Abstract: An insert (cover member) is formed of an iron-based alloy. A casting mold is constituted by a fixed mold and a movable mold. An insert housing portion (cover housing portion) for housing the insert is formed in a separation surface between the fixed mold and the movable mold, and a magnet is embedded in the insert housing portion of either the fixed mold or the movable mold. A robot grips the insert with a gripping portion (hand) to convey the insert to a position facing the insert housing portion, releases the insert at the facing position in a state where a predetermined clearance is secured between the insert and the insert housing portion, and causes the insert to be attracted to the insert housing portion by the magnet.

Abstract: A diecasting tool system has a machine-related base plate, at least one set of contour-imparting mould components which in an assembled position on the base plate form a casting contour for an associated cast part to be cast, and a plurality of not contour-imparting tool receptacle module components. The base plate, the tool receptacle module components and the contour-imparting mould components are configured for releasably assembling the associated set of contour-imparting mould components and an assigned set of the tool receptacle module components on a fastening side of the base plate for casting the respective cast part. The base plate on the fastening side has a fastening grid of a plurality of fastening points which are disposed so as to be distributed in a regular or irregular pattern across a fastening region.

Abstract: A method is provided of cleaning of a portion of a mold component, the portion of the mold component including a passage configured, in use, to allow passage of fluid and to prevent passage of melt, the method comprising: entering the mold component into a cleaning configuration, whereby a portion of the passage becomes part of a molding surface; performing a molding cycle to fill in at least the portion of the passage with molding material for incorporation and removal of a residue there from. Also provided is a mold having a first mold half and a second mold half, the halves being movable relative to each other. A mold shut height adjustment apparatus can provide for a change in the mold shut height.

Abstract: Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Abstract: A positioning station supports a sand mold half while centering using two sets of moveable arms. A gripping structure having two inwardly facing pads are each mounted for rotation about a common axis on separate axles. The pads remain in a fixed angular relationship to one another throughout rotational movement. Each pad has plural individual compressible fingers and a fixed fulcrum structure pointing inwardly towards the opposite pad and adapted to grip a sand mold half by engaging the surface of the sand mold half. The gripping structure is lifted away from the platform sufficient to allow a second sand mold half to be placed on the platform and then the gripping structure is lowered to accurately mate the two mold halves.

Abstract: A gravity casting mold including a first mold, a second mold and an exhaust runner mold, which are combined with each other and form a turbine housing cavity having a twin scroll part, a first riser, a sprue, a runner, a second riser, an exhaust manifold cavity, third risers and gates. A heating sleeve is provided in the first riser so as to prevent shrinkage of the molten metal in the twin scroll part. The heating sleeve is closed in an upper end, with a gas ejection hole formed through the upper end of the heating sleeve. A sprue cup is provided in the sprue so as to maintain the temperature of the molten metal in the sprue. The gravity casting mold further includes a twin scroll mold, a main gate core, an exhaust runner core, a twin scroll part core and a bypass part core, and a sub-gate core.

Abstract: A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

Abstract: A positioning station supports a sand mold half while centering using two sets of moveable arms. A gripping structure having two inwardly facing pads are each mounted for rotation about a common axis on separate axles. The pads remain in a fixed angular relationship to one another throughout rotational movement. Each pad has plural individual compressible fingers and a fixed fulcrum structure pointing inwardly towards the opposite pad and adapted to grip a sand mold half by engaging the surface of the sand mold half. The gripping structure is lifted away from the platform sufficient to allow a second sand mold half to be placed on the platform and then the gripping structure is lowered to accurately mate the two mold halves.

Abstract: The mold handler includes a mold closer mechanism that supports the cope and drag halves and effects movement in a closing direction whereby cope and drag halves are moved into mating alignment with one another. The cope and drag halves are with respective alignment structures that mediate the mating alignment of cope and drag halves as they are moved into mating alignment with one another. An air bearing mechanism that supports at least one of said cope and drag halves permits low friction lateral movement in a plane perpendicular to the closing direction to thereby adjust the relative positional relationship of cope and drag by interaction of the alignment structures.

