Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end.

Abstract: A defective engine block recycling method in a continuous casting line includes inserting a bore pin into an engine block mold, fitting a real liner to an outer circumferential surface of the bore pin, and injecting molten aluminum into the engine block mold to cast an engine block body. If an abnormality is generated in the engine block mold or the molten aluminum and if a defect is expected to generate in the engine block body, a defective engine block unit is produced by fitting a dummy liner, which is made of a material identical with or similar to a material of the engine block body, to the bore pin. The defective engine block unit thus produced is directly melted and recycled.

Abstract: Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

Abstract: Embodiments of the present invention provide apparatus for forming a component from a solidified fluid medium. The apparatus comprises a body defining a cavity into which the fluid medium may be introduced, the cavity optionally being shaped to define a shape of the component, and a carrier for supporting one or more elements to be embedded in the component. The carrier is arranged to be introduced into the cavity to support the one or more elements within the cavity while the fluid medium is introduced into the cavity. Embodiments of the invention are useful in a range of fabrication technologies including casting of metals and injection molding operations.

Abstract: A method for manufacturing a pipe with a rib, in which a rib portion formed inside a pipe portion includes bent portions in accordance with bending of the pipe portion or a twisted portion in accordance with twisting of the pipe portion, includes drawing out molten metal held in a furnace by using a starter, from a surface of the molten metal, and drawing up the molten metal through a shape defining member defining a sectional shape of the pipe with the rib to be cast, and cooling and solidifying the molten metal passed through the shape defining member and drawn up. The bent portions are formed by moving at least one of the starter and the shape defining member in a horizontal direction. The twisted portion is formed by rotating at least one of the starter and the shape defining member about an axis extending along a vertical direction.

Abstract: A die casting assembly has a cavity defined by multiple dies, the cavity includes at least one sharp corner. Each of the dies includes multiple die segments. A die segment joint between at least two of the die segments is aligned with the sharp corner.

Abstract: There are provided a manufacturing method of a casting capable of easily manufacturing a casting having a complex form and of increasing the degree of freedom of form of the casting to be manufactured, a manufacturing device thereof and a casting. At the time of forming a casting by drawing out molten metal from a bath surface of a molten metal bath and solidifying the molten metal which has been drawn out, an outer contour unit configured from a plurality of outer contour defining members for defining the outer contour of a casting is arranged in a region between the bath surface of the molten meth bath and a solid region where the molten metal is solidified and the molten metal which has been drawn out from the bath surface is drawn out through a region determined by the outer contour unit, and the form of the casting is changed by moving at least one of the plurality of outer contour defining members according to the drawing out of the molten metal.

Abstract: An injection molding system and method of operating the system are disclosed. The system may include a hopper, a barrel configured to receive injection material from the hopper, a screw disposed within the barrel, and a mold defining a mold cavity configured to receive the injection material from the barrel. A pressure-balancing conduit may connect the mold cavity and a rear end of the barrel and be configured to allow air to flow from the mold cavity to the rear end of the barrel. A mold valve may be disposed between the pressure-balancing conduit and the mold cavity and a barrel valve may be disposed between the pressure-balancing conduit and the rear end of the barrel. The method may include opening the mold valve and injecting a material into the mold cavity from the barrel.

Abstract: An up-drawing continuous casting apparatus according to one aspect of the present invention is an up-drawing continuous casting apparatus including a molten metal holding furnace (101) configured to hold molten metal (M1) therein, and a shape determining member (102) placed on a molten metal surface of the molten metal (M1) and configured to determine a sectional shape of a casting (M3) to be casted when retained molten metal (M2) led out from the molten metal surface passes through the shape determining member (102). The shape determining member (102) includes inner shape determining plates (1041, 1042) connectable to each other, and an inner shape determining plate (1043) serving as a connecting member configured to connect the inner shape determining plates (1041, 1042) to each other.

Abstract: A method for casting an internal feature within an object is provided. An internal mold is formed from a mold powder, comprising a base powder and an acid powder mixed into the base powder. A molten material is cast around the internal mold. The molten material is solidified. The internal mold is reacted with water, wherein the reacting causes the acid powder to neutralize the base powder.

