Abstract: The invention relates to a method for producing articles in moulds, the moulds themselves and articles produced by the method and/or in the moulds.

Abstract: A method of automatically counting a number of inclusions by eliminating the effects of shrinkage cavities in the conventional method and securing a high correlation with a value measured by a skilled worker and a casting mold for obtaining a cast sample used for the same are provided. A method of measurement of a number of nonmetallic inclusions comprising capturing an image of a rectangular fracture surface of a cast sample consisting of an aluminum alloy by a CCD camera or other image capturing means, processing the image captured by the image capturing means for color density, digitalizing the processed image by a predetermined threshold value, and counting the number of pixel clusters of a predetermined size or more, the method characterized by detecting the end edges of the short sides of the rectangular fracture surface before the capturing of its image and automatically setting measurement regions of an area of ¼ to ? of the area of the fracture surface at the two ends of the fracture surface.

Abstract: A method for producing wide strips of copper is performed by pouring a molten liquid into a revolving wide strip mold via a distribution container and a pour nozzle. A surface of the molten metal in the distribution container is maintained at a constant level above the place where the pour nozzle is fixed in the distribution container in the range of 75 mm to 90 mm with respect to the level of the bath surface of the mold. The molten metal is guided by an ascending channel from the distribution container to the pour nozzle and is distributed within the pour nozzle symmetrically over a width corresponding to the width of the strip. Within the pour nozzle, the molten metal is guided through first and second flow restrictors and is separated into numerous small individual flows in a vertical direction over the entire strip width of the mold.

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 mould for use in directionally solidifying a component has a casting cavity including a single crystal selector spiral which is a helical passage having not less than 1¼ and not more than 1½ turns.

Abstract: A method and apparatus for forming a sheet are disclosed. A melt is cooled and a sheet is formed on the melt. This sheet has a first thickness. The sheet is then thinned from the first thickness to a second thickness using, for example, a heater or the melt. The cooling may be configured to allow solutes to be trapped in a region of the sheet and this particular sheet may be thinned and the solutes removed. The melt may be, for example, silicon, silicon and germanium, gallium, or gallium nitride.

Abstract: This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.

Abstract: Small, high velocity liquid metal droplets are produced for applications that require the accurate and remote placement of small quantities of a metal. The magnetic pressure of current flowing through liquid metal is used to force small quantities of liquid metal through an orifice. Examples of applications are to feed metal fuel into plasma extreme ultraviolet sources, and to place solder bumps on an integrated circuit prior to the attachment of connections.

Abstract: To cast one or more metal articles, a mold structure is positioned on a support with an anchor extending upward from the support into the mold structure. The mold structure and anchor are interconnected by a retainer which extends through a portion of the mold structure into the anchor. When the mold structure is immersed in a cooling bath, force is transmitted between the mold structure and anchor to retain the mold structure against movement relative to the support.

Abstract: Method for forming directionally solidified articles in tightly packed mold cavities withdrawn into liquid metal cooling bath. The withdrawal rate and the spacing between adjacent mold cavities cooperate to provide a high thermal gradient. The cast articles exhibit primary dendrite arm spacing of between about 6 to about 12 mils (about 150-300 microns).

Abstract: An expendable salt core has the shape of a water jacket by, e.g., die casting using a salt of bromine and at least one of sodium and potassium, and a salt of carbonic acid and at least one of sodium and potassium. The expendable salt core is formed to contain at least one of potassium and sodium as a cation, and bromine and carbonic acid as anions. For example, the expendable salt core is formed by casting using a melt obtained by melting a salt mixture of sodium bromide and sodium carbonate.

Abstract: A foundry shell core includes an outer shell made of a polymerised sand and resin mixture suitable for withstanding the heat and metallostatic pressure produced by molten metal during casting, and of an inner core body made of a material suitable for being thermally dissolved before using the shell core forming an inner cavity inside the core itself that facilitates the intake of smoke and gases produced during the casting. Alternatively, the inner core body is dissolved after the solidification of the casting. The shell cores are obtained by injection with the use of a conventional core box into which the core bodies, previously obtained by a die, have been inserted.

