Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: A method of automatically placing a core package (301) in a mold (505) is provided. Locators (501) and a cavity (503) designed to receive at least a part of the core package (301) are formed in the mold (505). The mold (505) is positioned such that the locators (501) may be illuminated and one or more images are obtained of the locators (501). The images are processed to determine a target location for the core package (301) in the cavity (503), and an automated device (303) places the core package (303) in the mold (505) at the target location.

Abstract: Fluid pressure of a first fluid chamber of a driving means, which acts as a back pressure, is monitored by a monitoring means when a core pin is driven by the driving means in an inserting direction before injection of a molten material into a cavity of a die arrangement. When the monitored fluid pressure of the first fluid chamber exhibits abnormal behavior that is different from normal behavior observed during a normal period, the monitoring means controls the driving means to stop the driving of the core pin in the inserting direction.

Abstract: An apparatus and method for casting metallic components is disclosed. The apparatus has a vertical parting line and a gate configuration which reduces defects within the cast components.

Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.

Abstract: The invention provides a method with which high-quality complex-shaped castings can be manufactured and with which, after the end of the casting process, the casting mould parts can be easily removed out of or from the casting without any risk.

Abstract: A multiple-slide die-casting machine is equipped with improved mechanical structure and unique injection control system to improve the quality of molded products, to achieve flash free castings of improved surface finish. The clamping assemblies are mounted on one side of a base plate of the machine for applying clamping force to the mold sections in a preloaded state. A reinforcement ring interconnects the clamping assemblies to inhibit deflection of the base plate and the brackets which support the clamping assemblies so that an accurate parting line between the contacting surfaces of mold sections is insured.

Abstract: A mold and method for producing a two-stroke engine casing of a radio control model are to define a core cavity and a main cavity in the mold. A first core has a first end inserted into the mold and the core cavity is defined around the first end of the first core for forming a core and simplifying the manufacturing processes. The first core with the core is inserted into the main cavity to from the cylinder of the engine and the blocks of the core define grooves in the inner periphery of the cylinder of the engine.

Abstract: An apparatus for injection-molding products, comprising an injection mold (2) divisible into at least two parts (6, 8) such that consequently at least one mold cavity (14) is cleared, wherein on at least one part of the injection mold guiding means (22) are provided for a transfer device (4) for providing an insert in the mold cavity and/or for taking a product from the mold cavity.

Abstract: A method of automatically placing a core package (301) in a mold (505) is provided. Locators (501) and a cavity (503) designed to receive at least a part of the core package (301) are formed in the mold (505). The mold (505) is positioned such that the locators (501) may be illuminated and one or more images are obtained of the locators (501). The images are processed to determine a target location for the core package (301) in the cavity (503), and an automated device (303) places the core package (303) in the mold (505) at the target location.

Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.

Abstract: Die opening apparatus (50) of a die-casting system (10) is operable to open a die (D1, D2). A first cylinder (51) may perform an initial die opening operation and a second cylinder (55) may perform a subsequent die opening operation. The thrust generated by the first cylinder is preferably directly transmitted to the die in a die opening direction, optionally via a push pin (52).

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus of the present invention may be located adjacent the mold in use.

Abstract: A cast end shield includes an opening extending therethrough and an insert at least partially embedded within the end shield at the opening. The end shield also includes a plurality of slots extending to the insert. In one embodiment, the insert is a substantially circular steel insert ring concentric with the opening and oriented such that an inner diameter of the insert ring is exposed from the end shield.

Abstract: A casting machine is provided for producing an as-cast product by using horizontally split type metal molds, which are closed and held horizontally to define a cavity, and by pouring molten metal from a holding furnace into the cavity. The casting machine includes a metal drag held horizontally at a fixed position; a plurality of upwardly-facing cylinders disposed around the metal drag and mounted on a floor or a base, each cylinder having a cylinder rod that extends and retracts; and a cope die base mounted for vertical movement on the distal ends of the cylinder rods of the upwardly-facing cylinders for horizontally holding a metal cope at a position above the metal drag so that the metal cope is mated with the metal drag to define the cavity when the cope die base is lowered by the upwardly-facing cylinders.

Abstract: The invention relates to a method and tools for producing a braking band (2) of a disk-brake disk (1) by casting, in which the disk comprises at least two plates (3, 3′) connected to one another by connecting elements (4) forming an internal air-duct (7) for the cooling of the braking band (2). With the method and the tools, a disk is produced in which at least one of the plates (3, 3′) has, in its surface (8, 8′) defining the air-ducts (7), at least one groove (10, 10′) having a cross-section which becomes wider towards the air-duct.

