Abstract: A tundish, in particular a tundish for continuous steel casting for placement between a steel casting ladle and a continuous casting mold, with an inlet region and an outlet region, wherein in the inlet region, molten steel can be supplied in particular through a ladle shroud and in the outlet region, the molten steel can be drained from the tundish in particular by means of a plug and an outlet opening; in the vicinity of the inlet region in the tundish, a threshold or ramp is provided, which forms a region of the tundish bottom into a cup or tundish; the threshold or ramp has at least one channel at the side, which locally reduces the height of the threshold or ramp or breaks through the threshold.

Abstract: A coupling device is fixed to a ladle shroud for reversibly coupling an inlet orifice of said ladle shroud to a collector nozzle fixed to the outside of a bottom floor of a ladle in a metal casting installation, by means of at least a first and second elongated latch pivotally mounted on a hinge, such that the latch can pivot from a fixing position to an idle position. The idle position of the latches allows the engagement of the ladle shroud into its casting configuration about the collector nozzle, and the fixing position of the latches engages catches provided on said latches into matching fasteners located on the gate frame holding the collector nozzle.

Abstract: Described herein is a crucible with a rod fused thereon to optimize pouring of molten material, and method of using the same. The crucible has a body configured for receipt of an amorphous alloy material in a vertical direction, and the rod extends in a horizontal direction from the body. The body of the crucible and the rod are formed from silica or quartz. The rod may be fused to the body of the crucible and provided off a center axis so that pouring molten material is improved when the crucible is rotated.

Abstract: A casting apparatus having a main chamber connected to at least one casting tower. The main chamber may contain molten metal and the temperature within the main chamber may be maintained by a furnace. A pump may pump the molten metal up the tower and into an upper pool chamber. A feeder nozzle may feed the molten metal from the upper pool chamber and onto a chilling wheel, which may turn the molten metal into metal flakes.

Abstract: Methods and apparatus for forming high aspect ratio metallic glass, including metallic glass sheet and tube, by a melt deposition process are provided. In some methods and apparatus a molten alloy is deposited inside a tubular channel formed by two concentrically arranged substrates, and shaped and quenched by conduction to the substrates in a manner that enables the molten alloy to vitrify prior to undergoing substantial shear flow. The deposition method allows the molten alloy to be deposited and formed while being quenched, without undergoing substantial shear flow.

Abstract: A method of automatically pouring molten metal from a ladle into a mold by tilting the ladle. In the method, the height of molten metal located above a molten metal outlet and the weight of molten metal flowing out of the ladle are estimated using an expanded Kalman filter on the basis of: the weight of the molten metal flowing out of the ladle, said weight being measured using a load cell; the voltage inputted to a servo motor; the angle of tilt of the ladle measured by a rotary encoder; and the position of the ladle in the lifting and lowering direction thereof. The sum of the weight of the molten metal flowing out of the ladle when the ladle is tilted rearward, said weight being estimated from the angle of tilt of the ladle and the height of the molten metal located above the molten metal outlet estimated by the expanded Kalman filter, and the weight of the molten metal flowing out of the ladle estimated by the expanded Kalman filter are estimated as the final weight of outflowing molten metal.

Abstract: A casting system and method. The casting system can include an energy source and a hearth, which can have a tapered cavity. The tapered cavity can have a first end portion and a second end portion, and the tapered cavity can narrow between the first and second end portions. Further, the tapered cavity can have an inlet at the first end portion that defines an inlet capacity, and one or more outlets at the second end portion that define an outlet capacity. Where the cavity has a single outlet, the outlet capacity can be less than the inlet capacity. Where the cavity has multiple outlets, the combined outlet capacity can match the inlet capacity. Further, the cross-sectional area of the tapered cavity near the inlet can be similar to the cross-sectional area of the inlet.

Abstract: A casting apparatus having a main chamber connected to at least one casting tower. The main chamber may contain molten metal and the temperature within the main chamber may be maintained by a furnace. A pump may pump the molten metal up the tower and into an upper pool chamber. A feeder nozzle may feed the molten metal from the upper pool chamber and onto a cooling wheel, which may turn the molten metal into metal flakes.

