Part for Producing Castings and Process of Making the Same

Abstract

A process of producing a part for casting including the step of preparing a raw material slurry containing inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant. The raw material slurry preferably further contains an inorganic powder and/or a water repellant.

1 . A process of producing a part for casting comprising the step of preparing a raw material slurry comprising inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant. 
     
     
         2 . The process of producing a part for casting according to  claim 1 , wherein the raw material slurry further comprises an inorganic powder and/or a water repellant. 
     
     
         3 . The process of producing a part for casting according to  claim 2 , wherein the mass content of the inorganic powder is 0% to 70%, the mass content of the inorganic fibers is 1% to 60%, the mass content of the organic fibers is 1% to 40%, the mass content of the thermosetting resin is 1% to 40%, the mass content of the papermaking binder is 1% to 10%, and the mass content of the water repellant is 0% to 5%, the total of the inorganic powder, the inorganic fibers, the organic fibers, the thermosetting resin, the papermaking binder, and the water repellant being 100%. 
     
     
         4 . The process of producing a part for casting according to  claim 1 , wherein the sulfonate-based dispersant is a sodium β-naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6. 
     
     
         5 . The process of producing a part for casting according to  claim 1 , wherein the cellulose-based dispersant is a propylene oxide adduct derivative of cellulose. 
     
     
         6 . The process of producing a part for casting according to  claim 2 , wherein the raw material slurry contains at least one of obsidian, mullite, and graphite as the inorganic powder, at least one of carbon fiber, rock wool, and ceramic fiber as the inorganic fibers, and at least one of a phenol resin, an epoxy resin, and a furan resin as the thermosetting resin. 
     
     
         7 . A part for casting comprising inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant. 
     
     
         8 . The part for casting according to  claim 7 , which generates not more than 250 l/m 2  of combustion gas at 1000° C. 
     
     
         9 . The part for casting according to  claim 7 , which further comprises an inorganic powder and/or a water repellant. 
     
     
         10 . The part for casting according to  claim 9 , wherein the mass content of the inorganic powder is 0% to 70%, the mass content of the inorganic fibers is 1% to 60%, the mass content of the organic fibers is 1% to 40%, the mass content of the thermosetting resin is 1% to 40%, the mass content of the papermaking binder is 1% to 10%, and the mass content of the water repellant is 0% to 5%, the total of the inorganic powder, the inorganic fibers, the organic fibers, the thermosetting resin, the papermaking binder, and the water repellant being 100%. 
     
     
         11 . The part for casting according to  claim 7 , wherein the sulfonate-based dispersant is a sodium β-naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6. 
     
     
         12 . The part for casting according to  claim 7 , wherein the cellulose-based dispersant is a propylene oxide adduct derivative of cellulose. 
     
     
         13 . The part for casting according to  claim 9 , wherein the raw material slurry contains at least one of obsidian, mullite, and graphite as the inorganic powder, at least one of carbon fiber, rock wool, and ceramic fiber as the inorganic fibers, and at least one of a phenol resin, an epoxy resin, and a furan resin as the thermosetting resin.