Abstract: Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Abstract: A compressor impeller and a method of manufacturing the compressor impeller. The magnesium alloy compressor impeller as a die-cast part comprises a hub shaft part, a hub disk part having a hub surface extending from the hub shaft part in the radial direction, and a plurality of vane parts disposed on the hub surface. The impeller can be manufactured by a die-cast method in which a magnesium alloy heated to a liquidus temperature or higher is supplied into molds with cavities corresponding to the shape of the impeller for a filling time of 1 sec. or shorter, a pressure of 20 MPa or higher is applied to the magnesium alloy in the cavities, and the pressurized state is maintained for a time of 1 sec. or longer.

Abstract: Methods of casting improved scroll compressor components having high quality involute portions are provided. The casting method comprises gating molten metal through a patterned region of a core or mold defining the involute vanes. In certain aspects, during casting, molten metal passes through one or more gates that extend through a core in a central patterned region that forms the involute portion of the scroll component. In certain variations, the metal comprises a gray cast iron, so the cast part comprises an involute having a matrix of pearlite and Type A graphite that is substantially free of undercooling defects. Further, in certain variations, the involute portion is substantially free of Types B-E graphite. Thus, high-quality low-defect cast scroll components are formed having good machinability and superior fatigue strength.

Abstract: A mold and method for gravity casting may integrally cast a turbine housing having a twin scroll unit and a bypass unit and an exhaust manifold having a plurality of exhaust runner units. A turbine housing-side riser may be formed based on the end portion of the twin scroll unit within a first mold and a second mold in the state where the cavity of the turbine housing is formed so that the end portion of the twin scroll unit which is the outlet of the turbine housing is upward disposed.

Abstract: A mold and method for gravity casting may integrally cast a turbine housing having a twin scroll unit and a bypass unit and an exhaust manifold having a plurality of exhaust runner units. A turbine housing-side riser may be formed based on the end portion of the twin scroll unit within a first mold and a second mold in the state where the cavity of the turbine housing is formed so that the end portion of the twin scroll unit which is the outlet of the turbine housing is upward disposed.

Abstract: The method casts a disk rotor which can restrain partial abrasion in a sliding ring part, particularly, in the circumferential outer surface. A mold includes a casting cavity to cast the sliding ring part, an outer circumference forming surface, an inner circumference forming surface, a gate group including a plurality of gates formed in the outer circumference forming surface at positions spaced apart from each other at predetermined intervals with respect to a circumferential direction, each of the gates having a central line P2 inclined at an angle greater than 0° and less than 90° with respect to a normal line passing through a center of the casting cavity in a radial direction, and runners. A melt is injected from the gates into the casting cavity at angles ?1, ?2 and ?3 which are greater than 0° and less than 90° with respect to the normal lines, and is solidified.

Abstract: A core die is provided. The core die includes a first half and a second half where a cavity is formed between the two. Pins are arranged on the halves and the pins are replaceable. By virtue of the modular inner structure of a core die, the core die may be matched to the desired changes of the core, by small changes, more quickly and more easily than would be the case if the core die had only one part or if the pins were a fixed component of the core die halves.

Abstract: A mold that can prevent molten metal from leaking out of it as well as from leaking onto a parting plane of the mold. The mold includes a lower mold having a concave portion that has the shape of a product, into which the amount of molten metal required to produce a casting is poured and an upper mold comprising a convex portion that has the shape of the casting, and forming a cavity that molds the casting, when the upper mold overlaps the lower mold. A structure is formed so as to have certain clearances between the lower mold and the upper mold such that molten metal is prevented from leaking onto the parting plane that is formed where the upper mold and the lower mold overlap, when the casting is produced.

Abstract: A metal molding machine includes a fixed mold and a movable mold, a fixed platen holding the fixed mold, an end frame coupled to the fixed platen by tie rods such that the end frame is fixedly mounted on a bed, a movable platen guided by the tie rods, the movable mold being held by the movable platen, and a rolling support mechanism supporting the movable platen. The rolling support mechanism includes a swingable arm, a wheel disposed on a portion of the swingable arm that is closer to the fixed platen and held in rolling contact with the bed, and a spring disposed on a portion of the swingable arm that is closer to the end frame. The spring is interposed between the swingable arm and a portion of the movable platen, for applying a resilient force in a direction so as to lower the wheel.

Abstract: A casting die assembly which does not produce any burrs includes a stationary die and a movable die that are clamped in a condition in which a slide core is caused to move toward a center of a movable die, and a back surface of a protrusion of the slide core contacts a stopper section provided on a frame section. The stopper section is subjected to the pressure applied to the slide core during a casting operation. Since the stopper section is provided on part of the frame section, which is integrally formed on the periphery of the stationary die, the stopper section is not caused to retreat or deform by the casting pressure and as a result, the slide core is not moved and burrs are not produced.