Abstract: A casting method includes coupling a mold to a crucible, the mold having one or more part-defining cavities and one or more feed passageways. A first rotating of the crucible and mold pours molten metal from the crucible through the one or more feed passageways into the one or more part-defining cavities. A second rotating of the crucible and mold returns molten metal from the one or more feed passageways, while leaving the part-defining cavities filled.

Abstract: A system and method for continuous casting. The system includes a melt chamber, a withdrawal chamber, and a secondary chamber therebetween. The melt chamber can maintain a melting pressure and the withdrawal chamber can attain atmospheric pressure. The secondary chamber can include regions that can be adjusted to different pressures. During continuous casting operations, the first region adjacent to the melt chamber can be adjusted to a pressure that is at least slightly greater than the melting pressure; the pressure in subsequent regions can be sequentially decreased and then sequentially increased. The pressure in the final region can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melt chamber and the withdrawal chamber, which can prevent infiltration of the melt chamber by non-inert gas in the atmosphere, and thus can prevent contamination of reactive materials in the melt chamber.

Abstract: Exemplary embodiments described herein relate to methods and systems for casting metal alloys into articles such as BMG articles. In one embodiment, processes involved for storing, pre-treating, alloying, melting, injecting, molding, etc. can be combined as desired and conducted in different chambers. During these processes, each chamber can be independently, separately controlled to have desired chamber environment, e.g., under vacuum, in an inert gas environment, or open to the surrounding environment. Due to the flexible, independent control of each chamber, the casting cycle time can be reduced and the production throughput can be increased. Contaminations of the molten materials and thus the final products are reduced or eliminated.

Abstract: An arc melting furnace apparatus is provided which reduces an operation burden on a worker and shortens working hours. An arc melting furnace apparatus 1 includes a housing 2 having formed therein a melting chamber 2a, a hearth 4 provided within the melting chamber 2a and having a recessed portion 4a, and a heating mechanism 10 for heating and melting a metal material supplied into the recessed portion 4 to generate an alloy ingot. The apparatus comprises a turning member 23 rotatably supported on a supporting member 21 standing within the melting chamber 2a, a perimeter edge of the turning member 23 rotating and moving along the inner surface of the recessed portion 4a to lift the alloy ingot generated in the recessed portion 4a above the hearth 4 and turn it over, and a resilient turn-over assisting member 24 provided above an upper end of the recessed portion 4a.

Abstract: Described herein is a method of selectively depositing molten bulk metallic glass (BMG). In one embodiment, a continuous stream or discrete droplets of molten BMG is deposited to selected positions. The deposition can be repeated as needed layer by layer. One or more layers of non-BMG can be used as needed.

Abstract: A new anchoring mechanism for the mold-crucible set to the tube, to which the cable is to be welded is described, and the inclusion and use of some bushings which are inserted between the cable and the mold.

Abstract: A cast steel railway wheel includes a hub that has an axial bore. A rim is concentric with the bore. A plate extends substantially radially from the hub to the rim. The plate has a front face and a rear face. The plate has a plurality of spokes that extend between the hub and the rim. Adjacent spokes have different thicknesses defined between the front face and the rear face.

Abstract: The teachings provide a fill tube assembly for a casting mold and methods of using the assembly. The fill tube assembly includes a fill tube having a tubular member with a receiving end, a mold-engaging end and an intermediate portion. The mold-engaging end has a tapered flange radially extending therefrom, the remainder of the tubular member has a substantially, uniform cross-section. A clamping assembly is structured to maintain a substantially leakproof seal at the fill tube, casting mold interface while accommodating dimensional variations. The clamping assembly includes a gasket, a load ring, a clamping plate and a pre-load gap between the clamping plate and the casting mold and optionally includes a dimensional compensating ring. When tightened, the clamping plate biases the load ring against the flange thereby distributing a uniform load against the casting mold, compressing the gasket therebetween while narrowing the pre-load gap to accommodate dimensional variations.

