Including Means To Heat Mold Patents (Class 164/338.1)
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Patent number: 7377305Abstract: 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.Type: GrantFiled: August 23, 2005Date of Patent: May 27, 2008Assignee: Rolls-Royce CorporationInventors: Donald J. Frasier, Matthew Kush, Max Eric Schlienger, Michael Baldwin
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Patent number: 7322397Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.Type: GrantFiled: November 16, 2004Date of Patent: January 29, 2008Assignee: RMI Titanium CompanyInventors: Michael P. Jacques, Frank P. Spadafora, Kuang-O Yu, Brian W. Martin
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Patent number: 7225857Abstract: An apparatus for manufacturing a directionally solidified columnar grained article with a reduced amount of secondary misorientation of the columnar grains. The apparatus includes a casting assembly comprising a mold with a cavity, a selector section at a lower end of the mold, a heating chamber and a cooling chamber. The mold is fed with a liquid metal and then moved from the heating chamber to the cooling chamber where the columnar grained article is solidified. The article is solidified with at least two dendrites (or grains) emerging from the selector section and entering the main cavity of the shell mold. Further, the selector section is configured so that no dendrite or grain grows from the bottom of the selector section into the shell mold cavity along a continuous path of purely vertical growth.Type: GrantFiled: August 31, 2004Date of Patent: June 5, 2007Assignee: ALSTOMInventor: John Fernihough
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Patent number: 7011136Abstract: A method and apparatus for melting metals uses microwave energy as the primary source of heat. The metal or mixture of metals are placed in a ceramic crucible which couples, at least partially, with the microwaves to be used. The crucible is encased in a ceramic casket for insulation and placed within a microwave chamber. The chamber may be evacuated and refilled to exclude oxygen. After melting, the crucible may be removed for pouring or poured within the chamber by dripping or running into a heated mold within the chamber. Apparent coupling of the microwaves with softened or molten metal produces high temperatures with great energy savings.Type: GrantFiled: November 12, 2001Date of Patent: March 14, 2006Assignee: BWXT Y-12, LLCInventors: Alan F. Moore, Donald E. Schechter, Marvin Stanley Morrow
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Patent number: 7000678Abstract: Disclosed is an electromagnetic continuous casting apparatus for a material having a low electric conductivity. The casting apparatus includes a crucible having a vertical axis. The crucible comprises an upper hot crucible and a lower cold crucible. The crucible is surrounded with an induction coil. The hot crucible is formed of a non-metallic material having a high electric conductivity and is not water-cooled. The cold crucible has a cooling structure and is formed of a metallic material having a high thermal conductivity and a high electric conductivity.Type: GrantFiled: April 11, 2005Date of Patent: February 21, 2006Assignee: Korea Institute of Industrial TechnologyInventors: Byoung Moon Mon, Sang Mok Lee, Je Sik Shin
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Patent number: 6994835Abstract: The present invention reduces temperature gradient in the direction of the radius of solidified ingots of silicon immediately after solidification, which has serious influences on the quality as a solar cell and improves the quality. Silicon raw materials are melted inside a bottomless crucible combined with an induction coil by electromagnetic induction heating. The silicon melt formed inside the bottomless crucible is allowed to descend and solidified ingots of silicon are manufactured continuously. Plasma heating by a transferred plasma arc torch is also used for melting the silicon raw materials. The plasma arc torch is moved for scanning along the inner surface of the bottomless crucible in the horizontal direction. A plasma electrode on the solidified ingot side to generate transferred plasma arc is allowed to contact the surface of the solidified ingot at positions where the temperature of the solidified ingot becomes 500 to 900° C.Type: GrantFiled: December 28, 2000Date of Patent: February 7, 2006Assignee: Sumitomo Mitsubishi Silicon CorporationInventors: Kenichi Sasatani, Naritoshi Kimura, Masakazu Ohnishi
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Patent number: 6981541Abstract: A casting furnace for use in melting and molding metals. The furnace has a mold insertion and withdrawal system attached thereto and incorporates an offset mold elevator for moving a mold up and down from a mold chamber to a furnace chamber while eliminating the need for a pit. The furnace further includes a readily removable chill plate on which the mold rides. An overhead material feed system is also provided.Type: GrantFiled: October 22, 2004Date of Patent: January 3, 2006Assignee: Lectrotherm, Inc.Inventor: David O. Warren