Abstract: A method of casting a rotary friction plate includes preparing a casting mold with a cavity and a core shaped to form the friction plate. Molten metal is poured into the mold through a central sprue where a portion of the metal flows radially outward across the top of the core to fill friction plate forming regions of the cavity from above, while another portion flows through a central opening in the core to fill a hub forming region at the bottom of the cavity as well as additionally supply metal to the lower friction plate forming region from below. The metal is allowed to cool, which begins at the radially outer regions of the at least one friction surface and progresses radially inward to develop a uniform cast structure.

Abstract: A method of manufacturing a cylinder block using a die apparatus wherein a columnar hole includes a bore in the cylinder block. The method includes the steps of abutting first and second split cores against an upper surface of a distal end core, the upper surface being located opposite the inner core, and introducing a molten metal into a cavity. An inner core is withdrawn to move the first and second split cores toward an axis. The first and second split cores are released from a formed product made of solidified molten metal. The split cores are removed from the formed product to form the bore, and an inner surface of the bore is cut.

Abstract: The present invention provides a die plate and a mold clamping apparatus equipped with the die plate for a die casting machine and so on capable of reducing dimensions of die length as small as possible. A fixed die plate FXPL and a moving die plate MVPL of a mold clamping apparatus on a base BS place a versatile main mold inside, respectively. A pair of insert dies FINS and MINS is carried in to a mold opened space without disturbing tie bars TBU or TBD located in an upper portion or a side portion. The pair of insert dies are separated and fastened to each of the versatile main mold. The die length becomes zero or very small when the moving die plate positions at a mold closing position, and as the result dimension of the mold clamping apparatus in the direction of mold opening and closing can be shortened. Also, particularly the moving die plate can be avoided to tilt.

Abstract: A lost-wax cast impeller for a supercharger having no parting line on a hub surface and a blade surface in each space demarcated by pairs of long blades adjacent to each other and having excellent aerodynamic performance. A method of manufacturing the impeller involves forming a lost form pattern in substantially the same shape as the impeller, forming a mold by eliminating the lost form pattern after the lost form pattern is coated with a refractory, and pouring a molten metal in the mold for casting. In the molding step, lost material is injection-molded in a space demarcated by radially arranging, toward a center shaft, a plurality of slide molds having short blade-shaped bottomed groove parts and space shapes between the pairs of long blades adjacent to each other, and the slide molds are released by moving in the radial direction of the center shaft while rotating.

Abstract: A method of manufacturing a chassis is provided. The method comprises casting a first segment having a plurality of connected walls such that a window is cast in each of two of the plurality of connected walls in the first segment; casting a second segment having a plurality of connected walls such that a window is cast in each of two of the plurality of connected walls in the second segment; and coupling the first and second segments together to form the chassis having a window in four walls.

Abstract: Die opening-closing means includes a servo motor and a movement conversion mechanism and is disposed between a support plate and a base stand. A movable plate is mounted on the support plate that is disposed on the base stand via a linear movement guide. In a forging cycle, die opening and closing is performed by activation of the die opening-closing means and tie bar fixing means at a rear surface side of the movable plate, and clamping force is obtained using a die clamping cylinder provided in the movable plate. When it is necessary to change over exclusive dies and change over is performed by: extending tie bar removal cylinders provided in a frame behind the movable plate so as to remove tie bars from a fixed plate; and moving a movable rail of internal rails to an open position and moving the change over carriage in along the internal rails from the outside.

Abstract: Die opening-closing means 10 includes a servo motor 11 and a movement conversion mechanism and is disposed between a support plate 8 and a base stand 1. A movable plate 4 is mounted on the support plate 8 that is disposed on the base stand 1 via a linear movement guide 7. In a forging cycle, die opening and closing is performed by activation of the die opening-closing means 10 and tie bar fixing means 21 at a rear surface side of the movable plate 4, and clamping force is obtained using a die clamping cylinder 30 provided in the movable plate 2. When it is necessary to change over exclusive dies 3b and 5b, change over is performed by: extending tie bar removal cylinders 41 provided in a frame 40 behind the movable plate 4 so as to remove tie bars 6 from a fixed plate 2; and moving a movable rail 52b of internal rails 52 to an open position and moving the change over carriage in along the internal rails 52 from the outside.