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: A mold system and method for producing a casting. The mold system utilizes multiple channels, each channel comprising a sprue and gating system, to feed the mold cavity at different heights. When a lower portion of the mold is filled, a controller is signaled to initiate filling of the mold through a second channel positioned above the lower portion. This mold system desirably provides the hottest molten metal to the last portion of the casting to freeze with or without the use of risers, eliminating casting defects. The system also enables the controlled pouring of dissimilar metal castings.

Abstract: A casting die comprises a main cavity, a first reservoir and a first vent. The main cavity has a first interior volume for receiving a first molten volume of metal. The first reservoir is in serial fluid communication with the main cavity for storing a first molten backfill volume of metal to accommodate solidification shrinkage in the main cavity. The first vent is in serial fluid communication with the first reservoir.

Abstract: A casting apparatus and a method of forming a casting using the casting apparatus is disclosed, the casting apparatus comprising a ladle having a hollow interior adapted to receive a molten material therein; a nozzle in fluid communication with the hollow interior, the nozzle having a first portion disposed outside of the ladle and a second portion disposed within the hollow interio; an additive feeder in fluid communication with the hollow interior of the ladle; and a gas conduit in fluid communication with the hollow interior of the ladle.

Abstract: An automatic pouring method without using a servomotor having a vertical output shaft, establishing the pouring at a low level, eliminating the unstable pouring, sand inclusion, and gaseous defects. An automatic pouring method using a ladle to be tilted for pouring molten metal into a pouring cup of a flaskless or tight-flask mold in at least one pouring device movable along an X-axis parallel to a molding line in which the mold is transferred, wherein the ladle is moved along a Y-axis perpendicular to the molding line in a horizontal plane and is tilted about a first axis of rotation and further about a second axis of rotation.

Abstract: A mold including a product cavity that is to be filled with a molten metal to mold a product; a supply cavity that connects to one side of the product cavity to supply the product cavity with the molten metal that is poured from a casting port; and a cooling cavity that connects to the other side of the product cavity and in which the molten metal filling the cooling cavity is cooled before the molten metal filling the product cavity and the supply cavity is cooled. A modulus M (=V/S) as a ratio of a volume V to a cooling surface area S in each of the cavities has a relation of Ms>Mp>Mc, where Mp is a modulus of the product cavity, Ms is a modulus of the supply cavity, and Mc is a modulus of the cooling cavity.

Abstract: An automatic pouring method without using a servomotor having a vertical output shaft, establishing the pouring at a low level, eliminating the unstable pouring, sand inclusion, and gaseous defects. An automatic pouring method using a ladle to be tilted for pouring molten metal into a pouring cup of a flaskless or tight-flask mold in at least one pouring device movable along an X-axis parallel to a molding line in which the mold is transferred, wherein the ladle is moved along a Y-axis perpendicular to the molding line in a horizontal plane and is tilted about a first axis of rotation and further about a second axis of rotation.

Abstract: Disclosed is a mold 10 for forming cast rods including: a segment assembly 12 including a plurality of segments 14 being placed side by side, and a plurality of cavities 26 extending along a longitudinal direction 16; and clamping means (18 to 21) for clamping the segment assembly 12 in directions orthogonal to the longitudinal direction 16. The mold 10 has one or more cavity-forming portions 28 each forming a part of one of the peripheral surfaces of the cavities 26. Each cavity 26 is formed by a combination of two or more segments 14, and at least one of the plurality of segments 14 has two or more cavity-forming portions 28.

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 fill tube assembly is for a casting mold. The fill tube assembly includes a fill tube having a tubular member with a receiving end, a mold-engaging end and an intermediate portion. The mold-engaging end has a tapered flange radially extending therefrom, the remainder of the tubular member has a substantially, uniform cross-section. A clamping assembly is structured to maintain a substantially leakproof seal at the fill tube, casting mold interface while accommodating dimensional variations. The clamping assembly includes a gasket, a load ring, a clamping plate and a pre-load gap between the clamping plate and the casting mold and optionally includes a dimensional compensating ring. When tightened, the clamping plate biases the load ring against the flange thereby distributing a uniform load against the casting mold, compressing the gasket therebetween while narrowing the pre-load gap to accommodate dimensional variations. A method of use is also disclosed.

