Abstract: A process for manufacturing a cast metal heat exchanger housing (12) for a vehicle heater having a pot-shape housing wall (14) extending in a direction of a housing longitudinal axis (L) and having a plurality of heat transfer ribs (22) extending on an outer side of the housing wall (14) in the area of a circumferential wall (16) and in the area of a bottom wall (18) of the housing wall (14) in the direction of the housing longitudinal axis (L). The process includes metal casting wherein a sprue cross-sectional area including at least some of the heat transfer ribs (22). The cast metal heat exchanger housing has an axial end face formed upon cutting off metallic material that is essentially at right angles to the housing longitudinal axis and extends into an area of at least some of the heat transfer ribs.

Abstract: Methods for manufacturing a dental restoration for a patient and dental ceramics production devices are disclosed. A dental restoration may be designed based on a scan of the patient's mouth, using a CAD software module. The software module may produce conveyor channels for a positive model based on the dimensions of a muffle in relation to the size and shape of the positive model. The conveyor channels may extend at an angle of between 0° and 130° away from an axis of the pressing channel, the axis being located essentially along an isotherm inside the muffle. A docking site may be selected based on a position with the greatest wall thickness of the positive model. The present disclosure allows the creation of a high-quality dental restoration in a very efficient fashion, in particular when lithium disilicate is used as the dental ceramics material.

Abstract: A field of lost pattern casting, and more particularly to a casting tree for lost pattern casting, and also to its method of assembly is provided. The casting tree includes at least one part support, at least one pattern, and at least one first male-female connection connecting the pattern to the part support. The first male-female connection includes an orifice, a peg at least partially inserted inside the orifice, and a film of meltable material interposed at least between an outside surface of the peg and an inside surface of the orifice.

Abstract: A wax mold for investment casting includes a sprue having at least one pattern support. The pattern support includes a plurality of sockets formed therein. The wax mold further includes a plurality of wax patterns. Each wax pattern has a portion received in a respective one of the plurality of sockets to support the wax patterns on the at least one pattern support.

Abstract: A wax pattern forming die to form a wax pattern is first fabricated, and a molten wax is poured into a cavity in the wax pattern forming die to fabricate the wax pattern. Subsequently, the wax pattern is bonded to a casting sprue pattern made of the wax and fabricated separately from the wax pattern to fabricate an integrated pattern, a surface of the integrated pattern is coated with ceramics, sintering is effected, then the integrated pattern is molten and effused to fabricate a mold to cast a casting with a casting sprue. Further, a molten metal is poured into the mold and cured, then the mold is crushed to take out the casting with the casting sprue, and the casting sprue is cut off from the casting with a casting sprue to fabricate a casting.

Abstract: A method for manufacturing a shell mold for the production by lost-wax casting of bladed elements (1) of an aircraft turbine engine, including the following steps: creating an assembly (200) including a wax pattern (100) as well as a device for forming a cup for pouring metal (32b) and having an end surface (40a); depositing a hot wax coating layer on at least one portion of the end surface (40a); forming the shell mold around the assembly (200). In addition, the method includes, between steps b) and c), the implementation of a step of structuring the coating layer intended for reinforcing the adhesion between the layer (46) and the shell mold, and including the production of recesses (62) and projections (60) on the still-malleable coating layer.

Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

Abstract: A fugitive pattern assembly is made by preforming one or more fugitive patterns of an article to be cast, placing the preformed patterns in an injection die, and injecting fluid gating material into the die to form gating connected to the patterns. The fugitive patterns are disposed in end-to-end and/or side-by-side relation and are interconnected by the gating.

Abstract: A method for casting a thrower for a railcar coupler includes creating a mold box that is vertically parted in halves, each half defining a side of a thrower cavity and that includes at least a portion of a sprue at a location above the thrower cavity, the thrower cavity also being oriented vertically; pouring molten metal into the mold box through the sprue and into the thrower cavity while the mold is oriented vertically; and shaking out the mold box to release the thrower after the thrower has cooled. Creating the mold box may be executed through a cold shell process. The halves of the mold box may include reflective images of the sides of two thrower cavities and an ingate connected between the sprue and one of the two thrower cavities.

Abstract: The present invention arranges the part for removing impurities from a molten metal containing a filter holder constituted of a structure containing an organic fiber, an inorganic fiber and thermosetting resin and a heat-resistant filter in the runner of the mold.

