US2016271693A1PendingUtilityA1

Sand castings using calcium oxide compounds

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Assignee: WITMYER GREGORYPriority: Mar 20, 2015Filed: Mar 20, 2015Published: Sep 22, 2016
Est. expiryMar 20, 2035(~8.7 yrs left)· nominal 20-yr term from priority
Inventors:Gregory Witmyer
C25F 1/00B22C 9/02B22C 1/02B22D 29/00
10
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Claims

Abstract

A method for cleaning residual mold material from a sand casting, the mold material comprising sand, a binder, and an electrolytic material, the method comprising exposing the residual mold material to an electrolytic solution; and subjecting the residual mold material to an electric current.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A method for cleaning residual mold material from a sand casting, the mold material comprising sand, a binder, and an electrolytic material, the method comprising exposing the residual mold material to an electrolytic solution; and subjecting the residual mold material to an electric current. 
     
     
         2 . The method of  claim 1 , wherein the electrolytic material comprises sodium bicarbonate. 
     
     
         3 . The method of  claim 1 , wherein the electrolytic material comprises calcium oxide. 
     
     
         4 . The method of  claim 1 , wherein the electrolytic material comprises calcium carbonate. 
     
     
         5 . The method of  claim 1 , wherein the electrolytic material comprises sodium chloride. 
     
     
         6 . The method of  claim 1 , wherein the electrolytic material comprises a sodium salt. 
     
     
         7 . The method of  claim 1 , wherein the electrolytic material comprises two or more of: a sodium salt; calcium oxide, and calcium carbonate 
     
     
         8 . The method of  claim 1 , wherein the electrolytic solution comprises aqueous potassium carbonate. 
     
     
         9 . The method of  claim 1 , wherein the electrolytic solution has a pH of approximately 12. 
     
     
         10 . The method of  claim 1 , wherein exposing the residual mold material to an electrolytic solution comprises immersing the casting and the residual mold material in a bath of the electrolytic solution. 
     
     
         11 . The method of  claim 1 , wherein exposing the residual mold material to an electrolytic solution comprises spraying the residual mold material with the electrolytic solution. 
     
     
         12 . The method of  claim 1 , further comprising rinsing the sand casting after subjecting the residual mold material to the electric current. 
     
     
         13 . The method of  claim 1 , wherein subjecting the residual mold material to an electric current comprises electrically connecting the sand casting and the electrolytic solution to a source of direct current. 
     
     
         14 . The method of  claim 13 , wherein electrically connecting the electrolytic solution to a source of direct current comprises placing a cathode or an anode of the source of direct current in the electrolytic solution. 
     
     
         15 . The method of  claim 1 , wherein subjecting the aggregate to an electric current comprises electrically connecting the electrolytic solution, and an electrically-conductive member within a core of the mold, to a source of direct current. 
     
     
         16 . A method for creating a sand casting, comprising:
 forming a cavity in an aggregate material comprising sand, a binder, and an electrolytic material, the cavity being shaped as an approximate negative impression of an exterior shape to be formed in the sand casting,   forming a core from the aggregate material, the core having a shape approximating a desired shape of an internal passage or cavity to be formed in the sand casting;   pouring a molten metal into the cavity, where the molten metal, upon cooling and solidification, forms the sand casting;   exposing residual aggregate material on the sand casting to an electrolytic solution; and   subjecting the residual aggregate material to an electric current.   
     
     
         17 . The method of  claim 16 , wherein the electrolytic material comprises sodium bicarbonate. 
     
     
         18 . The method of  claim 16 , wherein the electrolytic material comprises calcium oxide. 
     
     
         19 . The method of  claim 16  wherein the electrolytic material comprises calcium carbonate. 
     
     
         20 . The method of  claim 16 , wherein the electrolytic material comprises sodium chloride. 
     
     
         21 . The method of  claim 16 , wherein the electrolytic material comprises a sodium salt. 
     
     
         22 . The method of  claim 16 , wherein the electrolytic material comprises two or more of: a sodium salt; calcium oxide, and calcium carbonate. 
     
     
         23 . The method of  claim 16 , wherein the electrolytic solution comprises aqueous potassium carbonate. 
     
     
         24 . The method of  claim 16 , wherein the electrolytic solution has a pH of approximately 12. 
     
     
         25 . The method of  claim 1 , wherein exposing residual aggregate material on the sand casting to an electrolytic solution comprises immersing the casting and the residual aggregate material in a bath of the electrolytic solution. 
     
     
         26 . The method of  claim 16 , wherein exposing residual aggregate material on the sand casting to an electrolytic solution comprises spraying the residual aggregate material with the electrolytic solution. 
     
     
         27 . The method of  claim 16 , further comprising rinsing the sand casting after subjecting the residual aggregate material to the electric current. 
     
     
         28 . The method of  claim 16 , wherein subjecting the residual aggregate material to an electric current comprises electrically connecting the sand casting and the electrolytic solution to a source of direct current. 
     
     
         29 . The method of  claim 28 , wherein electrically connecting the electrolytic solution to a source of direct current comprises placing a cathode or an anode of the source of direct current in the electrolytic solution. 
     
     
         30 . The method of  claim 16 , wherein:
 forming a core from the aggregate material comprises forming the core around an electrically-conductive member; and   subjecting the residual aggregate material to an electric current comprises electrically connecting the electrically-conductive member to a source of electric current.   
     
     
         31 . A sand mold, comprising a mixture of sand; a binder; and an electrolytic material. 
     
     
         32 . The sand mold of  claim 31 , wherein the electrolytic material comprises sodium bicarbonate. 
     
     
         33 . The sand mold of  claim 31 , wherein the electrolytic material comprises calcium oxide. 
     
     
         34 . The sand mold of  claim 33 , wherein the electrolytic material comprises calcium carbonate. 
     
     
         35 . The sand mold of  claim 31 , wherein the electrolytic material comprises sodium chloride. 
     
     
         36 . The sand mold of  claim 31 , wherein the electrolytic material comprises sodium salt. 
     
     
         37 . The sand mold of  claim 31 , wherein the electrolytic material comprises two or more of: a sodium salt; calcium oxide, and calcium carbonate.

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