Abstract: A spraying apparatus for forming low-melting-point metal mold. The spraying apparatus includes a frame body having a platform. A close space having an operation area is defined above the platform. An adjustment seat having an operation table is arranged on one side of the platform corresponding to the operation area. The adjustment seat is multidirectionally displaceable and 360-degree rotatable and adjustable in angle. A spraying system is mounted on the other side of the platform. The spraying system includes a material-supplying container, a high-pressure pump and a spraying gun. A temperature-controlling box is disposed on a lower side of the frame body. The temperature-controlling box has a power switch, a first-stage temperature control, a second-stage temperature control and a third-stage temperature control which are respectively electrically connected to the material-supplying container, the high-pressure pump and the spraying gun for heating the same to a set temperature.

Abstract: A mold for creating metal ingots, a hottop sideboard and a system and method of manufacturing metal ingots utilizing the same. A hottop sideboard utilizes a layer of a rigid refractory material integrally connected to a layer a flexible refractory material that is compressed between the rigid layer and the sidewalls of the mold during use. The mold for creating metal ingots comprises: a main body having a floor and sidewalls that form a cavity for receiving a molten metal; a plurality of sideboards connected to the sidewalls and forming a perimeter about the cavity in a spaced relation from the floor, the sideboards comprising a first layer of a rigid refractory material and a second layer of a flexible refractory material, the first layer and the second layer being connected to one another; and the sideboards are secured to the sidewalls so that the second layer is compressed between the first layer and the sidewall.

Abstract: The present invention provides a method for manufacturing a clad material and the equipment for manufacturing the clad material, in which the productivity is excellent, the surface state and the flatness of the clad material can be readily controlled and the deterioration in adhesion rarely occurs in the clad material.

Abstract: Disclosed is a metal-molding conduit assembly, including a body being configured to withstand higher temperatures, from approximately 30 to approximately 40 degrees Centigrade above approximately 650 degrees Centigrade for processing a molding material, and the molding material includes a molten metallic alloy having a light-metal alloy.

Abstract: A metallic, ferriferous permanent mold, especially a permanent steel mold, is provided that can be impinged upon with a liquid or flowable aluminum material, a layer for protecting the permanent form and for obtaining an optimum cast result being producible by means of a mold release agent. The invention also relates to a mold release agent for producing said layer and to a method for producing said layer.

Abstract: A method and apparatus for casting wherein molten metal is treated to create conditions of whole volume solidification in the mold. The treating of the molten metal can include the application of vibration in specified manner under specific frequency and amplitude for causing multiple sites of crystallization throughout the mold, or the treating can be by use of activators which are formed during casting, either directly from the molten metal stream by dispersion or from a mineral which concurrently with casting is milled, to a finely ground powder, dehydrated and fed into the molten metal throughout the metal to speed solidification and crystallization at multiple sites. Solidification speed can be more than doubled while eliminating pouring defects and improving the cast metal structure. The methods are applicable to various methods of casting including continuous casting and the methods of vibrating and use of activators can be combined with improved results.

Abstract: A device is provided for use at temperatures above 1000° C. or in steel melts. The device has a body based on sand, high temperature-resistant hollow balls and/or high temperature-resistant hollow fibers and contains water glass and a cement.

Abstract: A seal, fill head, and system are provided. The seal is adapted to cooperate with a fill head that is configured to place conductive bonding material into cavities on a mold. The seal comprises a first outer wall that is configured to abut a first adjacent wall of a support groove in a fill head. A second outer wall is configured to abut a second adjacent wall of a support groove in a fill head. An outer horizontal wall is situated between the first outer wall and the second outer wall. The outer horizontal wall comprises at least a first portion that is configured to abut an upper portion of the support groove. A convex bottom portion extends from the first and second outer walls. The convex bottom portion is configured to cooperate with a top surface of a mold.

Abstract: A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire.

