3-D printed PLA material of a selected density is formed into a pattern that is configured as the outer shell of a casting form to be used in the lost foam or evaporative casting process. The purpose of 3-D printing of the PLA material is used to maintain the proper configuration of the form to facilitate casting, and reduce buildup of carbon on the surface of the casting. Because the form is essentially hollow, PLA support pieces can be used on the interior to maintain the structural integrity of the form.

3-D printed PLA material of a selected density is formed into a pattern that is configured as the outer shell of a casting form to be used in the lost foam or evaporative casting process. The purpose of 3-D printing of the PLA material is used to maintain the proper configuration of the form to facilitate casting, and reduce buildup of carbon on the surface of the casting. Because the form is essentially hollow, PLA support pieces can be used on the interior to maintain the structural integrity of the form.

A lining structure for a refractory vessel contains a first layer containing refractory material; a second layer, in communication with and parallel to the first layer, containing a metal layer or component; and a third layer, in communication with and parallel to the second layer, containing refractory material. The metal component in the second layer contains filled transverse passages, between the surface of the second layer in contact with the first layer and the surface of the second layer in contact with the third layer, producing support structures to maintain the structural integrity of the refractory vessel in use.

A lining structure for a refractory vessel contains a first layer containing refractory material; a second layer, in communication with and parallel to the first layer, containing a metal layer or component; and a third layer, in communication with and parallel to the second layer, containing refractory material. The metal component in the second layer contains filled transverse passages, between the surface of the second layer in contact with the first layer and the surface of the second layer in contact with the third layer, producing support structures to maintain the structural integrity of the refractory vessel in use.

The invention concerns a method of manufacturing a shell mould (1) with several layers (2, 3, 4, 5), including at least one contact layer (2), from a model (6) of wax or other similar material of a part to be manufactured, the method comprising a step of dipping the model (6) into a contact slip forming the contact layer (2) and comprising an inorganic or organic binder and a powder, wherein the powder is a mullite-zirconia composite.

A structure for manufacturing a cast article includes an organic component, at least a portion thereof being an organic fiber. The structure has a mass reduction rate of 1 mass % or greater to less than 20 mass % when heated under nitrogen atmosphere at 1000 C. for 30 minutes. The cast-article-manufacturing structure includes an inorganic particle. The cast-article-manufacturing structure includes, as the inorganic particle, a first inorganic particle having a predetermined shape and/or physical property, and a second inorganic particle having a predetermined shape and/or physical property different from the first inorganic particle. In addition thereto or instead thereof, the cast-article-manufacturing structure has a maximum bending stress of 9 MPa or greater measured in conformity with JIS K7017, and a bending strain of 0.6% or greater at the maximum bending stress.

A structure for manufacturing a cast article includes an organic component, at least a portion thereof being an organic fiber. The structure has a mass reduction rate of 1 mass % or greater to less than 20 mass % when heated under nitrogen atmosphere at 1000 C. for 30 minutes. The cast-article-manufacturing structure includes an inorganic particle. The cast-article-manufacturing structure includes, as the inorganic particle, a first inorganic particle having a predetermined shape and/or physical property, and a second inorganic particle having a predetermined shape and/or physical property different from the first inorganic particle. In addition thereto or instead thereof, the cast-article-manufacturing structure has a maximum bending stress of 9 MPa or greater measured in conformity with JIS K7017, and a bending strain of 0.6% or greater at the maximum bending stress.

The invention concerns a method of manufacturing a shell mould (1) with several layers (2, 3, 4, 5), including at least one contact layer (2), from a model (6) of wax or other similar material of a part to be manufactured, the method comprising a step of dipping the model (6) into a contact slip forming the contact layer (2) and comprising an inorganic or organic binder and a powder, wherein the powder is a mullite-zirconia composite.

A lining structure for a refractory vessel contains a first layer containing refractory material; a second layer, in communication with and parallel to the first layer, containing a metal layer or component; and a third layer, in communication with and parallel to the second layer, containing refractory material. The metal component in the second layer contains filled transverse passages, between the surface of the second layer in contact with the first layer and the surface of the second layer in contact with the third layer, producing support structures to maintain the structural integrity of the refractory vessel in use.

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.