Abstract: An apparatus and method for manufacturing a down hole tool that reduces manufacturing costs and enhances the tool's performance. A belted mold assembly includes a casting assembly, a belt assembly, and a mid-belt. The belted mold assembly is used to fabricate a casting that allows for a larger diameter blank to be used which displaces the more expensive casting material and for using a smaller outer diameter thin-walled mold. The casting assembly is disposed within the belt assembly and the mid-belt is loaded in the volume created between the casting assembly's outer surface and the belt assembly's inner surface. The mid-belt provides a bracing for the casting assembly during the casting process. Optionally, a cap can be disposed on top of the blank for preventing metallurgical bonds from forming between the binder material and the upper portion of the blank. This allows for the excess binder material to remain high in purity so that it can be reprocessed.

Abstract: A dual temperature mold assembly for maintaining a mold cavity used in a cast on strap process at two different temperatures facilitates the removal of the solidified strap after the molten metal is solidified. The mold assembly includes a mold cavity having walls attached to different mold assembly segments that are heated or cooled by thermal energy input and coolant processes which can maintain the mold cavities at different temperatures, so that molten metal around the battery plate lugs in a mold cavity segment is solidified while the sides of the mold cavity are exposed to at least one adjacent heated segment to provide thermal energy thereinto, resulting in a reduction of the amount of molten metal necessary for a cast on strap, and reducing the amount of thermal energy input into the process for manufacturing the straps.

Abstract: Method and system for providing volume manufacturing of customizable items including receiving a data package including a plurality of manufacturing parameters, each of the plurality of manufacturing parameters associated with a unique item, verifying the received data package, and implementing a manufacturing process associated with the received data package is provided.

Abstract: A casting apparatus includes a hermetically sealed chamber, wherein the chamber includes: a melt-heating portion to melt external uranium deposits, the melt-heating portion being tiltable to allow the resulting liquid molten material to be discharged to the outside, an ingot-forming portion to receive the molten material discharged from the melt-heating portion and to cool-solidify the molten material, and a salt-capturing portion provided on the melt-heating portion, to solidify a salt gas produced when the uranium deposits are molten, and thereby recover the salt gas, wherein the ingot-forming portion includes: a horizontal turn-table rotated by an operating means, and a plurality of molds mounted on the edge of the turn-table, each containing the molten material, which is then cooled.

Abstract: A metal mold casting machine for a casting apparatus with which the worker can easily carry out his or her work, such as setting a core, cleaning a mold, taking out castings, etc. The casting apparatus includes a turntable 1 that is rotatable in a horizontal plane, and a number of metal mold casting machines 4, 4 that are placed on an upper side at the periphery of the turntable 1. Each of the machines 4, 4 has an opening and closing mechanism 3 for a mold 2. A pouring basin 9, from which molten metal is poured into the mold 2, is mounted on the casting machine, and moves over the mechanism 3 between the peripheral side and the side toward the rotation axis of the turntable 1. The pouring basin 9 is moved to the peripheral side when molten metal is poured into the mold. It is then moved to the side toward the rotation axis of the turntable 1 when work such as taking out of a casting from the mold is carried out.

Abstract: Disclosed is a metal casting system, an engineered mold for use therewith, a process for utilizing the system and mold, and articles having a clean, oxide-free sand casting of molten metals that have been produced under an inert environment. This is especially advantageous for making automotive and airplane parts from the manufacture of lightweight metals, and more especially for the production of magnesium parts in order to reduce weight while maintaining properties found in other lightweight metals. Currently, sand cast articles are being used for automotive, aerospace and semiconductor parts and other industrial applications.

Abstract: Apparatus (300, 400) for laying an elongate member such as a pipe (306) or a rail (472). Material carried by the apparatus is smelted in a furnace (340) and fed to a casting head (342) by which the elongate member is continuously cast. The so cast elongate member is then laid by the apparatus, as it travels on the ground surface.

