Patent ID: 8813811

Claim:
A method of forming a mold for use in the production of a railway freight car sideframe, the steps comprising: providing a sideframe drag flask, the sideframe drag flask including an oversize impression integral with the sideframe drag flask, the oversize impression and sideframe drag flask comprising at least one of cast steel and cast iron, providing a sideframe drag pattern, the oversize impression being an impression having a shape related to the sideframe drag pattern, placing the sideframe drag pattern on top of the sideframe drag flask to form a spacing between the sideframe drag pattern and the oversize impression in the sideframe drag flask, injecting a resin coated sand into the spacing between the sideframe drag pattern and the oversize impression in the sideframe drag flask through a plurality of openings in the sideframe drag pattern to form a layer of resin coated sand in the spacing between the sideframe drag pattern and the oversize impression in the sideframe drag flask, injecting a gas catalyst into the layer of resin coated sand to set the resin coated sand to form a sideframe drag mold in the sideframe drag flask, providing a sideframe cope flask, the sideframe cope flask including an oversize impression integral with the sideframe cope flask, the oversize impression and sideframe cope flask comprising at least one of cast steel and cast iron, providing a sideframe cope pattern, the oversize impression in the sideframe cope flask being an impression having a shape related to the sideframe cope pattern, placing the sideframe cope pattern of the on top of the sideframe cope flask to form a spacing between the sideframe cope pattern and the oversize impression in the sideframe cope flask, injecting a resin coated sand into the spacing between the sideframe cope pattern and the oversize impression in the sideframe cope flask through a plurality of openings in the sideframe cope pattern to form a layer of resin coated sand in the spacing between the sideframe cope pattern and the oversize impression in the sideframe cope flask, injecting a gas catalyst into the layer of resin coated sand to set the resin coated sand to form a sideframe cope mold in the sideframe cope flask, placing a plurality of cores in the sideframe drag mold, and placing the sideframe cope flask with the sideframe cope mold on top of the sideframe drag flask with the sideframe drag mold to form a complete mold ready to receive molten steel to form a railway freightcar sideframe.