Patent ID: 8839843

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