Abstract: A casted workpiece includes a wall including passages in the form of a three-dimensional grid. A casted three-dimensional grid coating of the passages is one piece with the remainder of the workpiece.

Abstract: A mold and method for producing a two-stroke engine casing of a radio control model are to define a core cavity and a main cavity in the mold. A first core has a first end inserted into the mold and the core cavity is defined around the first end of the first core for forming a core and simplifying the manufacturing processes. The first core with the core is inserted into the main cavity to from the cylinder of the engine and the blocks of the core define grooves in the inner periphery of the cylinder of the engine.

Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with downwardly converging sides that hold assembled mold and core elements together, without fasteners, during transportation and pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. After the casting is formed, the core sand from both the mold elements and core elements is recovered, and may be recycled and processed to form further mold elements or core elements or both.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: The invention provides equipment for molding castings in a mold having at least one sand core (Na1), in which the positioning of the or each core is obtained by the core co-operating with an element (S) of the mold, in particular a metal mold element. This equipment is remarkable in that the or each core possesses an insert (I) secured to the core while making said core and via which said core is suitable for co-operating with the mold element in question. The invention also provides an associated method of positioning cores. The invention is particularly applicable to improving the positioning of admission pipes in light alloy cylinder heads for engines.

Abstract: In a method of producing a turbine blade in hollow section, an especially low defect or scrap rate is to be ensured. To this end, a first core element is connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements.

Abstract: A disk rotor is produced using pre-forms. A manufacturing device 10 includes lower mold 11 and upper mold 12. The lower mold 11 includes support block 13, main body part of the lower mold 14, inclined pins 15, core elements 16 and slider 17. In securing and supporting pre-forms 4A, 5A, a cylinder 18 is actuated to cause upward movement of the support block 13 and the main body part of the lower mold 14, during which movement, core elements 16 and slider 17 are slid relatively outwards along inclined pins 15. In this state, the pre-forms 4A, 5A are guided to preset sites. The support block 13 and the main body part of the lower mold 14 are then moved downwards, during which movement, core elements 16 and slider 17 are slid relatively inwards along the inclined pins 15. In this state, the pre-forms 4A, 5A are supported and secured stably to define a cavity.

Abstract: A device for casting a workpiece, especially a turbine blade with inner cooling, includes a casting cavity in which casting cores which produce channels that pass through the workpiece are provided. There are no poorly cooled areas present in the workpiece. To this end, the casting cores are placed in the casting cavity in such a way that they rest against each other loosely.

Abstract: A moulding machine for providing flaskless moulds comprising a drag flask (4) and a cope flask (3) is provided with a core setter (40) for placing cores in upwardly facing cavities of a mould located in the drag flask (4). The core setter (40) comprises a core mask (45) with pockets (49) selectively operable to hold and release cores (50), said core mask being supported by a holder (55) that is pivotally journalled around a horizontal axis to swing between a core-releasing position and a core-loading position. The core mask (45) faces downwardly towards the mould when it is in the core-releasing position and faces laterally away from said mould when it is in the core-loading position. The drag flask (4) is arranged to be movable in a substantially horizontal direction to and from a core-setting position directly under the core mask (45) in its core-releasing position. The drag flask (4) is arranged to be movable upwards to and downwards from the core mask (45) when it is in the core-setting position.

Abstract: An interchangeable die system in accordance with the present invention may include two main parts: a shank and a die assembly. The shank is a structural frame that is secured to and remains attached to the die casting machine during a change of the die assembly. The die assembly consists of a die, an adaptor plate and an ejector plate assembly. The die assembly is secured to the shank using the adaptor plate and a locking cam. A spool assembly slides within the shank to actuate the ejector plate assembly.

Abstract: The invention relates to a mould (1) for the manufacture of a casting (2) using moulding material (3). In order to achieve simple and cheap manufacture, the mould (1) is provided with an outer first mould carrier (4), an outer second mould carrier (5), a mould body (6) arranged between said mould carriers (4, 5) and an inner layer (12) of moulding material (3) applied to said mould carrier (6) at least in areas, to form the mould cavity.