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Patent number: 6948548Abstract: An apparatus for casting an ingot includes a molten metal reservoir (51) positioned at an upper portion, a casting chamber (5) positioned at a lower portion and a partition wall (3) between the reservoir and the chamber, a spruce (7) formed in the partition wall, an opening/closing plug (8) for opening and closing the sprue and control means for controlling an opening and closing operation of the plug. The casing chamber is defined in a mold (1) that includes a lower mold member (4), a side mold member (2) and the partition wall (3) that constitutes an upper mold member. At least one of the lower mold member, side mold member and upper mold member includes a plurality of divided sections (21,22) in accordance with a shape of a cast ingot C.Type: GrantFiled: August 31, 2001Date of Patent: September 27, 2005Assignee: Showa Denko K.K.Inventors: Shigeru Yanagimoto, Masashi Fukuda, Tomoo Uchida, Kunio Hirano
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Patent number: 6896030Abstract: Apparatus and method for DS casting using one or more thermal baffle members positionable at a lower open end of a directional solidification casting furnace by movement of a ram on which a mold to be cast is moved relative to the casting furnace. A unique thermal baffle member can be used for each particular series or run of molds to be cast.Type: GrantFiled: July 30, 2003Date of Patent: May 24, 2005Assignee: Howmet CorporationInventors: Mark L. Soderstrom, Bradley Donaldson, John R. Brinegar
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Patent number: 6889747Abstract: An apparatus for use in casting a metal article includes a furnace assembly and a container which holds a fluidized bed. A mold support is movable relative to the furnace assembly to move a mold from the furnace assembly into the fluidized bed. A bame is disposed between the fluidized bed and at least a portion of the furnace assembly. The baffle may have a plurality of secondary openings which enable particulate to move from an upper side of the baffle into the fluidized bed. The baffle may be connected with the furnace assembly, the container which holds the fluidized bed, or floated on the fluidized bed itself. The baffle may be provided with flexible segments which engage the mold and at least partially block movement of particulate through a central opening in the baffle during withdrawal of the mold from the furnace assembly.Type: GrantFiled: March 4, 2003Date of Patent: May 10, 2005Assignee: PCC Airfoils, Inc.Inventor: Lawrence D. Graham
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Patent number: 6868893Abstract: Provided is a directional solidification casting apparatus capable of heightening a cooling effect when molten material poured in a mold is directionally solidified. A mold (20) disposed around a predetermined area is drawn out from a heating chamber (10) heated above a melting temperature of metals for producing a casting (31), and molten metals (32) held in a cavity (21) of the mold (20) are directionally solidified. The directional solidification casting apparatus (100) comprises a driving rod (42) by which the mold (20) is drawn out from the heating chamber (10), a gas nozzle (52b) through which a cooling gas is jetted from inside a predetermined area where the mold (20) is disposed so as to rapidly cool the mold (20), and a gas nozzle (52a) through which a cooling gas is jetted from outside the predetermined area where the mold (20) is disposed so as to rapidly cool the mold (20). A baffle (15) that does not move even when the driving rod (42) moves up and down is additionally provided.Type: GrantFiled: November 27, 2002Date of Patent: March 22, 2005Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Sachio Shimohata, Yuichi Ohtani, Tatsuya Ohira, Ikuo Okada
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Patent number: 6837299Abstract: A method for the production of a cast component comprising the steps of: 1) providing a molten metal mass in a casting mold and exposing the casting mold to a cooling environment thereby creating a solidification interface between molten metal regions and solidified metal regions, and 2) applying at least one focused energy source either to a portion of the filled casting mold to control a temperature gradient near the solidification interface.Type: GrantFiled: April 24, 2003Date of Patent: January 4, 2005Assignee: Sky+Ltd.Inventors: Max Eric Schlienger, Nina Bergen French
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Patent number: 6827125Abstract: A casting furnace for use in melting and molding metals. The furnace has a mold insertion and withdrawal system attached thereto and incorporates an offset mold elevator for moving a mold up and down from a mold chamber to a furnace chamber while eliminating the need for a pit. The furnace further includes a readily removable chill plate on which the mold rides. An overhead material feed system is also provided.Type: GrantFiled: September 20, 2002Date of Patent: December 7, 2004Assignee: Lectroltherm, Inc.Inventor: David O. Warren
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Publication number: 20040231822Abstract: 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.Type: ApplicationFiled: August 1, 2003Publication date: November 25, 2004Inventors: Donald J. Frasier, M. Eric Schlienger, Guy Allen Brady, Matthew T. Kush, Patrick A. Vessely
