Metal founding – Process – Shaping a forming surface
Patent
1988-01-28
1988-12-13
Foelak, Morton
Metal founding
Process
Shaping a forming surface
164 45, 521 56, 521 58, 521 60, 521149, B22C 902
Patent
active
047903678
ABSTRACT:
Expandable and expanded plastic materials having a majority of alkyl acrylate monomeric repeat units are disclosed. These materials when expanded have a volume expansion of at least 60 and maintain that volume expansion for a period of at least 30 minutes under expansion conditions after reaching the volume expansion of 60. Expandable and expanded plastic materials having a majority of alkyl acrylate monomeric repeat units and an inhibitor for the monomer(s) and a crosslinker incorporated into the plastic material upon monomer polymerization are also disclosed. Also disclosed are expandable and expanded plastic materials having a majority of alkyl acrylate monomeric repeat units with blowing agents of 2,2-dimethylbutane, 2,3-dimethylbutane or mixtures of one or both with 1-chloro-1,1-difluoroethane or mixtures of at least 30 percent of one or both with other volatile blowing agents.
These specific types of formed patterns and core assemblies, wholly or partially formed from the destructible expanded closed-cell cellular plastic materials of the present invention have a decreased tendency to form nonvolatile residue during the casting of metals such as iron. Superior castings are thereby obtained without resort to uneconomic casting methods.
Further disclosed is a method of casting metal castings using the disclosed expanded plastic material articles (Lost Foam or Evaporative Pattern Casting). The disclosed expanded plastic material articles are especially preferred for metal castings having a final carbon percentage of 1.8 weight percent or less in the final casting.
REFERENCES:
patent: 3615972 (1971-10-01), Morehouse et al.
patent: 4640333 (1987-02-01), Martin et al.
patent: 4711288 (1987-12-01), Harvey
patent: 4721149 (1988-01-01), Hesterberg
Johnson David R.
Moll Norman G.
Foelak Morton
The Dow Chemical Company
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