Abstract: A method is disclosed for making ductile iron castings having thin walls. Molten grey iron (preferably 3.5-4.2%C, 1.5-2.4% Si, and no greater than 0.65% carbide formers) is introduced to a mold assembly and nodularized/inoculated in such assembly prior to passing into the mold cavity of the assembly. The treated molten iron is fed into the mold cavity and into one extremity of a thin space thereof (0.2 inches thick or less and a length of at least 12 times the thickness). The treated molten metal is additionally mixed by vortical or turbulent flow immediately downstream of the treatment chamber as it is being conveyed to the mold cavity. While continuing to feed the treated molten iron to fill the mold cavity, a reservoir of the treated molten iron is created at a midstation of the thin space. The reservoir acts to conserve the heat of the molten metal and thus feed hotter molten metal to the remainder of the thin space and other connected cavity portions.

Abstract: A thin-walled exhaust gas manifold casting structure for an internal combustion engine is disclosed. The manifold is comprised of nodular iron and has walls defining a plurality of inlet ducts interconnecting with a shallow elliptical outlet duct, the walls having a generally uniform thickness in the range of 0.12-0.15 inches. An integrally cast rib extends across at least a plurality of inlet ducts to reduce thermal flexing in service. The rib, subsequent to casting, is bored to define a hollow cylinder having ports communicating with most of the inlet ducts for carrying a secondary air supply.

Abstract: A method of making metal castings is disclosed, and particularly a method for making ferrous castings employing multiple component sand core assemblies. The core assembly is devised to receive a disintegratable strap about one annular outer surface path of the assembly. The strap is drawn tight about the assembly by an automated strapping machine and fused to provide a positive mechanical securement. The strap is preferably arranged coplanar with the outer surface of core prints when used in the assembly. The strapped assembly is placed in any desired orientation within a bonded sand mold and molten metal introduced therein. The molten metal heats the mold and core surfaces and surrounding sand body to such an extent that the strap is volatilized immediately after the introduction of the molten metal.

Abstract: A method of reducing odors resulting from a ferrous metal molding operation is disclosed. A green sand molding mixture is employed having 1-2% by weight volatile organic material. The mold is provided with manifold-type channels each 0.5 inch in diameter which extend between the upper mold surface to a distance 1-2 inches from the mold cavity. The channels are spaced apart a distance 2-10 inches and at least one of the channels is located 2.5 inches from a pouring basin so that during a metal pouring operation all of the gas flows exiting from said channels will be autoignited and reduce odors by at least 50%.