Abstract: A method of manufacturing an aluminum alloy cylinder head includes providing a precision sand core and mold assembly, a liquid aluminum alloy delivery system, and a mold manipulator system. The precision sand core and mold assembly is disposed in the mold manipulator system and the liquid aluminum alloy delivery system includes an in-furnace ultrasonic actuator and a launder tube having at least an ultrasonic actuator. The liquid aluminum alloy delivery system is sealed to the precision sand core and mold assembly and provides liquid aluminum alloy into a gating system of the precision sand core and mold assembly. The precision sand core and mold assembly is rotated approximately 180°. The precision sand core and mold assembly is vibrated.

Abstract: A method of manufacturing an aluminum alloy cylinder head includes providing a precision sand core and mold assembly, a liquid aluminum alloy delivery system, and a mold manipulator system. The precision sand core and mold assembly is disposed in the mold manipulator system and the liquid aluminum alloy delivery system includes an in-furnace ultrasonic actuator and a launder tube having at least an ultrasonic actuator. The liquid aluminum alloy delivery system is sealed to the precision sand core and mold assembly and provides liquid aluminum alloy into a gating system of the precision sand core and mold assembly. The precision sand core and mold assembly is rotated approximately 180°. The precision sand core and mold assembly is vibrated.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: A method of manufacturing an aluminum alloy cylinder head includes providing a mold assembly including a gating system, a head deck mold, and a mold cavity. Liquid aluminum alloy is pumped at low pressure into the gating system of the mold assembly filling the mold cavity. Next, the head deck mold is removed from the mold assembly and the head deck and combustion chambers of the cylinder head are quenched.

Abstract: A method of improving riser feedability in semi-permanent mold casting is disclosed. The method includes providing a first receptacle fluidly connected to a mold cavity and providing a second receptacle fluidly connected to a riser. Further, the method includes delivering molten metal to the first receptacle and conveying the molten metal into the mold cavity through a sprue. Delivery of molten metal to the first receptacle is terminated when the mold cavity reaches a predetermined fill level delivery of molten metal to the second receptacle is initiated. In certain embodiments, the first receptacle and the second receptacle are combined into a single receptacle and the sprue is connected to the mold cavity through a lower runner and is connected to the riser through an upper runner.

Abstract: A method of improving riser feedability in semi-permanent mold casting is disclosed. The method includes providing a first receptacle fluidly connected to a mold cavity and providing a second receptacle fluidly connected to a riser. Further, the method includes delivering molten metal to the first receptacle and conveying the molten metal into the mold cavity through a sprue. Delivery of molten metal to the first receptacle is terminated when the mold cavity reaches a predetermined fill level delivery of molten metal to the second receptacle is initiated. In certain embodiments, the first receptacle and the second receptacle are combined into a single receptacle and the sprue is connected to the mold cavity through a lower runner and is connected to the riser through an upper runner.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: Methods, systems, and apparatus for reduction of gas pressure within a core, such as a sand casting core package, during a casting process in order to reduce bubble defects. Some embodiments may comprise a mold configured to receive a molten metal to create a metal casting, such as an engine block casting. The mold may comprise a mold core configured to create a cavity within the metal casting. The system may further comprise a filling device configured for delivering a molten metal into the mold for creating the metal casting. The mold core may comprise a material that is permeable to certain gases known to often result in bubble defects. The system may further comprise a vacuum configured to be coupled with the mold to reduce gas pressure within a permeable portion of the mold in order to reduce the incidence of bubble defects within the casting.

Abstract: Methods, systems, and apparatus for reduction of gas pressure within a core, such as a sand casting core package, during a casting process in order to reduce bubble defects. Some embodiments may comprise a mold configured to receive a molten metal to create a metal casting, such as an engine block casting. The mold may comprise a mold core configured to create a cavity within the metal casting. The system may further comprise a filling device configured for delivering a molten metal into the mold for creating the metal casting. The mold core may comprise a material that is permeable to certain gases known to often result in bubble defects. The system may further comprise a vacuum configured to be coupled with the mold to reduce gas pressure within a permeable portion of the mold in order to reduce the incidence of bubble defects within the casting.

Abstract: A method of forming a casting using a casting apparatus is disclosed, the method including the steps of lowering a ladle having a hollow interior into a source of molten material and an aperture facilitating flow into the hollow interior, filling the interior of the ladle with the molten material through the aperture, introducing an inert gas into a portion of a nozzle, removing the ladle from the source of molten material, causing the nozzle to contact a casting mold, and pressurizing the hollow interior with an inert gas to cause the molten material to flow into the casting mold.

Abstract: A casting apparatus and a method of forming a casting using the casting apparatus is disclosed, the casting apparatus comprising a ladle having a hollow interior adapted to receive a molten material therein; a nozzle in fluid communication with the hollow interior, the nozzle having a first portion disposed outside of the ladle and a second portion disposed within the hollow interio; an additive feeder in fluid communication with the hollow interior of the ladle; and a gas conduit in fluid communication with the hollow interior of the ladle.

Abstract: A casting apparatus and a method of forming a casting using the casting apparatus is disclosed, the casting apparatus comprising a ladle having a hollow interior adapted to receive a molten material therein; a nozzle in fluid communication with the hollow interior, the nozzle having a first portion disposed outside of the ladle and a second portion disposed within the hollow interio; an additive feeder in fluid communication with the hollow interior of the ladle; and a gas conduit in fluid communication with the hollow interior of the ladle.