Abstract: Systems and methods for reducing the potential for riser backfilling during investment casting are provided. In this regard, a representative method for performing investment casting includes: providing a mold having an opening communicating with an interior, the interior having a part cavity and a riser; providing an insert; and using the insert to form a physical barrier to reduce a potential for molten metal to backfill into the riser while the molten metal is introduced into the interior of the mold via the opening.

Abstract: A metal molding machine includes a fixed mold and a movable mold, a fixed platen holding the fixed mold, an end frame coupled to the fixed platen by tie rods such that the end frame is fixedly mounted on a bed, a movable platen guided by the tie rods, the movable mold being held by the movable platen, and a rolling support mechanism supporting the movable platen. The rolling support mechanism includes a swingable arm, a wheel disposed on a portion of the swingable arm that is closer to the fixed platen and held in rolling contact with the bed, and a spring disposed on a portion of the swingable arm that is closer to the end frame. The spring is interposed between the swingable arm and a portion of the movable platen, for applying a resilient force in a direction so as to lower the wheel.

Abstract: A device for moving a metal cope towards and apart from a stationary metal drag, used in a metal mold casting device that uses the metal cope and drag, comprising: an upper die plate (9) for carrying the metal cope; a frame (5; 25); a metal mold opening and closing device (6) mounted on the frame for carrying and vertically moving the upper die plate relative to the frame so as to move the metal cope attached to the upper die plate between a position that is above and relatively near the metal drag and a position that is at the metal drag; and an actuator (3; 23, 23) connected to the frame for moving the frame so as to move the metal cope attached to the upper die plate between the position that is above and relatively near the metal drag and a position that is relatively far from the metal drag.

Abstract: A heat-dissipating device and its manufacturing process are provided for significantly increasing the number and size of blades so as to enhance the heat-dissipating performance. The heat-dissipating device has a plurality of blades arranged around the hub of the heat-dissipating device and there is an overlapped region formed between every two adjacent blades. A single mold is used to manufacture such a heat-dissipating device so that not only can the manufacturing cost be reduced but it can significantly increase the number and size of blades so as to increase the heat-dissipating efficiency.

Abstract: A water-jacket core and slab core for a V-block of an internal combustion engine are assembled into a jacket and slab sub-assembly and are placed on an apparatus for the automatic insertion of staples in the jacket and slab sub-assembly to thereby retain the water-jacket core and slab core together in the jacket and slab sub-assembly. The apparatus automatically positions four automatically operable staple guns so that each of the staples is inserted with one tine of each staple in the water-jacket core and the other tine of each staple in the slab core with the crown of each inserted staple lying across the interface between the assembled water-jacket core and slab core and retaining the water-jacket core and slab core together. As few as two staples per sub-assembly can be used to retain the water-jacket and slab core in their sub-assembly.

Abstract: An apparatus for injection-molding products, comprising an injection mold (2) divisible into at least two parts (6, 8) such that consequently at least one mold cavity (14) is cleared, wherein on at least one part of the injection mold guiding means (22) are provided for a transfer device (4) for providing an insert in the mold cavity and/or for taking a product from the mold cavity.

Abstract: A diecast machine comprises: a sleeve extending in the vertical direction; a plunger moving upward in the vertical direction inside the sleeve; a mold disposed above an upper side of the sleeve; a case member constituted of a nonconductive member, which covers at least a lower end of the sleeve and forms a closed space including the lower end of the sleeve; a communicating pipe connecting the inside of the closed space to the outside of the closed space; and high-frequency induction coil configured to heat metal material disposed on the plunger from the outside of the case member and melt the metal material.

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus may be located adjacent the mold in use.

Abstract: This invention relates to a mold rollover apparatus including a wheel member defining an axis and selectively rotatable about the axis and at least one carrier member carried by the wheel member and adapted to carry at least one mold member having a cast part disposed therein. The at least one carrier member is selectively rotatable at least from a first position, wherein the cast part is generally retained in the at least one mold member, to a second position, wherein the cast part is generally free to fall or drop from the at least one mold member. According to the present invention, the at least one carrier member is selectively rotatable about the axis at least from the first position to the second position independent of the rotation of the wheel member about the axis.

