Patent ID: 7967053
Filing Date: 2011-06-28
Classification: B01D,B22C

Abstract:
1. A process for casting a part from a pour of molten metal into a mold assembly, comprising the steps of: inserting, in a flow path of the molten metal into the mold assembly, a foundry shape having openings through which the molten metal flows and having a surface that traps and removes contaminants therefrom, the foundry shape comprising a refractory material that comprises at least 50 weight percent of hollow insulating aluminosilicate microspheres having an average diameter of about 10 microns to 350 microns, based upon the weight of the refractory material, and an effective amount of a foundry binder selected from the group consisting of phenolic resin binders, phenolic urethane binders, furan binders, alkaline phenolic resole binders, epoxy-acrylic binders, and sodium silicate binders; filtering the pour through the foundry shape; allowing the metal to cool and solidify; and separating the cast metal part from the mold assembly.