Provided is a catalyst suitable for curing a composite resin composition that includes comprising a blend of at least two tertiary amines selected from dimethylethylamine (DMEA), diethylmethylamine (DEMA), dimethylisopropylamine (DMIPA), and dimethyl-n-propylamine (DMPA), where each of the at least two tertiary amines is present in the blend in an amount of not less than 10% by weight and not more than 90% by weight.

A method of manufacturing molds and cores suitable for producing fiber composite bodies or cast parts of metal or plastic from a mold base material and a multicomponent binder by 3D printing includes pretreating the particulate mold base material with at least one silicon-organic compound having a polar hydrophilic end and a nonpolar hydrophobic end, forming a layer of the pretreated particulate mold base material, and applying the binder or at least one component of the binder in liquid form to the layer, wherein b. and c. are repeated.

Defects can arise in a product of a metal casting process from reactions occurring at a metal-mold interface. A method that reduces the defects uses an organic binder system by introducing a separate third component to a two-part polyurethane-based binder system used in the cold box or no bake process. The third part is added only after the first two parts are mixed with a refractory molding material to provide a shapeable foundry mix. The third part is an alkyl silicate, such as tetraethyl orthosilicate (TEOS), an alkyl orthoformate, such as trimethyl orthoformate (TMOF) or triethyl orthoformate (TEOF), or combinations thereof.

A casting slurry for the manufacture of shell molds, including powder particles and a binder, further including a surfactant. Use of such a casting slurry for the manufacture of a shell mold.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.

A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition.

A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition.

The present invention provides a hydraulic composition for an additive manufacturing device having an excellent initial flexural strength development property and dimensional stability, the hydraulic composition for an additive manufacturing device including: 1.5 to 14 parts by mass of a polymer with respect to 100 parts by mass of an inorganic binder. In addition, the present invention preferably provides a hydraulic composition for an additive manufacturing device in which the inorganic binder contains 50 to 100 mass % of a calcium aluminate with respect to 100 mass % of the entire inorganic binder, and more preferably provides a hydraulic composition for an additive manufacturing device in which the inorganic binder contains 0 to 50 mass % of rapid hardening cement with respect to 100 mass % of the entire inorganic binder.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.

Methods are disclosed of making metal casting molds and components thereof by the three-dimensional printing process in which an untreated sand is used as the build material and a polymer is used as a component of the binder that is printed onto the build material.