Abstract: A sensor for measuring the distance between two surfaces injects pressurized fluid (e.g., air) between the surfaces. The pressurized fluid passes through two flow restrictors prior to reaching the surfaces to be measured. The fluid pressures between the flow restrictors and between the downstream flow restrictor and the surfaces are compared to yield the distance between the two surfaces. An accurate distance measurement can be obtained even where the surfaces to be measured are located in a hostile environment which would destroy many other types of sensors.

Abstract: A mold has outer mold parts and inserted molding material cores. Together, the parts and cores form a mold cavity. The inner cores of molding material are arranged in several layers one above the other. The inner cores are clamped in between the outer mold parts and a final covering core of mold material. A continuous clamping force is applied between the parts and cores. The mold cavity is formed by surfaces of the outer mold, surfaces of the inner cores and the covering core.

Abstract: The number of cores used in casting bolsters and sideframes is reduced. End cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the bolster or sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the bolster or sideframe.

Abstract: The present invention provides a method of casting a sideframe including the steps of dividing the sideframe into design zones, and providing a core module for forming internal surfaces of the sideframe casting in the design zones. The design zones include a right outer leg design zone, a left outer leg design zone, a right tension member design zone, a left tension member design zone, and a bolster opening design zone. The present invention also includes the step of varying at least one core module to correspond with varying sideframe casting geometry in at least one design zone. The core modules include a right outer leg core module, a left outer leg core module, a right tension member core module, a left tension member core module, a right column wall core module, a left column wall core module, and a bolster opening bottom core module. The core modules define internal surfaces of the sideframe casting in their respective design zones.

Abstract: A clamping assembly for providing lock-up pressure between die blocks of a die cast machine includes at least one tie bar engagement mechanism adapted to releasably engage a tie bar of a die cast machine, thereby preventing the tie bar engagement mechanism from sliding with respect to the tie bar. The clamping assembly also includes at least one hydraulic piston assembly having a first end and a second end, wherein the first end is adapted to apply pressure to a die block of the die cast machine when the piston assembly is extended, and wherein the second end abuts the tie bar engagement mechanism when the tie bar engagement mechanism is engaged with the tie bar and the piston assembly is extended.

Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with tapered sides that hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. Although the carrier sides can use a refractory liner, preferably the sides are made of replaceable sheet metal backed by an open structural framework to enhance cooling of the casting. After the casting is formed, the core sand from both the mold elements and the core elements is recovered, and may recycled and processed to form further mold elements or core elements or both.

Abstract: A movable insert for a die-casting mold. The movable insert has a parallel-sided cavity which slidably receives a retractable core. The retractable core is movable between a retracted position within the movable insert to an extended position extending from the movable insert. The retractable core has a connector for its releasable securement to a locator which moves it between the extended and retracted positions. The retractable core is further provided with a sealing member extending thereabout and between it and the sides of the cavity walls. The sealing member provides a slidable seal between the retractable core and the sides of the cavity.

Abstract: Method making a multi-wall ceramic core for use in casting airfoils, such as turbine blades and vanes, wherein a fugitive pattern is formed having multiple thin wall pattern elements providing internal wall-forming spaces of a final core, the pattern is placed in a core molding die cavity having a desired core configuration, a fluid ceramic material is introduced into the die cavity about the pattern and between the pattern elements to form a ceramic core, and the core is removed from the die cavity. The fugitive pattern is selectively removed from the core to provide a multi-wall green core. The green core then is fired to develop core strength for casting and used to form an investment casting mold for casting an airfoil.

Abstract: The number of cores used in casting sideframes is reduced. A pair of end cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the sideframe.

Abstract: Methods and apparatus for forming a plurality of uniformly sized solder balls utilize a stencil having a plurality of holes of uniform volume disposed on a substrate. Solder is disposed in the holes of the stencil on the substrate. Typically, the solder is in the form of solder paste which is distributed into the holes using a squeegee. While within the holes of the stencil on the substrate, the solder is melted to form solder balls. The stencil may then be removed to leave the solder balls on the substrate, or the solder balls may be removed while the stencil remains on the substrate.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: An object of this invention is to provide a connecting rod in which a pair of ball-shanks are connected to a rod main body such that they are axially perpendicular to each other, having a sufficient strength and which can be produced easily and at low cost, and a manufacturing method thereof. The connecting rod of this invention to achieve such an object comprises first and second ball-shanks and a rod main body to which the first and second ball-shanks are connected freely swingably and rotatably. The first ball-shank is connected to the rod main body such that the shank portion is perpendicular thereto, while the second ball-shank is connected to the rod main body such that the shank is in parallel thereto. Further, the rod main body is die cast with a ball portion of each ball-shank inserted as a core.