Abstract: An alloy part is cast in a mold (280) having a part forming cavity (292, 294, 296). The method comprises pouring a first alloy into the mold. The pouring causes: a surface (550) of the first alloy in the part forming cavity to raise relative to the part forming cavity; a branch flow of the poured first alloy to pass upwardly through a first portion (304) of a passageway; and the branch flow to pass downwardly through a second portion (310), of the passageway; solidifying some of the first alloy in the passageway to block the passageway while at least some of the first alloy in the part forming cavity remains molten. A second alloy is poured into the mold atop the first alloy and solidified.

Abstract: There is provided a twin roll strip casting method. The twin roll strip casting method includes: continuously producing a strip by forming a molten steel pool using rotating rolls and edge dams contacting ends of the rotating rolls, and supplying molten steel to the molten steel pool; and lifting the edge dams by taking an amount of wear of the edge dams, occurring during casting, into consideration.

Abstract: A pressure casting machine can be configured to mold a molten material into a workpiece. The pressure casting machine can include a vacuum chamber and a pressure casting mechanism coupled to the vacuum chamber. The vacuum chamber can include a processing section having a top wall and a bottom wall opposite to the top wall, a first gate configured to seal the processing section, and a first vacuum pump coupled to the processing section. The pressure casting mechanism can include a first driver positioned adjacent to the top wall, a first core received in the processing section and coupled to the first driver, a second core received in the processing section, and a plurality of pushing members received in the processing section. The second core can be coupled to the bottom wall and opposite to the first core. The pushing members can be coupled to the top wall.

Abstract: A field of casting, and more particularly to a shell mold, and also to methods of fabricating and using such a shell mold. This shell mold includes a central cylinder, a plurality of molding cavities arranged in an assembly around the central cylinder, and at least one heat shield that is substantially perpendicular to the main axis. The central cylinder extends along a main axis between a casting cup and a base. Each molding cavity is connected to the casting cup by at least one feed channel, and also, by a baffle-selector with a starter in the base. The at least one heat shield completely surrounds each molding cavity in a plane that is substantially perpendicular to the main axis.

Abstract: Disclosed is an apparatus comprising at least one gate and a vessel, the gate being configured to move between a first position to restrict entry into an ejection path of the vessel and contain a material in a meltable form within the vessel during melting of the material, and a second position to allow movement of the material in a molten form through the ejection path. The gate can move linearly or rotate between its first and second positions, for example. The apparatus is configured to melt the material and the at least one gate is configured to allow the apparatus to be maintained under vacuum during the melting of the material. Melting can be performed using an induction source. The apparatus may also include a mold configured to receive molten material and for molding a molded part, such as a bulk amorphous alloy part.

Abstract: The subject matter of the invention is a device for the direct cooling of a mould for the vertical semicontinuous casting of rolling ingots or extrusion billets (3) with gradual quenching by double jet (4 and 5), the first at substantially 32° and second at substantially 22°, simultaneously and delivering substantially the same flow rates and speeds from a single liquid chamber (2). Another subject of the invention is a method using said device, with or without graphite insert (1) on the working faces and in association with various bottom block configurations.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: A casting pattern for a lost-pattern casting, the pattern being in a shape of a turbine engine blade with a root and a body on either side of a platform that is substantially perpendicular to a main axis of the blade, and a method of producing a shell mold from the pattern, and a casting method using the shell mold. The blade body presents a pressure side, a suction side, a leading edge, and a trailing edge. The pattern also includes an expansion strip adjacent to the trailing edge, and a refractory core embedded in the pattern but presenting, both on the pressure side and on the suction side, a respective flush varnished surface between the trailing edge and the expansion strip. A web extends between the platform and the expansion strip and presents a free edge between them.

Abstract: Disclosed is an apparatus for loading one or more alloy ingots into a molding machine. The apparatus includes a holder configured to hold a plurality of the alloy ingots and dispense one or more of the alloy ingots into a melt zone of the molding machine through an opening in a mold of the machine. The holder is moved in a perpendicular direction with respect to an axis along a center of the opening in the mold between a first position in line with the opening in the mold to dispense one or more of the alloy ingots and a second position away from the opening in the mold. The apparatus can carry ingots of amorphous alloy material so that when the machine melts and molds the material, it forms a bulk amorphous alloy containing part.