Abstract: A mold device and a method of manufacturing a cylinder block. The mold device comprises a split core having two first split cores formed so that the tip parts thereof may be in a tapering shape, two second split cores installed between the first spilt cores, and an inner core is installed at the center part and pushing out the first split cores in the direction receding from the center axis thereof. When the inner core is pushed out to push out and position the first spilt cores, both end parts of the second split cores are brought into contact with the tip parts of the adjacent first split cores, and the outer side-faces of the first split cores and the outer side-faces of the second split cores form a cylindrical shape. When the inner core is raised, the first split cores and the second split cores are pulled to the axial center by first engagement pieces and second engagement pieces.

Abstract: A die casting mold includes a resistance member (17) disposed in a vent passage (16) to reduce a flow velocity of molten metal as the molten metal advances along the vent passage. The resistant member comprises a plurality of discrete protrusions (24) arranged in staggered relation to one another in both a longitudinal direction and a transverse direction of the vent passage so as to define therebetween a labyrinthine part (34) extending between an inlet side and an outlet side of the vent passage.

Abstract: A balancing system for different compressors utilizes a counterweight having a common exterior configuration. The mass of the counterweight is optimized for each compressor by changing the size of a recess located in the counterweight. In one embodiment, the recess is an arcuately shaped recess; and in another embodiment, the recess is a plurality of holes.

Abstract: Apparatus and method of co-casting metal ingots in direct-chill casting apparatus. The apparatus and method employs at least one divider (divider member or divider wall) that separates a casting mold into two or more chambers for receiving molten metal that is combined into a single ingot. The divider may be moved, angled and/or flexed during casting to produce ingots that are designed primarily for rolling into thin plate or sheet. The ingot has at least one outer layer that is thicker adjacent to the side (width) edges than in the center, and/or thicker adjacent to the butt or head regions. This compensates for wiping of the outer layer from the ingot core during rolling. Also, the divider may be outwardly bowed outwardly towards one of the mold walls during the casting run.

Abstract: A process of reducing friction, which is encountered in molds utilized in injection molded, solder processing, and wherein glass mold plates have mold pits etched therein. The mold pates are subjected to a heat treatment so as to smooth or round-off sharp edges along the periphery of the mold pits.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: A casting core for a turbine blade includes a plurality of rods extending above a shank. The rods define internal cooling channels in the airfoil of the blade, and the shank defines an inlet channel in the dovetail of the blade. A plurality of stubs are clustered together at a bulb joined to the shank and radiate outwardly to integrally join different ones of the rods for increasing strength of the core.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold. The precision pouring system is driven by a pressure differential.

Abstract: A mold used to manufacture, through metal mold casting, a damper that is fixed onto a housing in a disc drive and reduces a vibration of the housing, the disc drive recording information in and reproducing information from a recording medium. The mold includes a sectionally concave body that defines a shape of the damper, a first gate that introduces molten metal to the body from a runner, and is provided on a first side opposite to a concave of the body, and a second gate that introduces the molten metal to an overflow well from the body, and is provided at least one of a second side perpendicular to the first side, and a third side perpendicular to the second side and parallel to the first side.

Abstract: A spraying apparatus for forming low-melting-point metal mold. The spraying apparatus includes a frame body having a platform. A close space having an operation area is defined above the platform. An adjustment seat having an operation table is arranged on one side of the platform corresponding to the operation area. The adjustment seat is multidirectionally displaceable and 360-degree rotatable and adjustable in angle. A spraying system is mounted on the other side of the platform. The spraying system includes a material-supplying container, a high-pressure pump and a spraying gun. A temperature-controlling box is disposed on a lower side of the frame body. The temperature-controlling box has a power switch, a first-stage temperature control, a second-stage temperature control and a third-stage temperature control which are respectively electrically connected to the material-supplying container, the high-pressure pump and the spraying gun for heating the same to a set temperature.

Abstract: Material is incrementally deposited using material directed toward a deposition zone. The scan path of the directed material is controlled according to a path plan derived to reduce derivation from an ideal uniform temperature profile for the deposition during the deposition process. A path plan having angled scan passes that intersect (or overcross one another), for example in a mirrorbox path plan, is preferred.