Abstract: A method for casting a thrower for a railcar coupler includes creating a mold box that is vertically parted in halves, each half defining a side of a thrower cavity and that includes at least a portion of a sprue at a location above the thrower cavity, the thrower cavity also being oriented vertically; pouring molten metal into the mold box through the sprue and into the thrower cavity while the mold is oriented vertically; and shaking out the mold box to release the thrower after the thrower has cooled. Creating the mold box may be executed through a cold shell process. The halves of the mold box may include reflective images of the sides of two thrower cavities and an ingate connected between the sprue and one of the two thrower cavities.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58,60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.

Abstract: A sprue former of the type used to produce a casting mold includes a generally hollow body or a body having hollow sections. The body includes an inlet forming member and at least one first interface member. The inlet forming member is configured to provide an inlet cavity in the casting mold to enable casting material to enter the casting mold. The first interface members are configured to couple to casting patterns. The casting patterns represent items to be cast. The body can also includes a reservoir forming member and at least one connecting member coupling the reservoir forming member to the inlet forming member.

Abstract: This invention consists of the use of an evaporative foam riser made with expanded polystyrene and with a cavity on top that contains an exothermic mixture. The reaction of the exothermic material, which is set off when it comes in contact with the metal, prolongs the solidification time of the riser thus rendering it more effective.

Abstract: A method for producing dental restoration components includes filling a retort cylinder of a retort system with a forming mass, the retort cylinder being at least partially encircled by a charging body, and hardening the forming mass. After the hardening of the forming mass, the retort cylinder and the charging body are removed from the forming mass, thereby leaving behind a retort. Thereafter, with the assistance of a press blank apparatus, a press blank having an outer contour substantially corresponding to the outer contour of the charging body is pressed into the retort.

Abstract: Pattern for the lost foam casting process including a pouring-basin-foming portion, a sprue-forming portion, a runner-forming portion, a gate-forming portion, and a riser-forming portion. The sprue-forming portion forms an inverted conical sprue having a blade-lightener therein for quickly filling, and substantially simultaneously firing, the gates. A glue joint may be used between the pouring- basin-forming portion and the sprue-forming portion to increase the residence time of the melt in the pouring basin. The runners formed by the pattern each have an inline riser through which melt flows during pouring and in which melt is stored to feed the casting with melt during shrinkage of the casting A sand dam surrounds the mouth of each gate and traps particulates from a liquid styrene layer that precedes the melt front in the riser.

Abstract: A sprue structure is specifically designed to facilitate the rapid filling of molded polystyrene patterns with molten metal. It comprises a down sprue and parallel columnar members that are connected to the down sprue. The flow of molten metal is initially downward through the first columnar member and then it reverses direction to flow upwardly through second and third columnar members so that the patterns to be cast receive molten metal as it travels upwardly through the second and third columnar members. This decreases the amount of pyrolyzation products that could otherwise flow through in-gates and into the patterns to be cast.

Abstract: A gating system for adding an alloying material to a molten base metal in immediate connection with a casting process. The gating system has a runner having an inlet whose cross-sectional area is throttled, a reaction chamber whose sectional area varies along the height of the reaction chamber as a function of the teeming rate, and a pressure and mixing chamber which is connected after the reaction chamber and provided with a partition. This results in a constant alloying material content of the metal being obtained at a varying teeming rate during the casting process.

Abstract: A high pressure die casting method including providing first and second accumulator assemblies, wherein the first accumulator assembly provides pressurized fluid toad die assembly while the second accumulator assembly provides pressurized fluid to remaining portions of the die casting machine. A barrel insert loader inserts cylinder barrels into the die assembly, and then the dies are closed to permit molten aluminum to be injected therein and thereby form the cast engine block. The dies include side gates and sub-gates through which molten aluminum is introduced into the mold. The dies are opened, and the cast engine is removed from the dies by operation of a robot arm, and a die spraying assembly is inserted between the open dies and sequentially sprays the dies, to clean and cool the dies in preparation for a subsequent casting operation.

Abstract: Apparatus for the gravity-cast, “lost-foam” casting of metal castings, including a fugitive, pyrolizable foam pattern forming a casting cavity in a bed of loose sand, and a hollow sprue for supplying melt to the casting cavity, wherein the sprue consists essentially of the same metal as is being cast. A high-temperature, porous vent is provided adjacent the discharge end of the metal sprue to expel air from the sprue that would otherwise be trapped therein.

