Apparatus for cleaning metal parts

Abstract

An apparatus comprising a holder to secure a cast part and a cleaner dispersing system operable to remove residual casting material from the cast part. The casting material is made using a disintegration additive comprising a foundry sand, a binder, and a disintegration additive, which enhances electron/ion conduction when the casting material is contacted with the electrolyte or creates porosity upon volatilization during the casting process at high temperatures. The present invention also provides a system for producing clean industrial parts, using a casting material comprising a disintegration additive.

1 . An apparatus comprising: 
 (a) a holder adapted to secure a cast metal part; and    (b) a cleaner dispersing system operable to remove residual casting material from the cast metal part;    wherein the casting material is made using a disintegration additive.    
   
   
       2 . An apparatus according to  claim 1 , wherein said cleaner dispersing system comprises at least one spray head.  
   
   
       3 . An apparatus according to  claim 2 , wherein said cleaner dispersing system additionally comprises a fluid recirculator operable to collect and recycle cleaning fluid.  
   
   
       4 . An apparatus according to  claim 1 , wherein said cleaner dispersing system comprises a reservoir operable to immerse the metal part in cleaning fluid.  
   
   
       5 . An apparatus according to  claim 4 , wherein said cleaner dispersing system comprises a fluid circulator operable to circulate fluid within said reservoir.  
   
   
       6 . An apparatus according to  claim 1 , wherein said holder is suitable for holding an automotive drive train part.  
   
   
       7 . An apparatus according to  claim 1 , wherein said cleaner dispersing system is operable to contact the metal part with an electrolyte.  
   
   
       8 . An apparatus according to  claim 7 , further comprising a power source having a first electrode and a second electrode of opposite polarity.  
   
   
       9 . An apparatus according to  claim 8 , wherein said first electrode is adapted to contact the metal part.  
   
   
       10 . An apparatus according to  claim 9 , wherein said first electrode is a cathode.  
   
   
       11 . An apparatus according to  claim 8 , wherein said holder comprises said first electrode.  
   
   
       12 . An apparatus according to  claim 7 , wherein the disintegration additive enhances electron/ion conduction when the casting material is contacted with said electrolyte.  
   
   
       13 . An apparatus according to  claim 1 , wherein the disintegration additive volatilizes during the process of making the casting material.  
   
   
       14 . An apparatus according to  claim 1 , wherein said residual casting material comprises foundry sand and a binder.  
   
   
       15 . An apparatus according to  claim 14 , wherein said foundry sand comprises a material selected from the group consisting of synthetic sand, bank sand, silica sand, and mixtures thereof.  
   
   
       16 . An apparatus according to  claim 14 , wherein said binder comprises a material selected from the group consisting of phenolic urethane resin, clay, and mixtures thereof.  
   
   
       17 . An apparatus comprising: 
 (a) a cast part, a surface of which is coated with residual casting material comprising a disintegration additive;    (b) a holder adapted to secure said cast part; and    (c) a fluid tank adapted to contain cleaning fluid for cleaning said cast part.    
   
   
       18 . An apparatus according to  claim 17 , further comprising: 
 (d) a fluid propulsion device connected to the fluid tank; and    (e) a spray device connected to the propulsion device and adapted to apply cleaning fluid on a surface of said cast part;    wherein the apparatus is operable to remove residual casting material from said metal part.    
   
   
       19 . An apparatus according to  claim 18 , comprising a plurality of said spray devices.  
   
   
       20 . An apparatus according to  claim 18 , additionally comprising a fluid recirculator operable to collect and recycle said cleaning fluid.  
   
   
       21 . An apparatus according to  claim 18 , wherein said part is an automotive drive train part.  
   
   
       22 . An apparatus according to  claim 18 , wherein said cleaning fluid comprises an electrolyte.  
   
   
       23 . An apparatus according to  claim 18 , additionally comprising a power source having a first electrode and a second electrode of opposite polarity.  
   
   
       24 . An apparatus according to  claim 23 , wherein said first electrode is configured so as to contact said metal part.  
   
   
       25 . An apparatus according to  claim 23 , wherein said first electrode is a cathode.  
   
   
       26 . An apparatus according to  claim 23 , wherein said holder comprises said first electrode.  
   
   
       27 . An apparatus according to  claim 22 , wherein said disintegration additive enhances electron/ion conduction when said casting material is contacted with said electrolyte.  
   
   
       28 . An apparatus according to  claim 18 , wherein said disintegration additive volatilizes during a process of making said metal part.  
   
   
       29 . An apparatus according to  claim 18 , wherein said residual casting material comprises foundry sand and a binder.  
   
   
       30 . An apparatus according to  claim 29 , wherein said foundry sand comprises a material selected from the group consisting of synthetic sand, bank sand, silica sand, and mixtures thereof.  
   
   
       31 . An apparatus according to  claim 29 , wherein said binder comprises a material selected from the group consisting of: phenolic urethane resin, clay, and mixtures thereof.  
   
   
       32 . A system for the production of a clean industrial part, comprising: 
 (a) a casting material suitable for casting a part, comprising (i) foundry sand, (ii) binder, and (iii) a disintegration additive wherein a portion of said casting material remains on said part after casting;    (b) a parts washer operable to contact said cast part with cleaning fluid.    
   
   
       33 . A system according to  claim 32 , wherein said parts washer comprises one or more spray devices operable to apply said cleaning fluid on a surface of said cast part.  
   
