Process for preparing detailed foundry shapes and castings

Abstract

This invention relates to a process for preparing detailed foundry shapes (e.g. molds and cores) used in casting metal articles. The process involves preparing foundry shapes from hollow ceramic microspheres bonded with organic or inorganic binders. The foundry shape is then detailed by machining, cutting, stamping, or otherwise removing material from the foundry shape to provide special shapes, letters, numbers, insignia, machine readable codes, etc. on the surface of the foundry shape. The foundry shapes are used to produce detailed metal castings. This detail can be unique to a single casting to provide a permanent traceable mark for casting identification from the time of manufacture to disposal.

We claim:  
     
         1 . A process for preparing detailed foundry shapes which comprises: 
 (a) mixing aluminosilicate microspheres with an effective binding amount of a foundry binder to form a foundry mix;    (b) shaping said foundry mix to form a foundry shape;    (c) curing said foundry shape; and    (d) detailing said foundry shape by removing material from said foundry shape.    
     
     
         2 . The process of  claim 1  wherein the detailed shape is a mold, core, or an insert.  
     
     
         3 . The process of  claim 2  wherein the foundry shape is detailed by stamping, embossing, machining, or cutting.  
     
     
         4 . The process of  claim 3  wherein the detailed foundry shape contains one or more numerals or letters.  
     
     
         5 . The process of  claim 3  where the detailed foundry shape contains a bar code, design, or a label.  
     
     
         6 . The process of  claim 5  where the detailed foundry shape can be scanned and identified using an ultraviolet light scanner.  
     
     
         7 . A process for preparing a detailed foundry casting comprising pouring molten metal around a foundry shape prepared in accordance with claims  1 ,  2 ,  3 ,  4 ,  5 , or  6 .  
     
     
         8 . The process of  claim 7  wherein the mark on the casting is raised.  
     
     
         9 . The process of  claim 7  wherein the mark on the casting is imprinted.  
     
     
         10 . A process for tracking a metal part comprising: 
 (a) preparing a marked casting in accordance with  claim 8  that is permanently fixed to said casting; and    (b) reading the permanent mark on said casting.    
     
     
         11 . A process for tracking a metal part comprising: 
 (a) preparing a marked casting in accordance with  claim 9  that is permanently fixed to said casting; and    (b) reading the permanent mark on said casting.