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Patent number: 6796362Abstract: An apparatus for producing a metallic slurry material for use in semi-solid forming of a shaped part. The apparatus is generally comprised of a forming vessel and a thermal jacket. The forming vessel defines an inner volume for containing the metallic slurry material and has an outer surface. The thermal jacket has an inner surface disposed in thermal communication with the outer surface of the forming vessel to effectuate heat transfer therebetween. At least one of the forming vessel and the thermal jacket defines a number of grooves to limit the rate of heat transfer adjacent the grooves. In one embodiment, the forming vessel defines a plurality of axially-offset grooves extending about the entire periphery of the outer surface of the forming vessel. In another embodiment, a stator is disposed about the thermal jacket to impart an electromagnetic stirring force to the metallic slurry material contained within the forming vessel.Type: GrantFiled: September 3, 2002Date of Patent: September 28, 2004Assignee: Brunswick CorporationInventors: Patrick J. Lombard, Shaupoh Wang, Walter L. Winterbottom, George Spiller
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Publication number: 20040173336Abstract: An apparatus for use in casting a metal article includes a furnace assembly and a container which holds a fluidized bed. A mold support is movable relative to the furnace assembly to move a mold from the furnace assembly into the fluidized bed. A baffle is disposed between the fluidized bed and at least a portion of the furnace assembly. The baffle may have a plurality of secondary openings which enable particulate to move from an upper side of the baffle into the fluidized bed. The baffle may be connected with the furnace assembly, the container which holds the fluidized bed, or floated on the fluidized bed itself. The baffle may be provided with flexible segments which engage the mold and at least partially block movement of particulate through a central opening in the baffle during withdrawal of the mold from the furnace assembly.Type: ApplicationFiled: March 4, 2003Publication date: September 9, 2004Applicant: PCC AIRFOILS, INC.Inventor: Lawrence D. Graham
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Patent number: 6786272Abstract: The present invention provides a method and apparatus for die-casting copper and other metals that are cost-effective and practical for production use in die-casting, for example, copper motor rotors. In motor rotors, the incorporation of die-cast copper for conductor bars and end rings in place of aluminum is known to result in improvements in motor energy efficiency. Previous attempts to die-cast copper motor rotors in a commercially feasible manner have failed because copper's high melting point places too great a stress on the die material, resulting in cracking and fracturing of the molds. High temperature die materials such as nickel, tungsten and molybdenum based alloys with a high melting point are employed, and a die casting apparatus is provided to pre-heat the molds prior to injection of the molten copper. Pre-heating and high operating temperatures provide extended die life.Type: GrantFiled: November 30, 2000Date of Patent: September 7, 2004Assignee: Copper Development Association, Inc.Inventors: John G. Cowie, Dale T. Peters, Edwin Brush, Kenneth P. Young, Stephen Midson, Jack Daugherty
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Patent number: 6776213Abstract: An apparatus for use in casting a metal article includes a furnace assembly into which a mold is raised and an annular fluidized bed adjacent to the furnace assembly. The mold is filled with molten metal and lowered into the fluidized bed. The molten metal is solidified in the mold as it is lowered into the fluidized bed. The mold and fluidized bed are then lowered. The fluidized bed is disposed in a container having annular inner and outer walls which are cooled and function as heat sinks. A mold support member may extend through a passage in the annular inner wall of the fluidized bed.Type: GrantFiled: July 3, 2002Date of Patent: August 17, 2004Assignee: PCC Airfolis, Inc.Inventors: Lawerence D. Graham, Brad L. Rauguth, Michael J. Beffel
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Publication number: 20040079511Abstract: The present invention provides improved heated manifolds, heaters and nozzles for injection molding, having a high strength metal skeleton infiltrated with a second phase metal having higher thermal conductivity. Also disclosed is method of forming a manifold, heater or nozzle preform and infiltrating the preform with a highly thermally conductive material. The invention also provides a method of simultaneously infiltrating and brazing injection molding components of similar or dissimilar materials together.Type: ApplicationFiled: December 8, 2003Publication date: April 29, 2004Inventors: Jobst U. Gellert, George Olaru
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Publication number: 20040079510Abstract: A baffle includes a base and a seal having flexible segments which engage a mold structure. The base of the baffle may have a noncircular opening in which article mold portions of the mold structure are disposed. The baffle may be connected with the furnace assembly before a mold is moved into the furnace assembly or may be connected with the furnace assembly as the mold is moved into the furnace assembly. A projection connected with the mold structure may be utilized to orient the baffle relative to the mold structure. The projection may be a thermocouple assembly which extends from the chill plate. Alternatively, the projection may be a portion of the mold structure itself.Type: ApplicationFiled: October 29, 2002Publication date: April 29, 2004Applicant: PCC AIRFOILS, INC.Inventors: Robert M. Garlock, Gary J. Vanek, Lawrence D. Graham
