Abstract: A mold for casting metal which allows solid impurities to be removed from the molten metal. The mold (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mold, a pattern for preparing the mold, a housing for use in the mold and a method for casting employing the mold.

Abstract: Composition for releasing sodium or strontium or both into molten aluminum or aluminum-based alloy. The composition is formed by fusing a mixture containing at least two salts, at least one of the salts having sodium as a cation and/or at least one of the salts having strontium as a cation, at least one of the salts having carbonate as an anion and at least one of the salts having a halide as an anion. The composition may be employed as a modifying flux for altering the microstructure of aluminum and aluminum alloy.

Abstract: An elongate collapsible feeder element for use in metal casting and a feeder system with attached feeder element and feeder sleeve. The feeder element has an A end and an opposite B end measured along the height, and a C end and an opposite D end measured along the length. The A end is for mounting on a mold pattern or swing plate and the opposite B end is for receiving a feeder sleeve. A bore is between the A and B ends defined by a sidewall having a stepped collapsible portion. The feeder element is compressible in use to reduce the distance between the A and B ends. The bore is offset from the centre of the feeder element along the length towards the C end and a second sidewall region is non-planar, contiguous with a third sidewall region and located between the bore axis and the D end.

Abstract: Feeder element for use in metal casting, having a first end for mounting on a mould pattern or swing plate, an opposite second end including a mounting plate for mounting on a feeder sleeve, and a bore between the first and second ends defined by a sidewall. The feeder element is compressible whereby to reduce the distance between the first and second ends. The bore has an axis that is offset from the centre of the mounting plate, and an integrally formed rim extends from a periphery of the mounting plate.

Abstract: A foundry coating composition for moulds and cores, a process for preparing coated foundry moulds and cores, and coated moulds and cores obtainable by the process. The foundry coating composition comprises a liquid carrier; a binder; and a particulate refractory filler. The particulate refractory filler comprises a first (relatively coarse) fraction having a particle size of d>38 ?m and a second (relatively fine) fraction having a particle size of d<38 ?m. No more than 10% of the total particulate refractory filler has a particle size of 38 ?m<d<53 ?m and no more than 50% of the second (relatively fine) fraction is constituted by calcined kaolin. The foundry coating composition is applied to moulds and cores to assist in the removal of the casting from the mould and prevention of casting defects.

Abstract: The present invention relates to a process for the production of ductile iron comprising the sequential steps of:—(i) treating liquid iron with an initialiser comprising an effective amount of a group IIa metal other than Mg, (ii) at a predetermined time after step (i), treating the liquid iron with a magnesium containing nodulariser, (iii) treating the liquid iron with a eutectic graphite nucleation-inducing inoculant, and (iv) casting the iron. The invention allows for the variability of oxygen content in the base iron to be processed such that the mechanical properties of components cast from the processed iron are independent of the original oxygen content of the base iron.

Abstract: Process for producing ductile iron by treating liquid iron with an initializer which is a ferrosilicon alloy comprising an effective amount of barium sufficient to inactivate the oxygen activity of the liquid iron. This is followed at a predetermined time thereafter by treating the liquid iron with a magnesium containing nodularizer, followed by treating the liquid iron with a eutectic graphite nucleation-inducing inoculant, and casting the iron.

Abstract: Rotary device for treating molten metal has a hollow shaft with a rotor having a roof and a base spaced apart and connected by a plurality of dividers. A passage extends between each adjacent pair of dividers and the roof and the base. A flow path extends through the shaft into inlets of the passages and out of outlets. A chamber in which mixing of the molten metal and gas can take place is located radially inwardly of the inlets, has an opening in the base of the rotor and is in the flowpath between the shaft and the inlets. Upon rotation of the device, molten metal is drawn into the chamber through the rotor base where it is mixed with gas passing into the chamber from the shaft. The metal/gas dispersion is pumped into the passages through the inlets before discharge from the rotor through the outlets.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: The present invention relates to a feeder element for use in metal casting. The feeder element comprises a first end for mounting on a mould pattern or swing plate, an opposite second end comprising a mounting plate for mounting on a feeder sleeve and a bore between the first and second ends defined by a sidewall. The feeder element is compressible in use whereby to reduce the distance between the first and second ends. The bore has an axis that is offset from the centre of the mounting plate and an integrally formed rim extends from a periphery of said mounting plate. The feeder element of the invention finds particular utility in high pressure vertically parted sand moulding systems.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58,60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: A process for making a filter suitable for filtering molten metal comprising (i) forming a slurry comprising (a) particles of a refractory material, (b) a binder and (c) a liquid carrier, (ii) coating a disposable former with a slurry, (iii) drying the coated former, (iv) optionally applying one or more additional coats of a refractory material and/or a binder, optionally with liquid carrier, and drying the one or more additional coats, and (v) firing the coated former to produce the filter, wherein the binder is a carbon rich source selected from one or more of the following classes of materials: pitches, tars and organic polymers that degrade to form carbon on pyrolysis.

Abstract: The present invention relates to a process for the production of ductile iron comprising the sequential steps of:—(i) treating liquid iron with an initialiser comprising an effective amount of a group Ha metal other than Mg, (ii) at a predetermined time after step (i), treating the liquid iron with a magnesium containing nodulariser, (iii) treating the liquid iron with a eutectic graphite nucleation-inducing inoculant, and (iv) casting the iron. The invention allows for the variability of oxygen content in the base iron to be processed such that the mechanical properties of components cast from the processed iron are independent of the original oxygen content of the base iron.

Abstract: The invention relates to a rotary device for dispersing a gas in a molten metal. The device comprises a hollow shaft at one end of which is attached a rotor. The rotor has a roof and a base which are spaced apart and connected by a plurality of vanes. A compartment is defined between each adjacent pair of vanes and the roof and the base, and each compartment has an inlet and first and second outlets. A flow path is defined through the shaft into the inlets of the compartments and out of the first and second outlets. Each first outlet is disposed radially outwardly of the respective inlet and arranged to disperse gas laterally of the rotor in use, and each second outlet is disposed in the roof of the rotor and arranged to disperse gas upwardly from the rotor in use.

Abstract: A stopper rod for controlling the flow of molten steel from a tundish has a metal carrier element partly received in an internal passageway of the stopper rod, the carrier element compressing sealing means between a frustoconical undersurface of a laterally enlarged portion thereof and a complementary seating surface of the stopper rod passageway, there being an insert threadedly engaged with one of the carrier element and stopper rod body at a position above a laterally enlarged portion of the carrier element, with further sealing means disposed between said insert and the carrier element. Preferably the insert is a nut screwed down onto a washer which compresses the further sealing means.