Compositions for lining casting moulds and related articles and method of making such articles

Claim 2

A LINING FOR METALLURGICAL PURPOSES COMPRISING 60 - 90 WT. % OF ALUMINUM WASTE METAL, 1 - 19 WT. % OF FIBROUS FILLER, 1 - 10 WT. % OF BINDING AGENT, WHEREIN THE BINDING AGENT IS SELECTED FROM THE GROUP CONSISTING OF PHENOPLASTS AND AMONOPLASTS, 0.01 - 1 WT. % OF WETTING AGENT, WHEREIN THE WETTING AGENT IS SELECTED FROM THE ANION-ACTIVE COMPOUNDS AND NONIONIC COMPOUNDS AND MIXTURES THEREOF, 0 - 22.5 WT. % ADDITIONAL CONSTITUENTS SELECTED FROM THE GROUP CONSISTING OF EXOTHERMIC MATERIALS, INSULATING MATERIALS, LIGHTWEIGHT FILLERS.

Claim 3

The lining of claim 1 adapted as an exothermic lining, wherein the other constituent is a mixture of aluminum and iron oxide.

Claim 4

The lining of claim 1, wherein the lightweight filler is selected from expanded clay, expanded corundum, vermiculite, perlite and light fireclay.

Claim 5

The lining of claim 1, wherein the wetting agent is selected from alkylbenzene sulfonates, alkyl sulfates, alkyl sulfonates, sulfated fatty acid esters and alkoxylated fatty acid condensation products.

Claim 6

A lining for metallurgical purposes having a predominantly exothermic effect, comprising 60 - 80 wt. % of aluminum waste metal, 1 - 6 wt. % of asbestos fibers, 0 - 6 wt. % of sawdust, 3 - 6 wt. % of phenol-formaldehyde resin, 0.01 - 0.5 wt. % of wetting agent selected from anion-active and non-ionic compounds, 7 - 10 wt. % of powdered aluminum, 3 - 6 wt. % of iron oxide and/or pyrolusite, and 0 - 6 wt. % cryolite.

Claim 7

A lining for metallurgical purposes having a predominantly exothermic effect, comprising 60 - 80 wt. % of aluminum waste metal, 1 - 6 wt. % of asbestos fibers, 0 - 6 wt. % of sawdust, 3 - 6 wt. % of phenol-formaldehyde resin, 0.01 - 0.5 wt. % of wetting agent selected from anion-active and non-ionic compounds, 7 - 10 wt. % of powdered aluminum, 3 - 6 wt. % of iron oxide and/or pyrolusite, and 0 - 6 wt. % cryolite.

Claim 8

In a method of preparing a lining for metallurgical purposes comprising 60 - 90 wt. % of aluminum waste metaL, 1 - 19 wt. % of fibrous filler, 1 - 10 wt. % of binding agent selected from phenoplasts and aminoplasts, up to 1 wt. % of wetting agent selected from anion-active compounds and non-ionic compounds and mixtures thereof, 0 - 22.5 wt. % additional constituent selected from the group consisting of exothermic materials, insulating materials, lightweight fillers, the method steps of providing an aqueous preparation of the fibrous filler and wetting agent, adding the aluminum waste metal in finely divided form, in the case of an exothermic mixture together with the components of the mixture, adding the binder or components reactive to form the binder, treating the resulting mixture to render it suitable for forming into the desired shape of the lining, forming the lining and drying the formed lining to harden it.

Claim 9

In a method of preparing a lining for metallurgical purposes comprising 60 - 90 wt. % of aluminum waste metaL, 1 - 19 wt. % of fibrous filler, 1 - 10 wt. % of binding agent selected from phenoplasts and aminoplasts, up to 1 wt. % of wetting agent selected from anion-active compounds and non-ionic compounds and mixtures thereof, 0 - 22.5 wt. % additional constituent selected from the group consisting of exothermic materials, insulating materials, lightweight fillers, the method steps of providing an aqueous preparation of the fibrous filler and wetting agent, adding the aluminum waste metal in finely divided form, in the case of an exothermic mixture together with the components of the mixture, adding the binder or components reactive to form the binder, treating the resulting mixture to render it suitable for forming into the desired shape of the lining, forming the lining and drying the formed lining to harden it.

Claim 10

The method as claimed in claim 6, including the processing of the resulting mixture in a drying process and during the drying process forming dry flakes or pellets and pressing said flakes or pellets into a desired mold shape.

Claim 11

The lining of claim 6, wherein the wetting agent is selected from the group consisting of alkylbenzene sulfonates, alkyl sulfates, alkyl sulfonates, sulfated fatty acid esters and alkoxylated fatty acid condensation products.