Title: Vibration welding of expanded bead polystyrene

Abstract: A method of making a composite consumable pattern for use in the cavityless type of metal casting is disclosed. At least two mateable pattern parts are formed entirely of a low density expanded closed-cell polymeric material which is ignitable upon contact with molten metal. The parts are brought together with predetermined mateable surfaces in contact under a pressure of 5-10 psi; one of the parts is vibrated with a frequency of 120-240 cycles per second and an amplitude of 0.03-0.10", to promote a controlled friction at the interface. A predetermined depth of the parts is melted and merged to create a water-tight bond between the mating surfaces upon relief of the vibration.

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Inventors: Kearney, Dolores C. (Inkster, MI, US)
Matz, Bruno (Milford, MI, US)

Application Number: 957376
Filing Date: 1978-11-02
Publication_date: 1980-02-26
Assignee: Ford Motor Company (Dearborn, MI)
Primary Class(es): 164/34 156/73.5, 164/45, 164/246
Other Classes:
US Patent Ref:

3002871	Oct, 1961	Tramm et al.	156/73.
3275179	Sep, 1960	Lux et al.	156/73.
4064927	Dec, 1977	Ostrowski	164/249.

Other Refs:
Primary Examiner: Baldwin, Robert D.
Assistant Examiner: Lin, K. Y.
Attorney: Malleck; Joseph W., Zerschling; Keith L.