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Publication number: 20040069437Abstract: A moulding apparatus (10) for moulding a strap on to a group of battery plates including a mould block (14) with moulds (24), each of which has an inlet weir (28) and an outlet weir (29). The ridge (30) of these weirs is effectively a knife edge but includes a thermal break. This construction allows rapid processing whilst avoiding the formation of solid tails.Type: ApplicationFiled: November 6, 2003Publication date: April 15, 2004Inventor: Robert T. Hopwood
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Patent number: 6715661Abstract: While one preform (A) is being shaped between two dies (4, 11), another preform (B) is being prepared by heating in a compartment (14) on a lower die (5) similar to the preceding one (4). When the preform (A) has been shaped, a mobile section (3) of the furnace is lifted to release the upper die (11) and make it possible to place the new preform (B) and its lower die (5) beneath it. Thus, when one preform has been shaped, the following one is already prepared by heating.Type: GrantFiled: January 24, 2002Date of Patent: April 6, 2004Assignee: SNECMA MoteursInventor: Gilles Klein
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Publication number: 20040045692Abstract: A thermally efficient method for the heating a gas permeable wall of a bonded refractory mold wherein the mold wall defines a mold cavity in which molten metal or alloy is cast. The mold wall is heated by the transfer of heat from hot gas flowing inside of the mold cavity to the mold wall. Hot gas is flowed from a hot gas source outside the mold through the mold cavity and gas permeable mold wall to a lower pressure region exterior of the mold to control temperature of an interior surface of the mold wall.Type: ApplicationFiled: September 10, 2002Publication date: March 11, 2004Inventor: John A. Redemske
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Patent number: 6698493Abstract: As a mold containing molten metal is lowered from a heating chamber, a baffle extends around the mold. Force is transmitted from the mold to an inner section of the baffle to release connectors between the inner section of the baffle and an outer section of the baffle. As the connectors are released, a side surface on the inner section of the baffle moves out of the coplanar relationship with a side surface on the outer section of the baffle. The baffle may be integrally formed as one-piece. Rather than being formed as one-piece, the baffle may include separate pieces which form the inner and outer sections of the baffle. Alternatively, the inner section of the baffle may be disposed above and supported by the outer section of the baffle. Latches may be provided to interconnect the outer section of the baffle and the furnace assembly.Type: GrantFiled: July 23, 2002Date of Patent: March 2, 2004Assignee: PCC Airfoils, Inc.Inventor: Lawrence D. Graham
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Patent number: 6695035Abstract: To restrict to a low level a temperature gradient of an ingot immediately after solidification in a bottomless crucible in a electromagnetic induction casting method using an electrically conductive bottomless crucible. An upper section and a lower section of an electrically conductive bottomless crucible to be disposed inside an induction coil are configured as a water-cooled section and a non-water-cooled section. Both the water-cooled section and the non-water-cooled section are divided by vertical slits into a plurality of portions in a circumferential direction. Rapid cooling with water in the lower section of the crucible is restricted.Type: GrantFiled: September 26, 2001Date of Patent: February 24, 2004Assignee: Sumitomo Mitsubishi Silicon CorporationInventors: Naritoshi Kimura, Kenichi Sasatani, Kyojiro Kaneko
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Publication number: 20040020628Abstract: A mold M for molding a metallic product including a fixed mold section 2 and a movable mold section 1, wherein heating means 7 is provided in the fixed mold section and cooling means 10 is provided in the movable mold section, which means are controlled by a temperature control device 14 so that any desired temperature is obtainable. Also, as the heating and the cooling of the mold are not repeated, but the fixed mold section is always heated and the movable mold section is always cooled, it is possible to shorten the cycle times.Type: ApplicationFiled: July 29, 2003Publication date: February 5, 2004Inventors: Hideyuki Suzuki, Koichiro Sato
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Publication number: 20040016529Abstract: As a mold containing molten metal is lowered from a heating chamber, a baffle extends around the mold. Force is transmitted from the mold to an inner section of the baffle to release connectors between the inner section of the baffle and an outer section of the baffle. As the connectors are released, a side surface on the inner section of the baffle moves out of the coplanar relationship with a side surface on the outer section of the baffle. The baffle may be integrally formed as one-piece. Rather than being formed as one-piece, the baffle may include separate pieces which form the inner and outer sections of the baffle. Alternatively, the inner section of the baffle may be disposed above and supported by the outer section of the baffle. Latches may be provided to interconnect the outer section of the baffle and the furnace assembly.Type: ApplicationFiled: July 23, 2002Publication date: January 29, 2004Applicant: PCC Airfoils, Inc.Inventor: Lawrence D. Graham