Abstract: The invention makes it possible to manufacture high-quality cast parts in a productive manner in that a casting mould with a filling opening pointing in the direction of gravity is provided during the casting of molten metal. The casting mould with the filling opening is coupled to a melt container containing the molten metal, and the molten metal is conveyed from the melt container into the casting mould counter to the direction of gravity. The casting mould is sealed directly after filling with molten metal using a locking means which is at least temporarily connected to the casting mould in a fixed manner, in that the casting mould is decoupled from the melt container directly after closure of the casting mould and in that the casting mould is rotated about a horizontal axis of rotation, wherein the casting mould remains in a sealed position with respect to the locking means.

Abstract: The invention relates to a casting system (1) having a reservoir (2) for a fluid (3), such as, in particular, liquid metal, a dispensing chamber (5) connectable by a connection (4) with the reservoir, and an application device (7) with which the fluid is spreadable to a predetermined width and with which it is spread on a movable strip (9), wherein the connection between the dispensing chamber and the application device is formed as a closed tubular connection (6).

Abstract: A horizontal continuous casting apparatus for continuously manufacturing a magnesium alloy plate and a method of manufacturing a magnesium alloy plate using the same. The horizontal continuous casting apparatus is structured such that the cross-sectional area of the plate is equal to or smaller than that of a melt inlet, and includes a cooling unit for indirectly cooling the melt using a cooling jacket provided to the outer wall of the mold and/or for directly cooling the melt through spraying of cooling water, and a drawing unit having a multi-step drawing cycle. Thereby, magnesium alloy plates having various sizes can be safely and continuously cast.

Abstract: Articles for use with highly reactive alloys that include a graphite crucible having an interior, and at least a first protective layer applied to the interior of the graphite crucible in which the graphite crucible having the first protective layer is used for melting highly reactive alloys.

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: 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: The invention concerns a casting apparatus which includes a crucible support and induction heating means (14, 16, 18) arranged to receive and support a crucible (10) containing material which is to be melted and poured from an outlet (38). The outlet is positioned on a vertical axis (40). The support and induction heating means also operates to apply induction heating to the material to melt it in the crucible. There is also a translation mechanism which tilts the crucible while the crucible is still supported and while heat is continuously applied to it. This mechanism operates in such a way that during tilting, the outlet of the crucible is maintained on the vertical axis so that the molten material pours from the outlet on the vertical axis. In the embodiments described, the crucible is simultaneously moved vertically towards the mould into which the melt pours.

Abstract: Methods for making refractory crucibles capable of managing thermal stresses and suitable for melting highly reactive alloys, the method involving providing a crucible having at least a facecoat and a backing, heating at least one retaining ring, applying the at least one retaining ring about at least a portion of the backing of the crucible; and allowing the at least one retaining ring to cool and shrink-fit about the crucible.

Abstract: Disclosed is a mold 10 for forming cast rods including: a segment assembly 12 including a plurality of segments 14 being placed side by side, and a plurality of cavities 26 extending along a longitudinal direction 16; and clamping means (18 to 21) for clamping the segment assembly 12 in directions orthogonal to the longitudinal direction 16. The mold 10 has one or more cavity-forming portions 28 each forming a part of one of the peripheral surfaces of the cavities 26. Each cavity 26 is formed by a combination of two or more segments 14, and at least one of the plurality of segments 14 has two or more cavity-forming portions 28.

Abstract: A method and apparatus is disclosed for casting a composite ingot made of metals that are susceptible to surface oxide formation when molten. The method involves co-casting at least two metal layers from at least two molten metal pools formed within a direct chill casting apparatus. During the casting operation, movement of metal oxide formed on the upper surface of at least one of the pools towards an edge of the pool is restrained by an oxide skimmer positioned close to an edge of the pool above an external surface or metal-metal interface of the ingot. The apparatus provides a DC caster with at least one oxide skimmer that operates in this manner.

