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) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.

The present disclosure relates to casting cores. The teachings thereof may be embodied in methods for producing a slip and components produced using such methods. For example, a method for producing a slip may include: mixing at least one inorganic constituent with at least one binder, wherein the binder comprises at least one epoxy resin and at least one silicone copolymer.

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.

Casting of non-ferrous metals, especially aluminum and magnesium, can have problems with erosion, in which molten metal contacts the mold or core surfaces during the pouring process, resulting in the sand being dislodged. Binder systems addressing this issue often use bisphenol F epoxy resin. A binder system is provided in which a major portion of the epoxy resin component is a bisphenol epoxy resin that has been modified by incorporating oxazolidone rings into an epoxy backbone of the bisphenol epoxy resin, especially a bisphenol A epoxy resin. The modification is preferably achieved by reacting the diglycidyl ether of the bisphenol with a methylene diphenyl diisocyanate.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The foundry 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) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.

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) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.

The subject matter of the invention are sizing compositions containing an aqueous carrier liquid, refractory base materials and CH-acidic compounds, as well as their use for casting molds, as well as casting molds coated with the sizing composition.

A release agent is disclosed for use with an organic binder system used in metal casting. The binder system has a Part I component including an epoxy resin and a free radical initiator and a Part II component having an epoxy resin and an acrylate, where the Part I and Part II components are kept separate until the time of use. The release agent will typically have a molecular weight in the range of 150 to 160, with eight to ten carbon atoms. Two examples of the epoxide are pinene oxide and decene-1 oxide, each of which is effective as an internal release agent when present in the binder for a cold box process in the range of about 0.15% to about 1% of the total weight of the Part I and Part II components.

The subject matter of the invention is mold material mixtures for producing molds or cores for metal casting, consisting of at least one refractory base mold material, a binder and an additive based on factice. The invention also relates to a component system, a method for producing molds and cores using the mold material mixtures or the component system respectively, and to molds and cores produced by said method.

The subject matter of the invention are sizing compositions containing an aqueous carrier liquid, refractory base materials and CH-acidic compounds, as well as their use for casting molds, as well as casting molds coated with the sizing composition.