Abstract: The specification and drawings present a new method and a system for organizing and structuring a process of tool manufacturing with a reduced lead time. The manufacturing of the component tooling can be applied (but not be limited) to: mold tooling, injection mold tooling, diecast tooling, press tooling, etc. Several techniques or elements are methodically combined with the focus to reduce overall manufacturing time for tooling components comprising (but not be limited to) the following: a) standard parts are designed, pre-manufactured and stocked in a pre-hardened condition; b) custom 3D CAD libraries are created which represent the standard parts and only allow a tool designer to select standard parts which are held as a pre-manufactured stock; c) manufacturing fixtures are utilized which allow consistent and rapid setup of the pre-manufactured standard components for customized machining operations specific to a tool design.

Abstract: Method and arrangement for spray forming an article. The method includes spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article. Each of the plurality of metal streams is composed of moltenized droplets, and as between the plurality of metal streams, each is composed of different constituent elements. In the spray form process, conditions of the metal streams are controlled, particularly around the time that the droplets land, to prevent adverse affects such as melting or burning the master model. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate. The segregated state is maintained through out solidification so that the resulting spray formed article is composed at least partially of psuedo-alloy.

Abstract: An ingot mold for metals which is intended for the production of an ingot through the cooling and solidification of a liquid metal mass. The mold includes a wall which defines a base and an inner surface having a part S, known as the cooling surface, which can discharge all or part of the heat energy released by the metal mass during the cooling and solidification thereof. The cooling surface S includes at least one flat surface element Si which forms all or part of the base (4) of the ingot mold. There is also at least one point C on a plane Pi which is tangential to each surface element Si, such that all of the segments of a straight line D connecting every point R of the cooling surface S to point C are only located inside the mold. Further, the total area of surface elements Si is at least equal to 10% of the surface S. The ingot mold can be used to accelerate the production of ingots.

Abstract: A system and method of solid freeform work piece fabrication through layered deposition of feedstock material on a mold structure. An energy beam and feedstock are fed to a feed point adjacent to a mold structure, thereby forming a molten puddle. The feed point is moved relative to the mold structure, thereby advancing the molten puddle of presently fed feedstock and rapidly solidifying previously fed feedstock. The feed point is sequentially advanced within a predetermined geometric volume containing at least a portion of the mold structure, thereby sequentially fusing the feedstock, by action of the advancing molten puddle, into a near net shape work piece built-up upon the mold structure.

Abstract: A high field contrast magnetic stamper/imprinter for use in patterning of magnetic and magneto-optical (MO) recording media by contact printing, comprises: (a) a layer of a magnetic material having a high saturation magnetization Bsat?˜1.2 and high permeability ??˜5, including a first, topographically patterned surface and a second surface opposite the first surface, the first, topographically patterned surface comprising a patterned plurality of spaced-apart recesses with a plurality of non-recessed areas therebetween, the topographical pattern corresponding to a magnetic pattern to be formed in a magnetic or MO recording medium; and (b) a layer of Ni on the second surface. A corrosion-resistant protective overcoat layer may be present on the topographically patterned surface. A method for manufacturing the stamper/imprinter is also disclosed.

Abstract: A system for incrementally depositing material includes a delivery system for directing a material toward a deposition zone (5), a monitoring system for monitoring a parameter of the deposited (a) material and a processing system (11) arranged to obtain a monitored value for the parameter, derive a predicted future parameter value for the monitored parameter, compare the predicted value with a reference parameter value for the monitored parameter, and produce a control output based on the comparison of the predicted value with the reference value, the control output being capable of modifying operation of the system. The parameter monitored has the tendency to vary over time (and space), and the processing means ensure that control output is not based upon the difference between an originally monitored parameter value and a reference value but rather between a prediction generated value (accounting for passage of time or spacital difference) and the reference value.