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: Apparatus for the gravity-cast, bottom-fill, “lost foam” casting of metal castings, including a fugitive, pyrolizable pattern (for forming a casting cavity), and a hollow sprue (for conducting melt to the casting cavity) embedded in a bed of loose sand. The sprue is free from pyrolyzable foam and conducts melt from above the pattern to a gating system supplying melt to the pattern. The sprue is constructed so as to cause the melt to approach the gating system from beneath and keep any pyrolysis products from entering the sprue.

Abstract: The invention relates to a camshaft made of cast steel having an inner cavity with a cylindrical inner shape, especially a profiled cylindrical inner shape produced rationally according to a lost-foam casting method known per se. A steel camshaft thus produced exhibits a long service life and can withstand extremely high hertzian surface pressures on its bearing surfaces without any damages.

Abstract: Apparatus for forming a pour hole and main sprue in an investment mold for lost wax casting. A sprue having a flared base, a base member adapted to receive the flared base of the sprue for vertically supporting the sprue, and a flask for containing investment material immersing the sprue, define the casting apparatus of the present invention. The present investment casting sprue apparatus forms a pour hole in the hardened investment material suitable for smoothly introducing liquid metals into the cavity formed by the sprue, thereby reducing the number of casting defects related to turbulent filling. This is accomplished as a result of the flared base of the sprue, which forms a gentle transition into the sprue. The current practice, by contrast, uses a sprue having a cylindrical base which is simply inserted into a hole in a finger or button formed in the supporting base member for the sprue without regard to this smooth transition.

Abstract: A riser sleeve apparatus (10) for preparing and insulating a passage (14) within which molten metal is accumulated prior to its movement into a mold cavity which includes an inner surface (12) which longitudinally extends between a first end (16) and a second end (18) wherein the inner surface bounds the passage. The riser sleeve further includes an annular lip (20) which is positioned adjacent the second end and extends inward into the passage. When the riser sleeve is positioned about a plug of a pattern, the annular lip deforms to seal the passage at the second end. A process for forming a cast metal article using said riser sleeve apparatus. A process for forming the riser sleeve apparatus.

Abstract: A riser sleeve apparatus (10) for preparing and insulating a passage (14) within which molten metal is accumulated prior to its movement into a mold cavity which includes an inner surface (12) which longitudinally extends between a first end (16) and a second end (18) wherein the inner surface bounds the passage. The riser sleeve further includes an annular lip (20) which is positioned adjacent the second end and extends inward into the passage. When the riser sleeve is positioned about a plug of a pattern, the annular lip deforms to seal the passage at the second end.

Abstract: A process of positioning a riser sleeve about a plug of a mold cavity pattern. The riser sleeve is positioned to engage the plug to prevent sand from entering the interstitial space between the riser sleeve and the plug. The riser sleeve may comprise a deformable annular lip for engagement with the perimeter of the plug. The riser sleeve may engage the plug in sealing relationship.

Abstract: Apparatus for forming a pour hole and main sprue in an investment mold for lost wax casting. A sprue having a flared base, a base member adapted to receive the flared base of the sprue for vertically supporting the sprue, and a flask for containing investment material immersing the sprue, define the casting apparatus of the present invention. The present investment casting sprue apparatus forms a pour hole in the hardened investment material suitable for smoothly introducing liquid metals into the cavity formed by the sprue, thereby reducing the number of casting defects related to turbulent filling. This is accomplished as a result of the flared base of the sprue, which forms a gentle transition into the sprue. The current practice, by contrast, uses a sprue having a cylindrical base which is simply inserted into a hole in a finger or button formed in the supporting base member for the sprue without regard to this smooth transition.

Abstract: A riser sleeve has a sleeve body and an evaporative pattern fit into the sleeve body to pass through a side wall thereof. The evaporative pattern is shaped to enable the casting, integrally with the riser cast by the sleeve body, of a projecting portion capable of receiving a wedge blade of an openable wedge blade type riser breaker. Even a top riser can therefore be broken off of the main casting at a neck portion by an opening force applied to the wedge blades of the riser breaker without the use of a special jig.

Abstract: A method and machine for forming an open riser in a mold includes a resiliently compressible plug received into the upper end of a riser sleeve, which projects above the riser sleeve and cope sand level so as to be advanced into the riser sleeve during squeezing of the mold sand. The plug is fixed to the upper squeeze plate to be withdrawn from the riser sleeve as the squeeze plates are separated, creating an open riser.