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Publication number: 20030234092Abstract: Method as well as apparatus for DS casting by withdrawing a melt-filled mold from an end of a casting furnace, spraying a liquid cooling medium to impinge on exterior surfaces of the mold as the mold is withdrawn, and collecting the cooling medium after it impinges on the exterior mold surfaces.Type: ApplicationFiled: June 20, 2002Publication date: December 25, 2003Inventor: John R. Brinegar
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Patent number: 6651728Abstract: A method of casting metal articles includes providing an array of article molds. The article molds are filled with molten metal. The molten metal is solidified in the article molds. During solidification of the molten metal, a plurality of solidification control elements function as heat sinks and radiation baffles. The solidification control elements are disposed between the article molds as the molten metal solidifies.Type: GrantFiled: July 2, 2002Date of Patent: November 25, 2003Assignee: PCC Airfoils, Inc.Inventor: Lawrence D. Graham
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Patent number: 6640876Abstract: A method and apparatus for manufacturing copper and/or copper alloy ingots having no shrinkage cavities and having smooth surfaces without wrinkles are provided. The apparatus comprises a bottom-casting type melting furnace and a heating furnace for heating a mold in which the molten metal is cast. The method comprises the steps of melting the material of copper and/or copper alloy, and casting the molten copper and/or molten copper alloy into a cylindrical mold which is placed on a cooled pedestal provided at the bottom of the heating furnace and the side wall of which is heated by the heating furnace so as to form a temperature gradient increasing from the bottom to the top of the mold.Type: GrantFiled: December 7, 2001Date of Patent: November 4, 2003Assignee: Mitsubishi Materials CorporationInventors: Kenji Yajima, Norikazu Ishida, Yutaka Koshiba, Keiji Nogami, Akihiro Kakimoto
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Patent number: 6637499Abstract: A heat shield for a casting furnace (e.g., a directional solidification or single crystal casting furnace) includes a plurality of heat insulating plates (e.g., 6 plates), each with a leading edge. The plurality of heat insulating plates are arranged, for example, in an overlapping layout, such that at least a portion of their leading edges define a discharge opening (e.g., a hexagonal discharge opening in the case of a heat shield with 6 heat insulating plates) circumscribed by the heat insulating plates. The heat insulating plates are moveable in a manner that adjusts (i.e., increases or decreases) the size of the discharge opening. The heat shield also includes a rotatable disk operatively coupled to the heat insulating plates such that when the rotatable disk is rotated in one direction, the heat insulating plates are moved in a manner which decreases the size of the discharge opening.Type: GrantFiled: February 6, 2002Date of Patent: October 28, 2003Assignee: Retech Systems LLCInventor: Leonard Charles Hainz, III
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Publication number: 20030145974Abstract: A heat shield for a casting furnace (e.g., a directional solidification or single crystal casting furnace) includes a plurality of heat insulating plates (e.g., 6 plates), each with a leading edge. The plurality of heat insulating plates are arranged, for example, in an overlapping layout, such that at least a portion of their leading edges define a discharge opening (e.g., a hexagonal discharge opening in the case of a heat shield with 6 heat insulating plates) circumscribed by the heat insulating plates. The heat insulating plates are moveable in a manner that adjusts (i.e., increases or decreases) the size of the discharge opening. The heat shield also includes a rotatable disk operatively coupled to the heat insulating plates such that when the rotatable disk is rotated in one direction, the heat insulating plates are moved in a manner which decreases the size of the discharge opening.Type: ApplicationFiled: February 6, 2002Publication date: August 7, 2003Applicant: Retech Systems LLCInventor: Leonard Charles Hainz
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Publication number: 20030141035Abstract: Provided is a directional solidification casting apparatus capable of heightening a cooling effect when molten material poured in a mold is directionally solidified. A mold (20) disposed around a predetermined area is drawn out from a heating chamber (10) heated above a melting temperature of metals for producing a casting (31), and molten metals (32) held in a cavity (21) of the mold (20) are directionally solidified. The directional solidification casting apparatus (100) comprises a driving rod (42) by which the mold (20) is drawn out from the heating chamber (10), a gas nozzle (52b) through which a cooling gas is jetted from inside a predetermined area where the mold (20) is disposed so as to rapidly cool the mold (20), and a gas nozzle (52a) through which a cooling gas is jetted from outside the predetermined area where the mold (20) is disposed so as to rapidly cool the mold (20). A baffle (15) that does not move even when the driving rod (42) moves up and down is additionally provided.Type: ApplicationFiled: November 27, 2002Publication date: July 31, 2003Applicant: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Sachio Shimohata, Yuichi Ohtani, Tatsuya Ohira, Ikuo Okada
