Abstract: In-Place Cope Molding or “IPCM,” is designed to reduce or eliminate certain inefficiencies present in traditional molding techniques during production of the cope half of a sand mold. IPCM allows the cope half of the mold to be produced on top of the drag half of the mold by use of a separation barrier which supports the sand above the mold cavity in the drag. This method reduces or eliminates parting line flash, and also avoids the need to turn over or otherwise handle the cope, allowing the cope to be made thinner than a traditional cope and allowing for lower material costs.

Abstract: Molding material mixture, molded part for foundry purposes and process of producing a molded part. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

Abstract: The present invention relates to spherical casting sand having an average particle diameter of 0.03 to 1.5 mm, produced by a flame fusion method, usable together with a urethane binder.

Abstract: A method for reducing pollutant emissions from a metal casting case used in foundry practice. The metal casting case includes at least a molding material formed to a metal casting mold. The pollutant emissions are released from material making up the casting cases after pouring molten metal in the metal casting mold. The method includes the steps of adding at least one additional combustible substance to at least one region of the casting mold located outside of a contact region of the casting mold with the casting, and burning the at least one additional combustible substance in one of a gaseous and vaporized state together with the pollutant emissions.

Abstract: Sand mold for shaping molten metal cast into the mold. The mold includes sand, a thermally oxidizable polymer amongst the grains of the sand, and a catalyst coating on the gains for promoting the thermal oxidation and breakdown of the polymer in the course of removing the sand from the casting and/or reclaiming the sand for reuse. The catalyst coating adheres so tenaciously to the grains of sand that the sand can withstand repeated casting and sand reclamation cycles without the need to replenish the catalyst.

Abstract: A casting device includes a wall which is formed in the manner of a sandwich structure from a front layer, a yielding intermediate layer and a supporting outer layer. In this way, the contraction-related internal stresses which occur during cooling are kept at a low level by the resilient properties of the intermediate layer. As such, the formation of cracks in the component to be cast can be avoided.

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

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

Abstract: Casting mold for metal casting, in particular precision casting of fine parts of steel, wherein at least the main part of the casting mold is comprised of porous ceramic with a high thermal coefficient of expansion which corresponds to the metal, and produced by generative rapid prototyping process, as well as generative rapid prototyping processes and coated powders particularly suitable therefore, as well as uses of the casting mold for tools and their components, in particular of steel.

Abstract: A weld mold assembly which includes a crucible section for exothermically reacting weld material to form a molten metal, a weld mold having a weld chamber with an opening for receiving the molten metal and a plurality of guide holes for receiving ground rods and wires, and a cylindrical or tapered conversion plug sealably inserted into at least one of the guide holes to provide a weld assembly with a variety of different configurations.

Abstract: A lost wax molding system has a re-usable, collapsible, chain-linked mesh exoskeleton, one or more inserts to be placed within the interior surface of the mesh exoskeleton to exert outward pressure on the mesh exoskeleton thereby creating a pre-formed, rigid, three-dimensional shape, a waterproof sleeve sized to cover the outer surface of the three-dimensional shape, and a base sized to seal said waterproof sleeve forming an investment mold container.

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

Abstract: A method and apparatus are provided to process collected sand. This method and apparatus allow the moisture content to be adjusted and the addition of a binder to be facilitated to renew the collected sand as casting sand for future use. Also, defective castings are prevented when they are made by a main mold using the renewed casting sand. The sand-collecting means can be compact. The method is performed and the apparatus is operated by separating a main mold of green sand, after casting is conducted, into parts unaffected and affected by the molten metal heat, adjusting the moisture content of the part unaffected by molten metal heat for use as facing sand in the next main mold making, and adding a binder and adjusting the moisture content of the part affected by the molten metal heat for use as back sand in making the next main mold.

Abstract: In the method of deoxidation casting, a disused metal left in a feeder head can be easily removed from a cast product, or the molten metal left in the feeder head can be removed from the cast product so as to easily finish the cast product. The method comprises the steps of: pouring a molten metal into a cavity of a casting die; and reacting a deoxidizing compound with the molten metal so as to deoxidize an oxide film formed on a surface of the molten metal. And the method is characterized in that rate of cooling the molten metal in a feeder head of the casting die is lower than that in the cavity, and that the molten metal in the feeder head, which is not solidified, is treated when the molten metal in the cavity is solidified so as to make an outline of a cast product correspond to that of a desired product.

Abstract: The present invention provides a casting method comprising the steps of obtaining a thermal distribution of mold sand for a casting, and determining a mold wall thickness profile based at least partially on the mold sand thermal distribution.

