The invention relates to an aqueous alkaline binder composition for curing with carbon dioxide gas, comprising a negatively charged or uncharged phenol-aldehyde resin, comprising phenol groups, which is selected from the group consisting of resoles and mixtures comprising one or more resoles and also one or more novolacs, an oxyanion selected from the group consisting of borate ions, aluminate ions, stannate ions, zirconate ions, titanate ions, and mixtures thereof, for forming a stable complex with the resole phenol-aldehyde resin, and one or more silanes in a total amount in the range from 2.5 to 10 wt %, based on the total mass of the binder composition, where the total molar to amount of the phenol groups of the phenol-aldehyde resin in the aqueous alkaline binder composition is in the range from 1 to 3 mol/kg, based on the total mass of the aqueous alkaline binder composition. The invention relates, moreover, to a corresponding use, to a molding mixture for producing a foundry mold, and also to a corresponding method for producing a foundry mold, and to a corresponding foundry 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.

A description is given of a use of a composition comprising an ortho-fused phenolic resole in an amount of up to 60 wt %; as first solvent for the ortho-fused phenolic resole, one or more compounds selected from the group consisting of alkyl silicates, alkyl silicate oligomers and mixtures thereof, the total amount of these compounds being greater than 30 wt %; optionally one or more further solvents for the ortho-fused phenolic resole; optionally one or more further additives; the weight percentages being based on the total amount of the composition, as a binder component for producing feeder elements by the cold box process. A description is also given of the use of a two-component binder system for producing feeder elements by the cold box process, and of a method for producing a feeder element for the foundry industry, and also of a feeder element.

In order to well perform recoating regardless of the type of granular material and reuse a refractory aggregate in an unprinted portion without any regeneration process in the manufacture of a three-dimensional lamination-shaped mold, this invention provides a granular material for use in shaping a three-dimensional laminated mold, which is coated with an acid as a catalyst which activates and cures an organic binder for binding the granular material. The acid contains at least one of sulfuric acid, phosphoric acid, a sulfonic acid and a carboxylic acid, and is one of a mixture of sulfuric acid and another acid, phosphoric acid only, a mixture of phosphoric acid and another acid, sulfonic acid only, a mixture of sulfonic acid and another acid and a mixture of a carboxylic acid and another acid.

The invention relates to a method of producing an article selected from the group consisting of casting mold, core, feeder and molding compound for production of part of a casting mold, core or feeder, comprising the following steps: (S1) producing or providing in the foundry: a first component (A), comprising a first binder component (b1) of a binder system and an amount of a first mold base material and, spatially separated therefrom, a second component (B), comprising a second binder component (b2) of the binder system and an amount of a second mold base material wherein the first binder component (b1) and the second binder component (b2) are suitable for chemical reaction with one another and for curing of a mixture of the first component (A) and the second component (B), (S2) mixing by contacting the first component (A) and the second component (B) in a particular mass ratio, so as to result in a self-curing molding compound.

The invention relates to a method for the layer-wise building of bodies comprising a refractory mold base material and resoles, to three-dimensional bodies manufactured according to said method, and to the use thereof in metal casting. According to the method, the refractory mold base material is contacted with at least one ester to obtain an ester-impregnated mold material mixture.

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.

Described is a phenolic resin composition for use in the polyurethane cold-box and/or no-bake process. The phenolic resin composition comprises an ortho-condensed phenolic resol having etherified and/or free methylol groups in a total amount of 40 to 60% by weight based on the total mass of the phenolic resin composition, free formaldehyde in an amount of less than 0.1% by weight based on the total weight of the phenolic resin composition, one or more reaction products of formaldehyde with one or more CH-acidic reactant compounds, other constituents in a total amount of at least 38% by weight, wherein the amount of water in the phenolic resin composition is not more than 1.0% by weight in each case based on the total mass of the phenolic resin composition. Also described is a two-component binder system for use in the polyurethane cold-box and/or no-bake process, a use of a CH-acidic compound as a formaldehyde scavenger for producing a phenolic resin composition for use in the polyurethane cold-box and/or no-bake process, a process for producing a phenolic resin composition, a process for producing a two-component binder system and a process for producing a feeder, a foundry mold or a foundry core from a molding material mixture and finally corresponding feeders, foundry molds and foundry cores.

The present invention is a granular material that can be well recoated regardless of the type of the granular material, and enables a refractory aggregate in an unprinted portion to be used without any regeneration process, in the manufacture of a three-dimensional laminated and shaped mold. This granular material is a granular material for use in three-dimensional laminated mold shaping, and obtained by adding a material that causes a hydration reaction having a moisture absorbing function and generates a catalytic effect to a coating material mixed with or coated with an acid as a catalyst which activates and hardens an organic binder for binding the granular material.

A method of creating a sand mold for rapid casting, including the steps of determining a mold shape, providing a generally uniform thickness layer of sand, curing at least a portion of the layer of sand, machining the cured portions of the layer of sand based on the desired mold shape, and repeating the layer-forming, curing and machining steps until the sand mold is complete. Another aspect includes a machine for creating the sand mold having a build envelope defined by side walls, a movable build platform and at least one movable tool assembly, the movable tool assembly having a single or plurality of tools chosen from the group consisting of a sand dispenser, a sand leveling device, a curing device, and a machining device.