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Patent number: 6578622Abstract: A lost core molding assembly (20) according includes a manifold (22) which minimizes adherence between a molten alloy and the manifold. The manifold (22) receives a heated fluid from a source and circulates the heated fluid through a heated fluid passage (66.) The heated fluid passage (66) arrangement assures that the heated fluid maintains the molten alloy in an even molten condition thereby reducing degradation of the molten alloy prior to injection into the mold.Type: GrantFiled: August 23, 2001Date of Patent: June 17, 2003Assignee: Siemens VDO Automotive Inc.Inventors: John Jacobs, Michael Robert Morency
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Publication number: 20030106664Abstract: A method and apparatus for manufacturing copper and/or copper alloy ingots having no shrinkage cavities and having smooth surfaces without wrinkles are provided. The apparatus comprises a bottom-casting type melting furnace and a heating furnace for heating a mold in which the molten metal is cast. The method comprises the steps of melting the material of copper and/or copper alloy, and casting the molten copper and/or molten copper alloy into a cylindrical mold which is placed on a cooled pedestal provided at the bottom of the heating furnace and the side wall of which is heated by the heating furnace so as to form a temperature gradient increasing from the bottom to the top of the mold.Type: ApplicationFiled: December 7, 2001Publication date: June 12, 2003Inventors: Kenji Yajima, Norikazu Ishida, Yutaka Koshiba, Keiji Nogami, Akihiro Kakimoto
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Publication number: 20030102103Abstract: An apparatus for producing a metallic slurry material for use in semi-solid forming of a shaped part. The apparatus is generally comprised of a forming vessel and a thermal jacket. The forming vessel defines an inner volume for containing the metallic slurry material and has an outer surface. The thermal jacket has an inner surface disposed in thermal communication with the outer surface of the forming vessel to effectuate heat transfer therebetween. At least one of the forming vessel and the thermal jacket defines a number of grooves to limit the rate of heat transfer adjacent the grooves. In one embodiment, the forming vessel defines a plurality of axially-offset grooves extending about the entire periphery of the outer surface of the forming vessel. In another embodiment, a stator is disposed about the thermal jacket to impart an electromagnetic stirring force to the metallic slurry material contained within the forming vessel.Type: ApplicationFiled: September 3, 2002Publication date: June 5, 2003Inventors: Patrick J. Lombard, Shaupoh Wang, Walter L. Winterbottom, George Spiller
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Patent number: 6557618Abstract: The present invention relates to metal casting and can be used in producing large sized blades with directional and single crystal structure having large horizontal shoulders. The apparatus comprises a vacuum chamber inside which there is positioned a mold preheating furnace with a ceramic mold and a vertical shield disposed therein, and a crystallizer. The shield is positioned concentrically to the casting vertical axis and is fixed on the mold upper portion or on a hanger. The shield can be made integral or as a row of members having projecting flanges which telescopically insert into each other. The shield is made of a graphitized foil or a carbon/carbon based composite material.Type: GrantFiled: April 27, 2000Date of Patent: May 6, 2003Assignees: General Electric Company, All-Russian Scientific Research Institute of Aviation MaterialsInventors: Vegeny Nikolaevich Kablov, Viktor Vladimirovich Gerasimov, Joseph Markovich Demonis, Elena Mikhailovna Visik
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Patent number: 6557620Abstract: An attachment apparatus for a heater for attaching the heater, which is configured in an almost circular shape in its side view and cut at a circumferential portion thereof to form opposite circumferential end portions, to an external peripheral portion of a heated member of a cylindrical or column shape, includes a pair of stop metal members fixed near the circumferential end portions of the heater and a spring, both end portions of the spring engaged with the stop metal members in a state being pulled by the stop metal members with a predetermined tension, respectively, the opposite circumferential end portions of the heater are attracted to each other and so the heater is elastically adhered to the external peripheral portion of the heated member.Type: GrantFiled: February 7, 2001Date of Patent: May 6, 2003Assignee: The Japan Steel Works, Ltd.Inventor: Junichi Oshimo