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

Abstract: A ceramic mould slurry is disclosed for forming moulds and metal castings of improved surface quality. The slurry comprises a binder, a gelling agent, a first refractory material having a density of &rgr;1 and a mean particle size of &agr;1, and a second refractory material having a density of &rgr;2 and a mean particle size of &agr;2, wherein &rgr;1>&rgr;2 and &agr;1<&agr;2. The denser refractory material migrates downward through the slurry toward the upward-facing mould surface, thereby allowing formation of a smooth and accurate surface.

Abstract: Molds are fabricated having a substrate of high density, high strength ultrafine grained isotropic graphite, and having a mold cavity coated with pyrolytic graphite. The molds may be made by making the substrate (main body) of high density, high strength ultrafine grained isotropic graphite, by, for example, isostatic or vibrational molding, machining the substrate to form the mold cavity, and coating the mold cavity with pyrolytic graphite via a chemical deposition process. The molds may be used to make various metallic alloys such as nickel, cobalt and iron based superalloys, stainless steel alloys, titanium alloys and titanium aluminide alloys into engineering components by melting the alloys in a vacuum or under a low partial pressure of inert gas and subsequently casting the melt in the graphite molds under vacuum or low partial pressure of inert gas.

Abstract: In the method of deoxidation casting, a disused metal left in a feeder head can be easily removed from a cast product, or the molten metal left in the feeder head can be removed from the cast product so as to easily finish the cast product. The method comprises the steps of: pouring a molten metal into a cavity of a casting die; and reacting a deoxidizing compound with the molten metal so as to deoxidize an oxide film formed on a surface of the molten metal. And the method is characterized in that rate of cooling the molten metal in a feeder head of the casting die is lower than that in the cavity, and that the molten metal in the feeder head, which is not solidified, is treated when the molten metal in the cavity is solidified so as to make an outline of a cast product correspond to that of a desired product.

Abstract: A process for preparing a molding sand for a green sand mold is provided. The process comprises the step of drying under a reduced pressure of 0 to 0.3 atm for 0.5 to 30 seconds a green molding sand obtained by kneading silica sand, clay, and water, to dry the clay superficial part and to retain in a moist state the clay deeper part on the silica sand core part in each particle of the molding sand. The molding sand prepared by this process has enhanced flowability. Furthermore, the sand mold prepared from the molding sand has sufficient strength.

Abstract: The invention provides methods for producing semi-permanent casting tooling, as well as semi-permanent casting tooling apparatus. Casting tooling including a blend of high char resin and refractory powder; casting tooling prepared from a blend of sol-gel ceramic precursor and refractory powder; and a preform including a leachable core as well as methods for their production are provided. The casting tooling of the invention can be used in casting processes including die casting, permanent mold casting and pressure infiltration casting. Also provided is an investment mold casting technique compatible with a pressure infiltration process.

Abstract: A portable sand mold metal treating system having sand cope and sand drag portions, the treating system being attachable to a sand mold metal casting system.

Abstract: A core material for making cores to be used in molds for the casting of metals and comprising a mixture of hollow ceramic particles uniformly distributed throughout a resin binder of organic material. The hollow ceramic particles are individually in intimate surface contact with adjacent individual hollow ceramic particles throughout the core materials to allow the heat of the casting to be conducted efficiently through the core material. The amount of resin binder being maintained at a minimum to reduce the amount of gas generated by the resin binder as it is exposed to the heat of the metal being cast. The hollow ceramic particles comprising about 99.0 to about 96.5% by weight of the core material and the resin binder comprising about 1.0 to 3.5% by weight, respectively, of the core material prior to the core material being cured, and the hollow ceramic particles preferably ranging in diameter from about 200 microns to about 450 microns, with a preferred mean diameter of about 325 microns.

Abstract: Ski tow assembly for being secured to the transom of a boat. The ski tow fixture has an elongated vertically aligned body. Legs at the opposed ends of the fixture body secure the fixture to the transom. The body is further formed so as to define an elongated generally elliptically shaped opening through which a tow line is inserted. The tow line is coupled over a finger that extends diagonally upwards toward the transom from a small tap attached to a lower part of the fixture and that projects inwardly toward the transom. The assembly includes opposed rails that are mounted to the transom that are coupled to the opposed ends of the fixture by ears that extend outward from the ends of the fixture.