   
       34 . A system according to  claim 32 , wherein said parts washer comprises a fluid recirculator operable to collect and recycle said cleaning fluid.  
   
   
       35 . A system according to  claim 32 , wherein said parts washer comprises a reservoir operable to immerse said cast part in said cleaning fluid.  
   
   
       36 . A system according to  claim 35 , wherein said parts washer additionally comprises a fluid circulator operable to circulate fluid within said reservoir.  
   
   
       37 . A system according to  claim 32 , wherein said parts washer comprises a holder operable to hold an automotive drive train part.  
   
   
       38 . A system according to  claim 32 , wherein said cleaning fluid comprises an electrolyte.  
   
   
       39 . A system according to  claim 38 , wherein said parts washer comprises a power source having a first electrode and a second electrode of opposite polarity.  
   
   
       40 . A system according to  claim 39 , wherein said first electrode is configured so as to contact said cast part which is electrically conductive.  
   
   
       41 . A system according to  claim 39 , wherein said first electrode is a cathode.  
   
   
       42 . A system according to  claim 39 , wherein said parts washer comprises a holder for said cast part, and said holder comprises said first electrode.  
   
   
       43 . A system according to  claim 38 , wherein said disintegration additive enhances electron/ion conduction when said casting material is contacted with said electrolyte.  
   
   
       44 . A system according to  claim 32 , wherein said disintegration additive volatilizes from said casting material during the process of making said cast part.  
   
   
       45 . A system according to  claim 32 , wherein said foundry sand comprises a material selected from the group consisting of: synthetic sand, bank sand, silica sand, and mixtures thereof.  
   
   
       46 . A system according to  claim 32 , wherein said binder comprises a material selected from the group consisting of: phenolic urethane resin, clay, and mixtures thereof.  
   
   
       47 . A method for making a clean metal part, comprising: 
 (a) casting a metal part using a mold formed using a casting material comprising (i) foundry sand, (ii) binder, and (iii) a disintegration additive;    (b) cleaning said cast metal parts using a parts washer comprising a cleaner dispensing system.    
   
   
       48 . A method for making a clean metal part according to  claim 47 , wherein said parts washer comprises at least one spray device operable to apply cleaning fluid on a surface of said cast metal part.  
   
   
       49 . A method for making a clean metal part according to  claim 48 , wherein said parts washer additionally comprises a fluid recirculator operable to collect and recycle said cleaning fluid.  
   
   
       50 . A method for making a clean metal part according to  claim 47 , wherein said fluid dispersion system comprises a reservoir operable to immerse said metal part in cleaning fluid.  
   
   
       51 . A method for making a clean metal part according to  claim 50 , wherein said fluid dispersion system comprises a fluid circulator operable to circulate said cleaning fluid within said reservoir.  
   
   
       52 . A method for making a clean metal part according to  claim 47 , wherein said parts washer comprises a holder suitable for holding an automotive drive train part.  
   
   
       53 . A method for making a clean metal part according to  claim 47 , wherein said parts washer is operable to contact said metal part with cleaning fluid comprising an electrolyte.  
   
   
       54 . A method for making a clean metal part according to  claim 53 , wherein said parts washer comprises a power source having a first electrode and a second electrode of opposite polarity.  
   
   
       55 . A method for making a clean metal part according to  claim 54 , wherein said first electrode is configured so as to contact said cast metal part.  
   
   
       56 . A method for making a clean metal part according to  claim 54 , wherein said first electrode is a cathode.  
   
   
       57 . A method for making a clean metal part according to  claim 54 , wherein said parts washer comprises a part holder comprising said first electrode.  
   
   
       58 . A method for making a clean metal part according to Clam  47 , wherein said disintegration additive promotes disintegration of said foundry cast material from said cast metal part.  
   
   
       59 . A method for making a clean metal part according to  claim 53 , wherein said disintegration additive enhances electron/ion conduction when said foundry casting material is contacted with said electrolyte.  
   
   
       60 . A method for making a clean metal part according to  claim 47 , wherein said disintegration additive volatilizes during the process of making a cast with said foundry casting material.  
   
   
       61 . A method for making a clean metal part according to  claim 47 , wherein said foundry sand comprises a material selected from the group consisting of synthetic sand, bank sand, silica sand, and mixtures thereof.  
   
   
       62 . A method for making a clean metal part according to  claim 47 , wherein said binder comprises a material selected from the group consisting of phenolic urethane resin, clay, and mixtures thereof.  
   
   
       63 . A method for making a clean metal part according to  claim 47 , wherein said cleaning step further comprises: 
 (i) physically separating said cast metal part from said mold, to expose a metal part, wherein residual mold material remains on a surface of said metal part;    (ii) attaching said metal part to a power source having a first and a second electrode of opposite polarities, wherein said first electrode contacts said metal part;    (iii) contacting said metal part with an electrolyte, wherein said electrolyte is in contact with said second electrode; and    (iv) generating current through said electrolyte, from said first electrode to said second electrode.    
   
   
       64 . A method for making a clean metal part according to  claim 63 , wherein said first electrode is a cathode.  
   
   
       65 . A method for making a clean metal part according to  claim 63 , wherein said contacting is by immersing said metal part in a reservoir of said electrolyte.  
   
   
       66 . A method for making a clean part according to  claim 63 , wherein said contacting is by spraying said electrolyte on a surface of said metal part.