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Patent number: 6523599Abstract: A casting furnace (1) for producing castings which are directionally solidified in monocrystalline and polycrystalline form. The casting furnace (1) includes an upper heating chamber (2), which is equipped with a heating chamber wall (4) which contains at least one heater element, a lower cooling chamber (3), and contains a casting mold (11) which is moved by means of a conveyor device. Inside the heating chamber (4) there is an internal heater (6) which heats the inner surfaces of the casting pieces (11a), which are shielded from the casting mold (11), and thus prevents the solidification front from sloping inside the casting pieces (11a).Type: GrantFiled: April 24, 2000Date of Patent: February 25, 2003Assignee: Alstom (Switzerland) LtdInventor: Martin Balliel
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Patent number: 6510889Abstract: Method as well as apparatus for DS casting using a multi-stage thermal baffle disposed proximate a lower end of a DS casting furnace. The thermal baffle comprises a fixed primary baffle disposed at the lower end of the casting furnace and a secondary baffle initially releasably disposed adjacent and below the primary baffle prior to withdrawal of the melt-filled mold from the casting furnace. The primary baffle includes a primary aperture oriented perpendicular to the mold withdrawal direction and having a cross-sectional configuration tailored to accommodate a relatively large exterior region or profile of the melt-filled mold, such as a relatively wide platform region of a mold for making a turbine blade or vane.Type: GrantFiled: May 8, 2001Date of Patent: January 28, 2003Assignee: Howmet Research CorporationInventors: Dennis J. Thompson, John R. Brinegar
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Patent number: 6488074Abstract: The present invention proposes an apparatus for casting dental prosthesis designed to save labor and costly malformations. In a form of the invention, a first arm mechanism 20 for conveying a ring and a second arm mechanism 30 for conveying a crucible are provided to slide along the same guide 27. A ring-placing platform C and a burning unit G are placed across the guide 27, and so are a crucible-placing platform D and a casting unit H. When the arm mechanism 20 places a ring on a lifting stage 44, the lifting stage 44 moves upward to contain the ring in a furnace 41, where the ring is heated to bum off the wax inside. Meanwhile, the arm mechanism 30 places the crucible in a container 50, where alloy ingots are melted. After completing the melting of the alloy ingots and the burning of the ring, the arm mechanism 20 conveys the ring onto the top of the crucible in the container 50.Type: GrantFiled: August 8, 2001Date of Patent: December 3, 2002Assignee: Denken Co., Ltd.Inventor: Masaki Usui
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Publication number: 20020170698Abstract: An apparatus for use in casting a metal article includes a furnace assembly into which a mold is raised and an annular fluidized bed adjacent to the furnace assembly. The mold is filled with molten metal and lowered into the fluidized bed. The molten metal is solidified in the mold as it is lowered into the fluidized bed. The mold and fluidized bed are then lowered. The fluidized bed is disposed in a container having annular inner and outer walls which are cooled and function as heat sinks. A mold support member may extend through a passage in the annular inner wall of the fluidized bed.Type: ApplicationFiled: July 3, 2002Publication date: November 21, 2002Applicant: PCC Airfoils, Inc.Inventors: Lawrence D. Graham, Brad L. Rauguth, Michael J. Beffel
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Patent number: 6474404Abstract: The invention relates to a method for controlling the temperature of a melt (10), preferably of a steel melt, in a distributing vessel (11), whereby the temperature of the melt is measured, the measured result is compared with a predetermined temperature range in the form of specified values, and as much heat is supplied or withdrawn from the melt such that the temperature remains inside said range. In order to control the melt temperature, a fireproof shaped part (20) which is closed on both sides and which is provided for accommodating a liquid cooled induction coil (1) is immersed in the melt (10). The transmission of heat is carried out by means of thermal conduction out of the wall of the shaped part (20) which is coupled to the induced electromagnetic field and/or by means of a direct coupling to the liquid melt (10).Type: GrantFiled: October 15, 2001Date of Patent: November 5, 2002Assignees: SMS Schloemann-Siemag Aktiengesellschaft, Didier Werke AGInventors: Horst Grothe, Markus Reifferscheid, Raimund Brückner, Karl Heinz Schmitt
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Patent number: 6471397Abstract: Apparatus and method for casting metals and alloys using a pyrometer positioned outside or inside of a casting chamber and relative to a mold heating element in the casting chamber to view a region of a hot melt-filled refractory mold to improve accuracy of the mold temperature readings. The pyrometer is disposed at an elevation outside the casting chamber to view the mold along a viewing path above an induction coil and through an opening in a tubular susceptor disposed about the mold. Alternatively, the tubular susceptor and induction coil both include horizontal openings through which the pyrometer views the melt-filled mold from outside the casting chamber. The pyrometer is positioned to view a uniform profile region of the melt-filled mold having multiple mold cavities as the mold and susceptor are relatively moved.Type: GrantFiled: August 6, 1999Date of Patent: October 29, 2002Assignee: Howmet Research CorporationInventors: Mark L. Soderstrom, Christopher R. Hanslits