Abstract: Thin wall lightweight panels which are subjected to high temperature solutioning and rapid quenching to impart high strength properties without distortion, warping or oil-canning. The panels are produced by casting in a mold cavity having an interconnected recess network which surrounds thin wall-forming areas and distributes molten metal uniformly thereto. The recess network forms a waffle pattern reinforcing rib network surrounding the thin-wall areas, lending strength and dimensional stability thereto during the heat treatment and quenching steps, to prevent distortion, warping and oil-canning.

Abstract: Metallurgically treated metal castings are produced using a consumable plug assembly made of a meltable material which is placed in a reaction chamber in an open treating basin and above a passage to a molding cavity. The consumable plug assembly has physical and chemical characteristics which maintain the plugged relationship for a preselected retaining period. All of a treating material is placed on the plug in the reaction chamber prior to metal pouring so as to react directly with the poured metal in a non-dynamic way.

Abstract: A mold comprising a cavity for defining the shape of a casting and a mold body for forming said cavity, comprising: a mold body formed of an ordinary temperature setting resin or thermosetting resin and casting sand, said mold body having a surface layer portion on the surfaces thereof including depressions, said depressions in the surface layer portion being filled up with at least one porous powdered material selected from the group consisting of hydrous magnesium silicate clay mineral, activated carbon and activated alumina, thereby providing the mold body with smooth surfaces whereby said mold generates less amount of material such as gums which cause defective castings during casting since molten metal is restrained from intruding into the walls of said mold.

Abstract: The mold formed of resin-bonded sand includes a vertical sprue in fluid flow communication with a horizontal chamber reservoir underlying the mold cavity defining the thin wall structure. The thin wall cavity portion is positioned about a common horizontal level above the reservoir. Vertical runners feed the metal from the horizontal reservoir up into the cavity. The number and location of these runners are such as to fill the cavity from several points of entry with uniform temperature metal before any solidification occurs.

Abstract: A filter for molten metal with a particulate coating for simultaneously metallurgically treating and filtering is disclosed. A layer of particulates such as ferroalloy, deoxidizer, grain refiner, inoculant or master alloy is placed on the surface of a hard-fired ceramic or refractory cloth filter for treating liquid metal. The particles are held in place by a coating of carbonaceous resin which is applied to the surface of the filter and which also protects the filter and particles against abrasion and moisture. The placement of the particulate additives on the filter allows the molten metal to be metallurgically treated and filtered simultaneously.

Abstract: A closed mold assembly having a mold cavity therein, an ingate extending from the mold cavity through the mold assembly with an opening having an outer wall for immersion into a bath of molten metal, and an expendable cap fitting around the outer wall of the ingate having a continuously upward tapering dimension to urge the top larger of the molten metal in a bath away from the ingate opening during the immersion process to minimize impurity inclusion in the mold. The expendable cap is preferably made from a non-contaminating sacrificial material intended to be melted after immersion into the molten metal bath without being detrimental to the quality of the workpiece.

Abstract: A mould for the production of a nodular or compacted graphite iron casting has parts comprising a treatment sprue, a runner, a slag trap, a filter chamber having an ingate and an outlet and having located therein a ceramic filter having an inlet and outlet, a casting cavity ingate, and a casting cavity, and the parts of the mould have a relationship one with another such that F2=0.8 F1 to 1.2 F1, F3=30% F4 - 100% F4, F4.gtoreq.4.5 F1, F5.gtoreq.1.3 F1, F6=2 F5 to 4 F5, F7.gtoreq.F5 and .ltoreq.F6, F8.gtoreq.F5 and .ltoreq.F6, F9=1.2 F1 to 3 F1, F10.gtoreq.

Abstract: A casting mold for foundry castings is proposed wherein the casting mold comprises a melt treatment chamber above a mold cavity wherein the treatment chamber and mold cavity are communicated via a duct. The treatment chamber is provided with a closure element formed as part of the casting mold which is shearable therefrom upon the application of a force for sealing the duct between the treatment chamber of the mold cavity.

Abstract: An adhesive paste for adhering two or more objects, a composite assembly comprising two or more elements bonded by such paste, and a process for preparing cast metal articles using such paste are provided. The adhesive paste comprises an aqueous solution of a specific alkali phenol-formaldehyde resin and a hardener for that resin, wherein the paste prepared by mixing the resin and hardener has a viscosity, as mixed, in the range of about 1,000 cps to about 15,000 cps. The composite assembly comprises at least two separate elements bonded by the adhesive paste of the invention. The process uses a mold or core assembly having at least two separate elements.

