A core shooting method includes: a. Inserting a first core shooting tool into a core shooting machine; b. Injecting core molding material and a binder into the first core shooting tool; c. Ejecting the first core shooting tool from the core shooting machine; d. Curing of the core in the first core shooting tool; e. Repeating the previous steps with at least one further core shooting tool, wherein the insertion of the further core shooting tool into the core shooting machine is carried out simultaneously with the ejection of the previous core shooting tool from the core shooting machine or simultaneously with the curing of the core in the previous core shooting tool.

A corresponding core shooting tool is further described.

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.

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.

A coating composition is described, for use in the foundry, in particular comprising particulate, amorphous silicon dioxide (SiO.sub.2) and an aqueous phase having a pH of at most 5, and also coated, waterglass-bound foundry molding elements, especially coated, waterglass-bound foundry molds and foundry cores, which each comprise a coating composition of the invention. Further described is the use of a coating composition of the invention for producing a coating on a waterglass-bound foundry molding element and a method for producing a waterglass-bound foundry molding element (mold or core) coated with a water-containing refractory coating. Likewise specified is a kit whose contents include a coating composition of the invention.

A coating composition is described, for use in the foundry, in particular comprising particulate, amorphous silicon dioxide (SiO.sub.2) and an aqueous phase having a pH of at most 5, and also coated, waterglass-bound foundry molding elements, especially coated, waterglass-bound foundry molds and foundry cores, which each comprise a coating composition of the invention. Further described is the use of a coating composition of the invention for producing a coating on a waterglass-bound foundry molding element and a method for producing a waterglass-bound foundry molding element (mold or core) coated with a water-containing refractory coating. Likewise specified is a kit whose contents include a coating composition of the invention.

A method is provided for casting a component. Accordingly, data indicative of at least one location of a unitary core-shell mold which is susceptible to a stress concentration is received. An additive manufacturing process is employed to form the unitary core-shell mold defining a casting cavity. The unitary core-shell mold includes a shell wall defining an outer component shape and a core wall positioned inward of the shell wall. The core wall defines an inner component shape. The core wall and/or the shell wall defines at least one reinforcement recess adjacent to the at least one location which is susceptible to the stress concentration. Following the forming of the unitary core-shell mold, at least one support member is positioned within the reinforcement recess in contact with the at least one location. With the support member in place, the component is cast within the casting cavity.

Sized molds for metal casting are obtained from molding material mixtures on the basis of inorganic bonding agents containing at least one phosphatic compound and at least one oxidic boron compound, especially sized, water glass-bound forms and cores, having at least one refractory base molding material, water glass as inorganic bonding agent and amorphous particulate silicon dioxide and one or more powdery oxidic boron compounds and one or more phosphatic compounds. The invention furthermore relates to a method for producing sized foundry mold bodies and use thereof, in particular for producing cast parts from iron alloys. The sizing is a water-based sizing.

Sized molds for metal casting are obtained from molding material mixtures on the basis of inorganic bonding agents containing at least one phosphatic compound and at least one oxidic boron compound, especially sized, water glass-bound forms and cores, having at least one refractory base molding material, water glass as inorganic bonding agent and amorphous particulate silicon dioxide and one or more powdery oxidic boron compounds and one or more phosphatic compounds. The invention furthermore relates to a method for producing sized foundry mold bodies and use thereof, in particular for producing cast parts from iron alloys. The sizing is a water-based sizing.

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.

The present invention describes a coating composition for the foundry industry, for use in the foundry, in particular comprising certain organic ester compounds of a formula (I) and particulate, amorphous silicon dioxide (SiO.sub.2); and also coated foundry molding elements, especially foundry molds and/or foundry cores, which each comprise a coating composition of the invention. The invention further describes the use of a coating composition of the invention for producing a coating on a foundry molding element and a method for producing a foundry molding element coated with a water-containing refractory coating. The invention likewise describes a kit whose contents include a coating composition of the invention.