Abstract: A method and system for eliminating near-surface porosity and surface tear defects in metal castings. The system includes a complex casting mold having at least one core pin or other regions susceptible to new surface porosity and surface tears. The system further includes a copper rod fused internally to the core pin to extract heat from a molten metal introduced in the mold. The copper rod extracts heat at a low thermal flux, preventing near surface porosity and surface tears. Moreover, the copper rod extracts heat from the hotter regions of the casting causing it to solidify at a rate comparable to the rate of solidification of other portions of the casting, thereby allowing uniform solidification of the casting.

Abstract: A numbering device is disclosed for marking molded cast parts, the device including a plurality of concentric cylinders having indicia disposed on an end thereof, the cylinders being rotatingly indexable to cause the indicia to move as desired to form the desired mark, the mark is then impressed into a sand mold and subsequently reproduced on the cast part.

Abstract: A crankshaft casting pattern insert 10 which includes selectively adjustable portions 14, 16, which respectively correspond the front and rear main bearing journal portions of the crankshaft. Each adjustable portion 14, 16 includes a removable insert or member 18, a key member 20, several “vertical” spacers 22, several “lateral” spacers 24, and a fastener 26. Adjustable portions 14, 16 allow the pattern 10 to be selectively modified in shape, effective to compensate for pattern wear and to allow multiple crankshafts to be produced which have a substantially similar balance capability. Pattern 10 may also include several validation pads or points 50 which allow the produced crankshafts to be measured with improved accuracy.

Abstract: A chill device for combination with a vaporizable pattern for casting metal by a lost foam process comprises a chill body receivable within a bore of the pattern and including a plurality of outwardly extending fins. The fins define channels therebetween for packing with mold sand to shape the cast metal and for venting pattern decomposition vapors during casting to avoid pore-forming entrapment in the cast metal. Also, the fins contact the bore surface to conduct heat into the chill body from the cast metal about the bore to accelerate solidification and thereby reduce shrink porosity. Thus, the chill device of this invention produces pore-free metal in the casting region immediately about the bore.

Abstract: A casting-marking apparatus is adapted for incorporation in a permanent foundry pattern of the type used to produce sand molds for metal casting. The apparatus carries a marking that is impressed in the sand old and subsequently reproduced on a casting. The apparatus is designed and constructed so that the marking that it carries can be altered from a station remote from the pattern. In the apparatus, the alterable marking is carried by a marking body that is rotated by an air actuated piston.