Abstract: The invention provides a molding die in which a whole or a part of an exclusive portion forming a cavity can be swiftly changed while leaving a general portion in a molding machine. A fixed insert, a movable insert, a pressing plate and a slide core which correspond to an exclusive portion can be automatically attached to and detached from a fixed main die, a movable main die, a pressing rod and a slide holder which correspond to a general portion by an attaching and detaching mechanism. Further, the fixed insert, the movable insert, the pressing plate and the slide core can be integrated in a die close state by a connection mechanism.

Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with downwardly converging sides that hold assembled mold and core elements together, without fasteners, during transportation and pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. After the casting is formed, the core sand from both the mold elements and core elements is recovered, and may be recycled and processed to form further mold elements or core elements or both.

Abstract: A core assembly apparatus includes a rotating table having a plurality of operation positions. A plurality of fixtures for assembling cores are carried by the rotating table adjacent its periphery, preferably one core assembly fixture for each operation position. The core assembly fixtures are inclined toward the central portion of the rotating table. In one of the operation positions, a completed core assembly is transferred from a core assembly fixture to a horizontal conveyor. A pick-and-place assembly engages a core assembly and removes it from an inclined core assembly fixture of a rotating table and placement on a horizontal conveyor. Alternatively, the fixtures may be pivotally attached to the rotating table and include core assembly gripping mechanisms so that the core assembly fixtures can pivot to lower assembled cores onto a horizontal conveyor.

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus may be located adjacent the mold in use.

Abstract: The invention achieves a more effective die changing work, reduces a time required for performing die changing of work of a die, and improves an operational availability of a molding machine, in various kinds of molding dies. A die changing operation can be efficiently performed by drawing out an exclusive portion which is automatically attached to and detached from a general portion of a molding die, from the general portion by a feeding means and pressing the exclusive portion to the general portion. Further, the exclusive portion (an old insert) drawn out to a predetermined position from the general portion can be carried out to an outer side of a die casting machine by a carrying means, and another exclusive portion (a new insert) can be carried in to a predetermined position within the machine from the outer side thereof, within the machine in a die unclamp state.

Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.

Abstract: An apparatus for injection-molding products, comprising an injection mold (2) divisible into at least two parts (6, 8) such that consequently at least one mold cavity (14) is cleared, wherein on at least one part of the injection mold guiding means (22) are provided for a transfer device (4) for providing an insert in the mold cavity and/or for taking a product from the mold cavity.

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus of the present invention may be located adjacent the mold in use.

Abstract: A two tiered mold handling system for use in a sand mold casting machine which comprises a two tiered conveyor for pouring and cooling, or a two tiered conveyor for cooling only. The two-tiered conveyor has an upper linear track and a lower linear track disposed at a lower vertical elevation. The tracks carry a plurality of mold pallets along an endless path around the upper and lower linear tracks. The application is directed toward several concepts including two tiered pouring conveyors in combination with two tiered cooling conveyors, two tiered combination pouring and cooling conveyors, and one tiered pouring conveyors in combination with two tiered cooling conveyors to provide a lower pouring elevation.

Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: An apparatus and method for pressure casting a battery part wherein at least one of the mold members forming the surfaces of an internal battery part cavity are displaced with respect to one another to reduce the volume of the mold cavity formed between the two parts to thereby intensify the pressure sufficiently high pressure so as to inhibit the formation of cracks and tears in a cast part.

Abstract: The invention relates to a mould (1) for the manufacture of a casting (2) using moulding material (3). In order to achieve simple and cheap manufacture, the mould (1) is provided with an outer first mould carrier (4), an outer second mould carrier (5), a mould body (6) arranged between said mould carriers (4, 5) and an inner layer (12) of moulding material (3) applied to said mould carrier (6) at least in areas, to form the mould cavity.

Abstract: A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise the filter during the cooling operation and facilitates removal of the filter upon completion of the pouring operation. The upper platen of a casting module is provided with a swinging cope which is movable between a horizontal position and a vertical position to facilitate cleaning of the cope.

Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with tapered sides that hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. Although the carrier sides can use a refractory liner, preferably the sides are made of replaceable sheet metal backed by an open structural framework to enhance cooling of the casting. After the casting is formed, the core sand from both the mold elements and the core elements is recovered, and may recycled and processed to form further mold elements or core elements or both.

Abstract: 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.