Abstract: A fill tube assembly is for a casting mold. The fill tube assembly includes a fill tube having a tubular member with a receiving end, a mold-engaging end and an intermediate portion. The mold-engaging end has a tapered flange radially extending therefrom, the remainder of the tubular member has a substantially uniform cross-section. A clamping assembly is structured to maintain a substantially leakproof seal at the fill tube, casting mold interface while accommodating dimensional variations. The clamping assembly includes a gasket, a load ring, a clamping plate and a pre-load gap between the clamping plate and the casting mold and optionally includes a dimensional compensating ring. When tightened, the clamping plate biases the load ring against the flange thereby distributing a uniform load against the casting mold, compressing the gasket therebetween while narrowing the pre-load gap to accommodate dimensional variations. A method of use is also disclosed.

Abstract: A device and method for producing, by molding, a circular-shaped mechanical part made of a metal alloy. The device has a rotatable hollow mold for receiving a predetermined quantity of the metal alloy. The predetermined quantity of the metal alloy is defined by at least one segment of a metal alloy rod. An inductive heating device melts the metal alloy to a melting point. A blank of the mechanical part being formed by centrifuging the melted metal alloy. Cooling the blank in the hollow mold to a second temperature which corresponds to a desired malleability. Processing the blank with a shaping tool to obtain a desired internal profile. To harden and form the circular-shaped mechanical part, the blank is further cooled to a tempering temperature.

Abstract: An apparatus for melting metals comprises a hearth for melting a metal raw material, a mold for forming an ingot by cooling the molten metal therein, the mold having a bottom, and a base unit for pulling down the ingot and provided at the bottom of the mold. The base unit has a surface provided with a concave portion at an optional location, and the surface of the base unit surrounding the concave portion is inclined toward the concave portion.

Abstract: Methods for reducing carbon contamination when melting highly reactive alloys involving providing a graphite crucible having an interior, applying at least a first protective layer to the interior of the graphite crucible, placing a highly reactive alloy into the crucible having the first protective layer, and melting the highly reactive alloy to obtain a melted alloy having reduced carbon contamination.

Abstract: A mold assembly for sand casting is disclosed. The mold assembly includes a drag having a first vertical axis and a first surface. The first surface extends generally perpendicular to the first vertical axis. The mold assembly also includes a cope having a second vertical axis positioned on the first surface such that the first vertical axis and the second vertical axis coincide to form a central vertical axis. The cope includes a second surface and a third surface both extending generally perpendicular to the second vertical axis. The mold assembly also includes a casting cavity disposed about the central vertical axis and located between the first surface and the second surface, and a core disposed about the central vertical axis and positioned in the casting cavity. The mold cavity further includes a pouring cup disposed about the second vertical axis and extending downward from the third surface to the casting cavity.

Abstract: The invention relates to a device and method for producing metal panels. First a metal melt is produced, then a substrate, which has a lower temperature than the metal melt, is brought into contact with it so that some of the metal melt crystallises on the substrate. The substrate is then moved relative to the metal melt so that a metal foil is formed on the substrate. Finally the metal foil is divided into metal panels. According to the invention the substrate comprises grooves which are used to fit partitions between the panels, as well as grooves which are filled with liquid metal. The latter grooves provide a reinforcement for the metal panels. In addition a pattern of recesses and/or elevations can be provided in the substrate so that the same pattern is formed in the metal foil. The pattern may consist, for example, of parallel grooves which ensure that the surface of the foil is enlarged. In the case of solar cells this results in greater efficiency.

Abstract: A pouring apparatus for molten metal includes a stirrer installed in a reservoir. The stirrer is rotated by a rotational drive mechanism installed on the reservoir. Molten solder is placed into the reservoir, high melting point metal particles are charged into the molten solder, stirring is performed with the stirrer to uniformly disperse the metal particles in the molten solder, and then the molten solder and dispersed metal particles are cast into a mold. Casting can be performed quickly after charging the metal particles into the molten solder, so the metal particles do not significantly melt into the molten solder.