermediate product in a mixer and mixed for 10 minutes to get a uniform/homogeneous mixture which is cooled to obtain a sand conditioner composition impregnated with nanoparticles into carbon.

A monolithic bypass includes an upstream conduit, the upstream conduit defining a first end and a second end, the upstream conduit defining an upstream bore extending from the first end to the second end, the first end defining an inlet opening to the upstream bore; a downstream conduit, the downstream conduit defining a first end and a second end, the downstream conduit defining a downstream bore extending from the first end to the second end, the first end defining an outlet opening to the downstream bore; and a bypass valve body seamlessly connected to the second end of the upstream conduit and the second end of the downstream conduit, the bypass valve body defining a bypass body bore, the upstream bore, the downstream bore, and the bypass body bore defining a seamless bypass bore extending from the inlet opening to the outlet opening; wherein the monolithic bypass is substantially U-shaped.