What is described is a process for producing an article for use in the foundry industry, selected from the group consisting of molds, cores, feeder elements and molding material mixtures, comprising the following steps: (S1) producing or providing a binder system comprising the following components in three spatially separate vessels: a component (A) comprising particulate amorphous silicon dioxide, a first liquid component (B) comprising waterglass, and a second liquid component (C) comprising aluminate ions dissolved in an aqueous phase, (S2) contacting a mold base material (D) and constituents of all the said components (A), (B) and (C) of the binder system in predetermined ratios in one or more steps, so as to result in a molding material mixture in which the aluminate ions and the particulate amorphous silicon dioxide are mixed wholly or partly into the waterglass, wherein steps (S1) and (S2) are conducted in a facility for producing molding material mixtures. Also described are a corresponding molding material mixture and apparatuses and uses

Disclosed herein are embodiments of a coating composition for use in investment casting. The coating composition embodiments provide a solidified coat that can be as a mold for casting castable materials and that is easily removed from the casted material using water. The coating composition embodiments disclosed herein are reusable and are non-toxic and exhibit high thermal stability.

Described is a method of preparing a particulate refractory composition for use in the manufacture of foundry moulds and cores from spent foundry moulds or cores formed of refractory material and a binder containing water glass, the method comprising the following steps: providing broken material from spent foundry moulds or cores or preparing broken material from spent foundry moulds or cores, wherein the broken material comprises particles and/or aggregates of particles of refractory material having hardened water glass binder on their surface, mixing the broken material with particulate amorphous oxide comprising silicon dioxide in an amount of 85% by weight or more, based on the total amount of the particulate amorphous oxide, to give a mixture and subjecting the mixture to a heat treatment at a temperature of 400° C. or higher. Also described are a corresponding use, a reclamation mixture, and a method of making a foundry mould or core.

A curing agent for water glass molding comprises: ester; amorphous silica; and water. The amorphous silica is formed by means of a pyrolysis method and/or by means of a precipitation method. Also disclosed is a use of the curing agent for water glass molding in preparation of a casting mold and a mold core. Respective components of the curing agent comprising ester, amorphous silica and water are mixed at a high speed to form a suspension. Next, the suspension is applied to prepare a water glass self-hardening sand. The curing agent does not cause powder contamination, and can be measured and added conveniently. Also disclosed are a manufacturing method of the curing agent for water glass molding and a water glass self-hardening sand.

A molding, comprising a zeolitic material having framework type MFI wherein from 98 to 100 weight-% of the zeolitic material consist of Ti, Si, O, and H, and wherein the zeolitic material having framework type MFI exhibits a type IV nitrogen adsorption/desorption isotherm, the molding further comprising a silica binder, wherein the molding has a pore volume of at least 0.8 mL/g.

Described is a method of preparing a particulate refractory composition for use in the manufacture of foundry moulds and cores from spent foundry moulds or cores formed of refractory material and a binder containing water glass, the method comprising the following steps: providing broken material from spent foundry moulds or cores or preparing broken material from spent foundry moulds or cores, wherein the broken material comprises particles and/or aggregates of particles of refractory material having hardened water glass binder on their surface, mixing the broken material with particulate amorphous oxide comprising silicon dioxide in an amount of 85% by weight or more, based on the total amount of the particulate amorphous oxide, to give a mixture and subjecting the mixture to a heat treatment at a temperature of 400° C. or higher. Also described are a corresponding use, a reclamation mixture, and a method of making a foundry mould or core.

A method of preparing a unique foundry premix composition that has a low bulk density of 30-45 lbs/ft.sup.3 and contains fine particles with an average particle size of 85-100 μm is described. The unique foundry premix composition is produced by using specially designed assemblies of mechanical equipment with improved efficiency so that the premix can be prepared at a site closer to a foundry. As a result, increase in premix density caused by handling and shipping across a long distance from a traditional premix manufacturing facility to a foundry can be suppressed; transportation cost can be saved; and safety would be of less concern. The use of the foundry premix composition to prepare a sand molding medium for casting molded articles is also described.

A molding material in a powder-fixing lamination method includes an aggregate and a powdery precursor of a binder that binds the aggregate mutually. The aggregate is a casting sand, and the powdery precursor contains a hardening component and a hardening accelerating component. A molded product is manufactured using the molding material.

The invention relates to a method for producing an article for use in the foundry industry, selected from a group consisting of granular material for producing a pourable additive, a solid pourable additive, an inorganic binder, and a molding material mixture. The invention also relates to a corresponding granular material comprising particulate amorphous silica and to a kit for producing an inorganic binder. The invention also relates to an apparatus for carrying out the method according to the invention and to a corresponding use of particulate amorphous silica and to the corresponding use of a granular material.

Both a hydraulic (wet) separation process and a dry separation process are used in combination to recover sand, bentonite clay and organics from foundry waste created during operation of a green sand foundry. These recovered ingredients are then recycled for reuse in making additional green sand molds.