Abstract: The casting assembly includes a horseshoe shaped casting ring having a plurality of handling posts; a horseshoe shaped crucible former having a flange for retaining the casting ring and a top surface for supporting the casting ring; and a pair of tongs having a plurality of openings, each of the openings adapted to receive one of the handling posts.

Abstract: A mold assembly and sprue configuration for dental investment casting includes a ring shaped casing, a base and a cover all made of resilient plastic material and fictionally engaged with each other. The base includes a raised neck having a top surface with a sighting bead for use in mounting wax forms on the sprue, positioned within the casing. The sprue includes a post for engaging a blind bore in a hub of the base. The cover includes a downwardly extending plug which extends into the body of the casing, and a curved lip with recess for facilitating the pouring of investment solution into the mold. The sprue has three spokes and a ring which are all triangular in cross-section to reduce the amount of metal needed in the precision casting to be made with the invention and also to provide a convenient flat upper surface for mounting wax forms to the sprue.

Abstract: The apparatus includes a rubber base with two inlets, a two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of the crucible is achieved by using a specially constructed two-head torch.

Abstract: Method of multi-color jewelry items production is based on a simultaneous casting of two metal alloys of different colors (yellow-red, white-yellow, etc.), as well as two different metals, with a purpose of obtaining jewelry art-works of high-quality and unique artistic impression. To serve that purpose, the following apparatus has been constructed: rubber base with two inlets, two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of crucible is achieved by using a specially constructed two-head torch. Usage of this invention in the process of jewelry work casting ensures a unique natural effect of smooth transition from one color to another in a jewelry piece (ring, brooch, pendant, charm, etc.

Abstract: A spruing assembly for receiving investment material in the production of an investment mold for castings by the "lost wax" process which includes a hollow chamber to receive the investment material. Included within the chamber is one or more sprue for supporting the wax pattern(s) to be cast and one or more corresponding predetermined shaped reservoir(s) being slidably moveable up or down the sprue to create the heat center of the investment mold. Where a long span casting is to be produced all the reservoirs are connected to form a continuous reservoir or Feeder Bar which conforms to the curve of a long span dental arch. A base member is provided within the chamber for supporting the sprue.

Abstract: An automatic matchplate molding machine, used to form sand cope and drag molds, includes a basin former to create a pouring basin in the cope mold. The basin former includes a two-piece liner, one of the pieces being a relatively short and inexpensive plastic sleeve which may be replaced at a relatively low cost when wear occurs. Air passages in the liner channel air into the center of the liner, creating a swirling air current, thereby blowing loose sand out of the liner.

Abstract: A basin former on a squeeze plate coacts with a sprue former on a pattern plate to form a pouring basin and a sprue in a sand mold. Sand which enters the basin former during formation of the pouring basin is ejected upwardly therefrom by pressurized air which is introduced into the basin former through an opening in the side of a plastic liner located in the basin former. The squeeze plate is modular in nature in that the basin former may be attached to the squeeze plate at any selected one of several locations without need of disconnecting and re-connecting the source of pressurized air when the position of the basin former is changed.

Abstract: The tube is at least two inches long and has successive sections of progressively smaller diameters to produce a correspondingly shaped sprue passage communicating with a pattern cavity in a casting investment, so that fluid casting material passes with increasingly fluid velocity between an inlet and outlet of the sprue passage during the casting process. A bulbous portion of the tube is spaced from its free end, to form a reservoir chamber in the sprue passage, spaced sufficiently from the pattern cavity, so that casting material flowing through the sprue passage attains maximum velocity at the outlet of the passage entering the pattern cavity.

Abstract: A metal casing pattern of expanded thermoplastics material such as polystyrene or polymethyl methacrylate has a filter comprising a porous ceramic body, such as a body having pores extending from one face to another face or a foam structure, incorporated therein.

Abstract: A plastic base for use with a cylindrical flask for the elimination of wax patterns prepared for making metal castings by the lost wax process is identified. The base is made of a plastic material which is used in place of conventionally found rubber bases. The base is constructed of a thin-walled resilient plastic material and allows for direct set up of the wax patterns, as well as increased speed in the preparation of the plaster mold in the cylinder for making metal castings. The plastic base comprises an inner annular raised platform comprising a shoulder and the cylindrical flask is pressed on the shoulder deforming the plastic about the bottom edge of the flask to form a seal between the base and flask.