Abstract: A twin roll casting machine that can reduce an amount of inert gas to be fed for prevention of oxidization. The machine includes an enclosure enclosing a strip in a range from chilled rolls to pinch rolls, a first swing wall within the enclosure and having a tip end movable toward and away from a surface of the strip, a sealing roll rotatably supported by the tip end of the first swing wall, a second swing wall within the enclosure and having a tip end movable toward and away from the other surface of the strip, a sealing roll rotatably supported by the tip end of the second swing wall, sealing members between peripheral edges of the swing walls and an inner surface of the enclosure, and conduits for supplying inert gas into the enclosure. The respective swing walls are swung to bring the sealing rolls close to the strip to thereby suppress flow of the inert gas from a first space to a second space.

Abstract: A mold and a method of casting a part wherein the casting surfaces of the mold including the nooks and crannies of the mold are bounded by pitted mold surfaces with the pitted mold surfaces having surface voids therein that are sufficiently small to prevent the molten metal to enter therein; however, when the molten metal is poured in the mold having the pitted surfaces the molten metal solidifies on top of the pitted surface without entering into the pits in the mold surface, yet at the same time the molten metal flows smoothly over all the mold surfaces including the structural nooks and crannies of the mold to form a cast product that is substantially free of voids and fissures.

Abstract: A system for incrementally depositing material includes a delivery system for directing a material toward a deposition zone (5), a monitoring system for monitoring a parameter of the deposited (a) material and a processing system (11) arranged to obtain a monitored value for the parameter, derive a predicted future parameter value for the monitored parameter, compare the predicted value with a reference parameter value for the monitored parameter, and produce a control output based on the comparison of the predicted value with the reference value, the control output being capable of modifying operation of the system. The parameter monitored has the tendency to vary over time (and space), and the processing means ensure that control output is not based upon the difference between an originally monitored parameter value and a reference value but rather between a prediction generated value (accouting for passage of time or spacital difference) and the reference value.

Abstract: Spray form cell including a two-wavelength imaging pyrometer adapted to provide real-time measurement of the surface temperature distribution of a metal billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.

Abstract: This invention provides a method and apparatus to produce metal or alloy ingots using spray casting with the features of easy manufacture of large diameter ingots and simultaneously their uniform microstructure due to followings. Firstly, spray deposition area on the top surface of the ingot can be enlarged by making use of multiple gas atomizers and also by controlling the their positions for the spray deposition. Secondly, at the same time, a mutually opposite-directional rotation between the gas atomizers and the catching plate provides a uniform deposition of sprayed droplets along the circumference-wise direction over the entire top surface of the ingot. In addition, a mutually opposite-directional reciprocation between the gas atomizer and the top surface of the ingot provides an enlargement of deposition area and an evenness of spray deposition along the radial direction on the top surface of the ingot.

Abstract: Present invention relates to a method and means for producing moulded bodies of a metal foam (9), in particular an aluminium foam. The Method involves the use of mould (1) having a cavity (8) and at least one entrance opening (3). The mould id filled with a metal foam in a manner where the entrance opening of the mould is submerged into a metal melt (4) and the melt is caused to foam inside the mould (1) and fill its cavity (8).

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: 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: There is claimed a method for depositing fluid material from a linear nozzle in a substantially uniform manner across and along a surface. The method includes directing gaseous medium through said nozzle to provide a gaseous stream at the nozzle exit that entrains fluid material supplied to the nozzle, said gaseous stream being provided with a velocity profile across the nozzle width that compensates for the gaseous medium's tendency to assume an axisymmetric configuration after leaving the nozzle and before reaching the surface. There is also claimed a nozzle divided into respective side-by-side zones, or preferably chambers, through which a gaseous stream can be delivered in various velocity profiles across the width of said nozzle to compensate for the tendency of this gaseous medium to assume an axisymmetric configuration.

Abstract: Spray form cell including a two-wavelength imaging pyrometer adapted to provide real-time measurement of the surface temperature distribution of a metal billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: There provided a powder supply means for supplying a powdery mold releasing agent to a basin and a pressure reduction means for reducing a pressure in a cavity, and in a casting work the powdery mold releasing agent is supplied through a basin into a cavity while reducing a pressure in the cavity.