Gm Global Technolgoy Operations, Inc.

Hal H Rice

Harry R Mitchell

Gary A Kruger

James R Abel

A foundry furnace lining is formed using an improved ramming mix composed predominantly of raw kyanite particles and alumina particles. The particulate mix is sintered to form a silica slag-resistant lining, which sintering is accompanied by reactions that produce compressive forces that strengthen the product lining.

Ramming mix for forming a mullite-corundum lining within a foundry

A foundry mold for casting to size a material-forming die of a zinc-base alloy is formed by compacting and sintering a particulate mixture composed predominantly of alumina particles and containing raw kyanite particles. During sintering, the raw kyanite particles react to expand the mold by an amount sufficient to compensate for shrinkage of the solidified alloy during cool down.

Foundry mold for cast-to-size zinc-base alloy

An insulating liner for use in an exhaust port of an internal combustion engine or the like consisting, in a preferred embodiment, of a formed thin wall tubular body of rigidized fibrous ceramic such as fibrous alumina-silica material (Fiberfrax) with an abrasion resistant ceramic coating fused onto the inner gas-exposed surface of the body. The coating comprises a mixture of fused silica cement and fine glass frit sintered in place on the body inner surface at a temperature below that which would damage the thin walls of the body.

Insulating engine exhaust port liner

Internal combustion engine pistons are provided with aluminum bodies with highly insulative ceramic inserts cast in place in the upper combustion chamber defining wall. In each of the disclosed embodiments, the ceramic insert has tapered edges to dovetail the insert in place. A fibrous ceramic cushioning layer applied around the insert edge before casting distributes cooling stresses and allows limited relative expansion and contraction of the aluminum body and ceramic insert without overstressing either of the members. Other features are also included.

Ceramic insulated engine pistons

A method for forming contoured refractory bodies characterized by a low coefficient of expansion, high flexural strength and resistance to thermal shock, wherein a fused silica material is pressed into the desired shape in a porous die at a pressure not greater than about 1500 psi, the batch composition consisting essentially of from about 70-85 parts by weight fused silica of -325 mesh, from about 15-30 parts by weight clay, together with from about 20-28 parts by weight de-ionized water and from about 0.1-0.6 parts by weight of at least one of the organic plasticizers selected from the group consisting of hydroxyethyl cellulose, hydroxypropyl cellulose, ethylene oxide resin and propylene glycol alginate, the composition containing less than 0.3% by weight on an after-fired basis of alkali and alkaline earth metal oxides, the green body being dried and then fired at about 1123.degree. C. for about 6 hours.

Method for low pressure forming of fused silica compositions and

An exhaust reactor manifold having a reaction chamber formed by a hardened insulative ceramic liner which is supported within a protective housing. The liner walls are protected and insulated by compessible fibrous insulation. Springs and wedges in the housing act through the insulation blanket to load the liner walls in compression. Inlet and exhaust ports are provided through angled sealing surfaces of the liner which are urged by the compressive loading of the liner into engagement with mating surfaces of a ported mounting portion of the housing.

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Birmingham, MI, United States of America

Hal H Rice