A structure for manufacturing castings, containing an inorganic fiber, a layered clay mineral, and an inorganic particle other than the layered clay mineral and having an organic content of 5 mass % or lower or having a mass loss of 5 mass % or lower when heated at 1000° C. for 30 minutes. The inorganic particle preferably contains one or more selected from obsidian, graphite, and mullite. The inorganic fiber preferably contains carbon fiber. The inorganic fiber preferably has an average length of 0.5 to 15 mm. The layered clay mineral preferably contains one or more selected from bentonite and montmorillonite.

A ceramic casting shell is formed by a method comprising the steps of coating a wax former with one or more layers of a ceramic slurry; drying the or each layer of ceramic slurry; wherein the dried layer or layers of ceramic slurry form a ceramic shell; applying over the ceramic shell, a coating of a polymer material; heating the formed assembly to melt and remove the wax former, wherein the polymer coating acts as a strengthening layer to the ceramic shell during the wax removal process; and subsequent to removal of the wax former, heating the ceramic shell to melt and remove the polymer coating. The polymer coating is preferably the outer coating of the ceramic shell. The polymer coating may be applied by spraying, dipping or painting onto the ceramic shell.

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.

A method for manufacturing a structure from a granular material, called sand, in particular a mold. A layer of sand is deposited. The layer of sand is selectively agglomerated by spraying, using a spray nozzle, an inorganic binder having an M2SiO3 type (meta)silicate dissolved in a solvent. Prior to the spraying, the inorganic binder is heated to a temperature to confer on it a viscosity less than 0.2 Pa.Math.s. A device for implementing the method is provided.

A cast mold fabricating device supplies thickener-coated sand and steam into a mold forming die at an optimum timing to shorten a mold fabrication time. The device includes the die 2 with an injection inlet 1, a sand supply head 4 for supplying and filling the thickener-coated sand 3 into the die, a steam supply head 5 for supplying steam into the die 2 to solidify and/or cure a thickener of the sand by application of heat of the steam. The device further includes a vertical drive 6 for lowering the sand supply head 4 to a position where the injection inlet 1 is connected to a sand nozzle 8 of the sand supply head 4, and a horizontal drive 7 for advancing the steam supply head 5 to a position where the injection port 1 is connected to a steam nozzle 9 of the steam supply head 5.

A cast mold fabricating device supplies thickener-coated sand and steam into a mold forming die at an optimum timing to shorten a mold fabrication time. The device includes the die 2 with an injection inlet 1, a sand supply head 4 for supplying and filling the thickener-coated sand 3 into the die, a steam supply head 5 for supplying steam into the die 2 to solidify and/or cure a thickener of the sand by application of heat of the steam. The device further includes a vertical drive 6 for lowering the sand supply head 4 to a position where the injection inlet 1 is connected to a sand nozzle 8 of the sand supply head 4, and a horizontal drive 7 for advancing the steam supply head 5 to a position where the injection port 1 is connected to a steam nozzle 9 of the steam supply head 5.

A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

The present invention relates to a resin composition that comprises an acetoacetate ester compound with at least two acetoacetate ester functional groups, an acrylate compound with at least two acrylate functional groups, and a tertiary amine curing catalyst. This resin composition acts as an isocyanate-free binder that is less toxic to the environment. The invention further discloses a method for preparation fiber reinforced parts comprising fibers and said resin composition as well as a method for the preparation of foundry molds for the casting industry, which is based on said binder.

The present invention provides a curing agent for casting a water glass, including an ester and an amorphous silicon dioxide obtained by a thermal decomposition of ZrSiO.sub.4; and the curing agent for casting the water glass does not contain water. According to the present invention, the curing agent for casting the water glass has a strong adhesion-enhancing effect and a long shelf life, and is easy to use.

The present invention provides a curing agent for casting a water glass, including an ester and an amorphous silicon dioxide obtained by a thermal decomposition of ZrSiO.sub.4; and the curing agent for casting the water glass does not contain water. According to the present invention, the curing agent for casting the water glass has a strong adhesion-enhancing effect and a long shelf life, and is easy to use.