The invention relates to a method for manufacturing a foundry body including the preparation of a granular mixture including a polycondensed resin having modified formaldehyde, optionally incorporating an aromatic or polyaromatic during the synthesis thereof, a hardening agent, a formaldehyde sensor compound, water and optionally at least one resin selected from the group comprising tannins, natural polyphenols, and lignins, placing said granular mixture in contact with the surface of a forming tool, and insufflating a flow of gas at 50 C. to 380 C. into the granular mixture for 1 to 300 seconds, in order to ensure at least partial hardening of said mixture. The invention also relates to a method for manufacturing a molded foundry piece made of metal or a metal alloy, which includes pouring metal into at least one body (mold and/or core) thus produced; and to a foundry piece thus manufactured.

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 a cold box core includes injecting unbonded sand into a cold box core tool, the unbonded sand including sand mixed with a resin, the cold box core tool including: a first platen; a first insert half secured to the first platen; a second platen; and a second insert half secured to the second platen and configured to alternately mate with and separate from the first insert half, each of the first insert half and the second insert half being three-dimensionally printed from a polymer material, the first insert half and the second insert half together forming a cavity therebetween defining an outer geometric shape of the cold box core; and injecting gas into the unbonded sand to harden the cold box core.

The invention relates to lithium-containing molding material mixtures comprising a refractory main molding material, an inorganic binder, and amorphous silicon dioxide as an additive in the production of molds and cores for metal casting. The invention further relates to a method for producing molds and cores using the molding material mixtures and to molds and cores produced according to the method.

The invention relates to mold material mixtures for producing molds and cores for metal casting, consisting of at least one refractory material, a binder based on resols and amorphous silicon dioxide. The invention also relates to a multicomponent system and methods for producing molds and cores using the mold material mixtures as well as molds and cores for metal casting produced according to this method.

A device for hardening foundry cores of a sand-containing molding material, wherein the core, for its hardening, is subjected in a core molding tool to a catalyst vapor/carrier gas mixture and subsequently to a pressurized air stream is provided. Each of the vapor/carrier gas and air stream are at a predetermined pressure and a predetermined temperature, wherein a heating and mixing stage, is connected to a container containing an organic catalyst in liquid form and to a pressurized air source. The liquid organic catalyst and the pressurized air are heated together in the heating and mixing stage. The device has a separate flushing line, wherein a first cutoff valve is arranged in the line to the heating and mixing stage, which is closed at the beginning of the flushing, and a second cutoff valve is arranged in the flushing line, which is open at the beginning of the flushing.

A method of neutralizing an amine gas odor in a cold box process, and an amine gas generator using the method are disclosed. The method includes: making molding sand by mixing sand and forming resin; putting the molding sand into a mold; hardening the molding sand by injecting an amine gas into the molding sand in the mold; and removing an amine gas odor remaining in the mold by injecting an amine gas odor neutralizer into the mold. Accordingly, it is possible to inject an amine gas odor neutralizer in casting of a core or a mold in order to reduce the amine gas odor that remains and leaks through a gap of a mold in the casting. Further, an odor neutralizer is immediately injected simultaneously with discharging of an amine gas, so it is possible to simply remove an odor.

The invention relates to mold material mixtures for producing molds and cores for metal casting, consisting of at least one refractory material, a binder based on resols and amorphous silicon dioxide. The invention also relates to a multicomponent system and methods for producing molds and cores using the mold material mixtures as well as molds and cores for metal casting produced according to this method.

Purposes of the present invention are to provide a dry coated sand having a high degree of fluidity at the room temperature, a method of advantageously producing the coated sand, and a method of producing a casting mold having excellent properties, by using the coated sand. The dry coated sand is obtained by mixing an aqueous solution of a water glass used as a binder, with a heated refractory aggregate, whereby water in the aqueous solution is evaporated, and a coating layer of the binder is formed on surfaces of the refractory aggregate. A moisture percentage in the thus obtained dry coated sand is controlled so as to be not more than 0.5% by mass. The intended casting mold is obtained by filling a molding cavity of a forming mold, with the dry coated sand, and passing a steam through the coated sand, to solidify or cure the coated sand.

Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.