Abstract: The invention provides a molding die in which a whole or a part of an exclusive portion forming a cavity can be swiftly changed while leaving a general portion in a molding machine. A fixed insert, a movable insert, a pressing plate and a slide core which correspond to an exclusive portion can be automatically attached to and detached from a fixed main die, a movable main die, a pressing rod and a slide holder which correspond to a general portion by an attaching and detaching mechanism. Further, the fixed insert, the movable insert, the pressing plate and the slide core can be integrated in a die close state by a connection mechanism.

Abstract: A toggle mechanism is supported at the front face of the housing and a forward end of the toggle mechanism is connected to a back face of the movable platen. Upon the closing and opening of dies, the toggle mechanism is stretched and contracted to move the movable platen forward and backward along the tie bars. An automatic control device calculates, before the dies are mounted, from a die thickness input and the kind of the dies input, such a stop position for the link housing as impart a target value to the stretching/contraction amount that the toggle mechanism has when the dies are in closed state, and calculates, from the kind of the dies input, an appropriate contraction amount greater than the target value, and the automatic controlling device moves the link housing to the stop position calculated and the toggle mechanism by the appropriate contraction amount calculated.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on an integral crankcase region and one or more locator surfaces on the crankcase region. The barrels are formed by a barrel-forming tool element of a core box. The barrel-forming tool element is configured to also form the locator surface(s) on the crankcase region such that the locator surface(s) is/are accurately positioned relative to the barrels and thus the cylinders formed in the engine block cast in the mold package. The locator surface(s) can be used to locate the engine block casting in subsequent aligning and machining operations without the need to reference a curved surface of a cylinder bore liner.

Abstract: The number of cores used in casting bolsters and sideframes is reduced. End cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the bolster or sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the bolster or sideframe.

Abstract: An expandable mold for use with metals that expand during solidification with the expandable mold having sidewalls that are forcibly laterally separated to thereby expand the mold cavity sufficiently so as to free at least one portion of the cast article from an interference fit with a first portion of the mold to thereby enable removable of the cast article from an interference fit with a further portion of the mold without fracture of the cast article and for forming a smooth surface finish on the cast article.

Abstract: Cost considerations have prevented the use of titanium compressor wheels (1) in automotive air boost devices. A hybrid process is disclosed, wherein a wax pattern used in the investment casting process is intentionally designed not to produce a final (net shape) compressor wheel, but rather, is designed to produce a near net shape pattern including filled in areas (10, 11) which must be subsequently machined or milled away to produce the desired non-pullable shape compressor wheel. Surprisingly, when forming a titanium compressor wheel using the hybrid or two-step process, the technical complexity of each step (pattern forming and machining) is substantially lower, distortion of the wax blades (4) during pattern casting is reduced, casting of titanium is simplified, the process allows itself to be fully automated, and the dimensional accuracy of the final product is greater than with conventional techniques.

Abstract: Disclosed is both a process and apparatus for forming a molded article. The molded article is formed in a vertically potted flaskless mold. The flaskless mold is closed having an opening in the top portion that receives a chill for directing the cooling of the molten metal introduced into the mold cavity. After the molten metal solidifies and before the mold is broken down, the chill is removed for reuse in the process.

Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: A heat sink of metal material, in particular a light metal alloy, for semi-conductor elements or similar components, has plate-like cooling ribs projecting from a base plate at intervals (f) and approximately parallel to each other, protrude with a connection strip into the base plate in which they are cast. A molding tool designed for production of the heat sink includes a casting mold with a mold chamber for the base plate. The mold chamber contains an area to receive the connection strips of the cooling ribs. Two parallel side walls of the casting mold and intermediate layers arranged parallel between them, each defining a receiver gap, are arranged displaceably on at least one shaft passing through them. The walls can be moved to produce the compact casting mold after insertion of the cooling ribs in the receiver gaps.

Abstract: An interchangeable die system in accordance with the present invention may include two main parts: a shank and a die assembly. The shank is a structural frame that is secured to and remains attached to the die casting machine during a change of the die assembly. The die assembly consists of a die, an adaptor plate and an ejector plate assembly. The die assembly is secured to the shank using the adaptor plate and a locking cam. A spool assembly slides within the shank to actuate the ejector plate assembly.

Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.