Abstract: A method and means are provided for treating molten metal with an additive in a foundry mold. A recessed treatment chamber for an additive is provided in the top of a mold. The chamber is covered with a discrete refractory core body. Molten metal poured on the core body is directed into the chamber where it reacts with the additive before entering the casting cavity. The subject invention is particularly adapted to making nodular or compacted graphite iron castings by treating grey iron with a magnesium containing additive.

Abstract: An apparatus for filling an open-top foundry flask with discrete refractory particles by pluviation to embed an expendable pattern to form a lost foam casting mold comprises conduits for directing pressurized gas toward the prepositioned pattern within the flask to deflect pluviating particles and thereby promote uniform packing of the particles about the pattern. The conduits comprise compressed air conduits vertically insertable into the flask through the open top thereof for disposition about the pattern and having multiple orifices for directing pressurized air laterally toward the pattern to achieve the desired uniform packing.

Abstract: A permanent casting mold has its casting cavity coated with a sand liner of varying thickness. The liner is thicker where the cast article section is thinner and the liner is thinner where the cast article section is thicker so as to permit the thicker sections to cool faster while the thinner sections cool slower. The different thicknesses of the liner are correlated so that the respective sections of the article are sufficiently cooled at about the same time for removal of the article from the mold. The mold is a cope and drag-type flask mold whose casting cavity halves are oversized relative to the cast article. The sand liner is formed therein by temporarily positioning a pattern within the permanent casting cavity halves and sand filling the space between the pattern and cavity wall. The exterior surface of the pattern corresponds to the cast surface of the article.

Abstract: An adhesive paste composition containing in admixture a resin component, a hardener component, a hydrophobic filler component and a curing agent. The resin component includes a polyol having at least two hydroxyl groups and the hardener component includes a liquid polyisocyanate containing at least two isocyanate groups. The admixture may be made by mixing together a premixed resin component contianing a filler and a catalyst and a premixed hardener component containing a hydrophobic filler. The fluid in the resin component, the hardener component, or both may be a thixotropic agent.

Abstract: A mould for use in the casting of molten ferrous metal is described comprising a mould cavity and a runner system comprising a sprue, a sprue well and a runner, and having located in the runner a ceramic filter having an open-cell foam structure. A sealed plastics container containing particles of a treatment agent, such as an inoculant for the molten ferrous metal is located in a chamber in the runner system on that side of the filter which is further from the mould cavity such that part of the container is in the sprue well.

Abstract: An alumina-carbon shape is manufactured from a composition comprising 1-8 weight percent fine silicon, 1-16 weight percent reactive alumina, 1-30 weight percent calcined fluidized bed coke, 1-30 weight percent of a spalling inhibiting additive, and the balance of the mix synthetic alumina, plus the additions of 5-10 weight percent of a high carbon yielding resin as a molding vehicle and 0.5-4 weight percent solvent, and up to 2 weight percent of a low temperature curing agent, such as, paraformaldehyde or hydrochloric acid. The mix is formed at ambient temperature into a shape through an injection molding process. Solidification is accomplished by curing in the mold at a temperature less than 100.degree. C. After stripping the shape from the mold, the solvents are removed from the shape by drying at a temperature above 100.degree. C. The shapes are then heated to a temperature above 550.degree. C. to coke the resin.

Abstract: A wear resistant compound body is disclosed which is comprised of a metallic basic material and has a wear resistant zone which includes hard substance and/or hard metal particles in addition to the basic material. The basic material is composed of0.001 to 1.5 weight percent carbon,0.5 to 8 weight percent boron,1 to 8 weight percent niobium,0.2 to 6 weight percent chromium,0 to 30 weight percent nickel,0 to 10 weight percent manganese,0 to 6 weight percent vanadium,0 to 5 weight percent molybdenum,0 to 5 weight percent silicon, the remainder being iron.Also disclosed is a casting process for producing the compound body.

Abstract: A binder for a foundry core or mould consists of an alkali metal salt of a polybasic organic acid or of a polymerized monobasic organic acid, for example sodium polyacrylate, an alkaline earth metal hydroxide such as calcium hydroxide, one or more polyvalent metal oxides, preferably magnesium oxide, and calcium citrate, together with water. The mixture may also include another polyvalent metal oxide, for example zinc oxide. The inclusion of calcium citrate in the binder composition, particularly in the presence of magnesium oxide, has been found to reduce the problem of `softening back` in which the strength of the core or mould interior deteriorates over storage periods of a few days due to the continued absorption of carbon dioxide from the atmosphere in damp conditions.