Abstract: An apparatus for the preparation of a dental casting from a dental pattern utilizing an exothermic investment material which expands upon curing which comprises a base having a top surface for supporting the dental pattern and a container having a first and a second open end. The container and the base partially enclose the dental pattern when the first open end of the container is disposed upon the top surface of the base. The second end of the container enables the introduction of the exothermic investment material to compeletly encompass the dental pattern. The container comprises a first and a second container portion with each of the first and second container portions having a first and a seond terminating edge. The first and second terminating edges of the first container portion respectively cooperate with the second and first terminating edges of the seocnd container portion for retaining the uncured exothermic investment material within the container.

Abstract: An improved sprue pin for producing castings by the lost wax method wherein the sprue pin gradually decreases in external circumference toward the tip of the sprue. The length and gauge of the sprue is such that it provides acceptable flow rates and solidification times for new base metal and palladium alloys. A set of lines about the circumferentially decreasing tip allows the user to conform the sprue to the size of the wax pattern being used to form the casting.

Abstract: A lost foam casting system (2) includes a sprue (8) have a receiving portion (56) for receiving molten metal (14) from a source (16), a distribution portion (58) with a plurality of radial fingers (59-62) for distributing the molten metal (14) radially outwardly, and a lower section (63) having a plurality of feed passages (35-38) receiving molten metal (14) from the respective radial fingers (59-62) and interconnected by thin flat support walls (39-42) providing a relatively rigid structure. Workpieces (18 and 20) and in-gates (23-25 and 26-28) are connected to the flat exterior surfaces (39 and 41) of the lower section (63) of the sprue (8) and fed with molten metal (14) from respective feed passages.

Abstract: A method, apparatus and feeder sleeves are described for producing casting moulds having feeder sleeves incorporated therein in instances when the mould pattern plate or the cope mould are not accessible. Two part feeder patterns having a lower part and an upper part and feeder sleeves whose lateral surface tapers from the bottom and to the top end of the sleeve are used. For moulds having a side feeder the lower part of the pattern produces a depressed seating surface for the feeder sleeve in the drag mould and the upper part which has substantially the same taper as the taper of the feeder sleeve and dimensions greater than the corresponding dimensions of the lateral surface of the feeder sleeve produces a cavity in the cope mould. The cope and drag moulds are closed in such a manner that the central vertical axis of the cavity in the cope mould is in line with the central vertical axis of the feeder sleeve, and there is a gap between the wall of the cavity and the outer lateral surface of the sleeve.

Abstract: An investment casting mold base has an enlarged, ellipsoidal-shaped body overlying a frusto conical-shaped body on the base. The enlarged body will form a molten metal staging cavity between a funnel cavity at the entrance of the mold formed by the frusto conical body and sprue channels leading to the article cavity in the mold. The staging cavity eliminates backup of molten metal at the mold entrance and possible spillover of the metal from the crucible mated to the mold during the centrifugal casting operation.

Abstract: Gate is a wax structure for forming part of a wax master in investment casting of a dental prosthesis. The gate has a square feeder with a circular disc on each end. The square feeder reduces the cracking stresses between adjacent feeders to reduce unwanted fins, and the square shape aids in final cutoff of the cast prosthetic. In the wax master, one of the discs is secured to the prosthetic form and the other disc to the conventional reservoir bar. The disc shape aids in filleting to the form and bar.

Abstract: An improved wax master tree used for precision casting is provided. The tree comprises a sprue rod and a plurality of wax masters attached to the sprue rod by fusing. In the improved wax master tree of the invention, the sprue rod is made of a substantially rigid material having a sufficient mechanical strength and withstanding to retain its integrity during the dewaxing step, and has a contour of generally tubular shape with the wall provided with a number of pores and covered with a wax covering layer. The rigidity of the tubular member ensures easy handling of the tree without the fear of damage during the handling operations. By the provision of hollow core portion internally of the tubular member having a wall provided with a number of pores, the risk of cracking of the ceramic shell mold applied on the wax master tree at the dewaxing step caused by the adverse affect of thermal expansion of the wax can be avoided.

Abstract: The apparatus comprises an expandable investment ring having a removable base. Formed on the top surface of the base, and within the void defined by the ring, is an indexed sprue former. A curved runner bar having an indexed coping is formed at one end thereof in mating relation to the sprue former. The curved full arch runner bar comprises a proximal end portion and distal end portion with the distal end forming a first and second curved configuration portion which together approximates the curved configuration of the jawbone of a patient. The first and second curved configuration portions are interconnected thereby resulting in extremely accurate full arch base metal castings. The apparatus is also useful for preparing precious metal castings.