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.

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.

An aggregate mixture for a mold, the aggregate mixture including an aggregate, a water-soluble binder, a water-soluble foaming agent, an aqueous mold release agent, and water.

An aggregate mixture for a mold, the aggregate mixture including an aggregate, a water-soluble binder, a water-soluble foaming agent, an aqueous mold release agent, and water.

Provided is a method of producing foamed sand (s) for forming a sand mold. The foamed sand (s) includes sand particles (p) and foam (f) adhering to surfaces of the sand particles (p). The foam (f) contains water glass (b), water (w), and a surfactant (c). According to the method, an aqueous surfactant solution (e) in which the surfactant (c) is dissolved is frothed to generate froth (d) from the aqueous surfactant solution (e). Then, the generated froth (d), the water glass (b), and the water (w) are kneaded with the sand constituted by the sand particles (p).

Provided is a method of producing foamed sand (s) for forming a sand mold. The foamed sand (s) includes sand particles (p) and foam (f) adhering to surfaces of the sand particles (p). The foam (f) contains water glass (b), water (w), and a surfactant (c). According to the method, an aqueous surfactant solution (e) in which the surfactant (c) is dissolved is frothed to generate froth (d) from the aqueous surfactant solution (e). Then, the generated froth (d), the water glass (b), and the water (w) are kneaded with the sand constituted by the sand particles (p).

Provided is a method of producing foamed sand (s) for forming a sand mold. The foamed sand (s) includes sand particles (p) and foam (f) adhering to surfaces of the sand particles (p). The foam (f) contains water glass (b), water (w), and a surfactant (c). According to the method, an aqueous surfactant solution (e) in which the surfactant (c) is dissolved is frothed to generate froth (d) from the aqueous surfactant solution (e). Then, the generated froth (d), the water glass (b), and the water (w) are kneaded with the sand constituted by the sand particles (p).

Provided is a method of producing foamed sand (s) for forming a sand mold. The foamed sand (s) includes sand particles (p) and foam (f) adhering to surfaces of the sand particles (p). The foam (f) contains water glass (b), water (w), and a surfactant (c). According to the method, an aqueous surfactant solution (e) in which the surfactant (c) is dissolved is frothed to generate froth (d) from the aqueous surfactant solution (e). Then, the generated froth (d), the water glass (b), and the water (w) are kneaded with the sand constituted by the sand particles (p).

An inorganic composite, the use of the inorganic composite in tools and molds, a mechanical forming tool, a mold, and a process for manufacturing inorganic composite tools and molds. The composite material mold and/or mechanical forming tool, metal forming, casting or injection mold, said molds or tools have physicochemical properties. The manufacturing process provides fast, low-cost, high-quality manufacture and reduced energy and raw material consumption, making industrial production economically feasible by forming of structural composite materials and bringing environmental advantages.

An inorganic composite, the use of the inorganic composite in tools and molds, a mechanical forming tool, a mold, and a process for manufacturing inorganic composite tools and molds. The composite material mold and/or mechanical forming tool, metal forming, casting or injection mold, said molds or tools have physicochemical properties. The manufacturing process provides fast, low-cost, high-quality manufacture and reduced energy and raw material consumption, making industrial production economically feasible by forming of structural composite materials and bringing environmental advantages.