Abstract: A cavity in a body of particulate moulding material has at least one rib-like formation for gripping an object received in the cavity. In the case of a metal casting mould a riser sleeve (1) is inserted into a cavity (9) in the top part of the mould and the cavity (9) is produced by means of a tapered former (5) the exterior of which has a plurality of radially spaced apart recesses (6) extending between the top and towards the bottom of the former and which has a negative taper from bottom to top. The depth of the recesses (6) is such that circles geometrically inscribed inside the base of the recesses (6) have diameters smaller than the corresponding mean outside diameters less three times the standard deviation of the riser sleeves (1) to be used. The recesses (6) form ribs (11) from the moulding sand and the ribs (11) grip the outer surface of the sleeve (1).

Abstract: A casting nozzle for molten steel with improved spalling resistance and corrosion resistance is prepared by kneading a raw material consisting of 42 to 93% by weight of an alumina simple substance powder, 4 to 44% of a graphite simple substance powder and 10 to 27% by weight of a fused silica simple substance powder after adding a binder thereto, pelletizing the resultant mixture, pressing the pellets with a rubber press, and sintering the pressed nozzle at a low temperature within a range such that the resultant nozzle may have the characteristics attributable to the addition of alumina, graphite and fused silica.

Abstract: It is known to contact molten cast iron with various treating agents in the casting mold in order to influence the base structure or the form of the graphite. Such casting molds for making castings of cast iron containing vermicular and/or spheroidal graphite are provided with an intermediate chamber, which is provided in the pouring system between the pouring gate and the ingate to the casting mold proper. That intermediate chamber serves to receive the graphitizing agent and to contact it with the molten cast iron. To permit a functional adaptation of the chamber surface area or the surface area of the treating agent contained in the chamber to the pouring gate, which changes as the pouring proceeds, the casting mold is provided with a frustopyramidal intermediate chamber which has a rectangular base disposed in the parting plane of the mold.

Abstract: Foundry sand molds and cores are provided which incorporate glassy metal reinforcing filaments. Molds prepared from the sand composition of this invention provide greater strength before and during metal casting. As the casting solidifies, the temperature of the reinforcing filaments rises, the filaments devitrify and become weak and the mold can be crumbled for easy removal of the casting.

Abstract: A method and an apparatus is provided for casting molten metallic materials through runners in the form of casting gates, flow-through tubes, feeders, rising gates and the like. The method basically comprises casting the molten metals through runners defined by bodies of porous calcium hydro-silicate such as gas concrete. A filler, such as quartz, may be used. The runner bodies are formed of gas concrete and provided with a moisture ratio of 3 to 30% so as to afford progressive evaporation of the moisture during casting to thereby produce a cooling effect on the runner walls. The runner bodies can be reinforced.

Abstract: A mold apparatus and method for minimizing the amount of chemically bonded molding sand needed to form a block mold which consists of a flask mounted upon a pattern plate and a sand minimizer blow plate which is selectively movable into engagement with the upper edge surface of the flask mounted upon the pattern plate so as to form a mold cavity therewith into which the chemically bonded molding sand is blown so as to form the sand mold. The sand minimizer blow plate is provided with pocket forming finger extensions which extend downwardly into the mold cavity so as to form block sand minimizer pocket cavities in the completed sand mold.

Abstract: A segmented mold assembly is utilized to cast a turbine engine component having an annular inner wall and an annular outer wall which are interconnected by a plurality of struts or vanes. The mold assembly includes a plurality of sections which are formed of a ceramic mold material and are interconnected at flange joints. A pair of mold sections are advantageously formed simultaneously by repetitively dipping a single pattern in a slurry of liquid ceramic mold material to form a wet coating on the pattern. This wet coating of ceramic mold material is then dried. After a covering of the desired thickness has been built up by repetitively dipping and drying the coatings on the wax pattern, the wax pattern is destroyed. To facilitate separating the mold sections after destroying the wax pattern, at least some of the wet coatings are wiped away in an area between portions of the wet coatings which will eventually form the mold sections.

Abstract: There is disclosed a method for molding a plate-like cross-structure on a heat pipe or a bundle of heat pipes to serve as a support plate or a baffle. The plate-like cross-structure is formed integrally on the heat pipe within a molding box, in an extremely simplified manner irrespective of the shape of the pipe.

Abstract: A foundry mold member made from a plurality of sand practice bound together with a binder which is concentrated at the contact points between contiguous particles and consists essentially of gelatins having a Bloom rating less than about 175 Bloom grams. The sand particles are first coated with a sol of the gelatin, cooled to ambient temperature and conditioned to prescribed water content necessary to effect migration of the gelatin to the interparticle contact points upon heating of the coated particles in a pattern mold.