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Patent number: 6457512Abstract: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.Type: GrantFiled: September 18, 1998Date of Patent: October 1, 2002Assignee: Concurrent Technologies CorporationInventors: Kuang-O Yu, Alex Simkovich
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Patent number: 6446701Abstract: An improved apparatus for producing unidirectionally solidified components over wide range of shapes and sizes from the smallest aero-engine turbine parts to the largest industrial gas turbine parts with improved quality and productivity where a chill block is equipped with a seed crystal ejector mechanism inserts seed crystals into shell mold at the instant of melt pouring and where an intermediate melt pouring funnel indexing device facilitates smooth pouring of melt in instalments in order to cast large and tall directionally solidified castings in relatively thin walled mold at faster mold withdrawl rate with finer and better metallurgical structure and higher production rate than the prior art.Type: GrantFiled: May 10, 2000Date of Patent: September 10, 2002Inventor: Niranjan Das
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Patent number: 6443213Abstract: An apparatus for use in casting a metal article includes a furnace assembly into which a mold is raised and a fluidized bed adjacent to the furnace assembly. The mold is filled with molten metal and lowered into the fluidized bed. The molten metal is solidified in the mold as it is lowered into the fluidized bed. The mold and fluidized bed are then lowered. The mold may be supported on a grid or support member having openings through which gas and particulate in the fluidized bed can flow. A stirrer member may be moved in the fluidized bed to promote uniform distribution of particulate in the flow of gas. Gas may be conducted from the support member for the mold into a container which holds the fluidized bed. Gas at different pressures may be conducted into the fluidized bed at different locations in the fluidized bed.Type: GrantFiled: May 11, 2000Date of Patent: September 3, 2002Assignee: PCC Airfoils, Inc.Inventors: Lawrence D. Graham, Brad L. Rauguth
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Patent number: 6443216Abstract: An apparatus for and method of controlling the cooling rate of a metallic melt in the production of a semi-solid slurry billet for use in a casting process. The apparatus comprises a thermal jacket including symmetrical halves, with each half having a rounded heat transfer surface extending between a pair of longitudinal edges. An actuator mechanism engages the heat transfer surfaces into intimate contact with a vessel containing the metallic melt to effectuate conductive heat transfer between the vessel and the thermal jacket, with the pairs of longitudinal edges of each halve being disposed in a generally opposite, spaced relationship. The thermal jacket includes a plurality of passageways adapted to carry cooling air for extracting heat from the metallic melt, and a plurality of electric heating elements for adding heat to the metallic melt. The cooling rate of the metallic melt is controlled within a range of about 0.Type: GrantFiled: June 1, 2000Date of Patent: September 3, 2002Assignee: AEMP CorporationInventors: Patrick J. Lombard, Shaupoh Wang
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Publication number: 20020117289Abstract: A lost core molding assembly (20) according includes a manifold (22) which minimizes adherence between a molten alloy and the manifold. The manifold (22) receives a heated fluid from a source and circulates the heated fluid through a heated fluid passage (66.) The heated fluid passage (66) arrangement assures that the heated fluid maintains the molten alloy in an even molten condition thereby reducing degradation of the molten alloy prior to injection into the mold.Type: ApplicationFiled: August 23, 2001Publication date: August 29, 2002Applicant: Siemens Canada LimitedInventors: John Jacobs, Michael Robert Morency
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Patent number: 6408929Abstract: In the production of precision castings by centrifugal casting with controlled solidification, a melt is cast under vacuum or shield gas into a pre-heated mold (15) with a central gate (19) and several mold cavities proceeding from the gate toward the outer circumference (Da) of the mold (15). To prevent the formation of shrinkholes and porous areas in the castings, to save energy, and to increase the production rate, the mold (15) is operated at temperatures which decrease from the inside toward the outside. The mold consists of a material or material combination with a coefficient of thermal conductivity lower than that of copper. Before the melt is poured, the mold (15) is heated, starting from the gate (19), by a heating device (20), which projects into the gate, so that the gate (19) reaches a temperature which is a function of the material being cast. Heating is carried out at a rate sufficient to produce a temperature Gradient of at least 100° C., preferably of 200-600° C.Type: GrantFiled: May 4, 2001Date of Patent: June 25, 2002Assignees: Ald Vacuum Technologies AG, W. C. Heraeus GmbH & Co. KGInventors: Alok Choudhury, Harald Scholz, Matthias Blum, Georg Jarczyk, Marek Gorywoda, David Francis Lupton