Abstract: A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component.

Abstract: This invention teaches an improved apparatus and method to make metal alloy castings, such as subway car undercarriage bearing housings. One embodiment of the invention comprises a core mold assembly unit, wherein the mold unit is filled with molten metal. The core mold assembly units may be further formed of the same material, such as phenolic urethane impregnated sand, which is used to accurately replicate the desired shape of a final desired product.

Abstract: An investment cast, stainless steel chain link is provided for chains used in water and wastewater treatment. The chain link comprises a pair of spaced apart, elongated sidebars having forward ends and rearward ends. The forward ends are spread apart and are provided with outwardly and laterally extending bosses having transverse boss pin bores coaxially aligned with each other. The rearward ends are interconnected by a cylindrical barrel having a barrel pin bore extending through each of the sidebars. The sidebars are formed with outwardly and laterally projecting reinforcing ribs extending between the bosses and the barrel pin bore along a substantial length of the sidebars. A freely rotatable chain pin is inserted through aligned boss and barrel pin bores from either end thereof for interconnecting first and second pairs of sidebars. An arrangement is provided for preventing the lateral dislodgement of the chain pin from the sidebars.

Abstract: A feeder insert is provided for a mold utilized for pouring metal. The insert includes a feeder body having a feed volume, in the form of an inner space, delimited by side walls and a top portion. A feed opening is provided in the base region for communicating with a hollow mold space. A domed feeder cap is displaceably disposed on a feeder body, surrounds the side walls of the feeder body to form an insulating gap, and is fixed in position relative to the feeder body prior to molding of the insert. At least one spacer of flexible material is disposed between the top portions of the feeder body and feeder cap such that during molding of the insert, and placement of the feeder body on the mold surface, due to molding pressure that occurs the feeder cap is displaceable relative to the feeder body while leaving an insulating gap between the top portions of the feeder body and feeder cap.

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: A metal die device for casting of a simpler device structure by which a cast product having an undercut may directly be produced is disclosed. A casting (cavity) S is provided between a fixed die 21 and a movable die 31 as a movable core 40 having an undercut forming projection 41 is interposed between the fixed and movable dies. A swing member 54, caused to swing by a cylinder 51, is provided overlying the movable die 31. On the swing member 54, there is provided a cylinder 57 for vertically sliding the core 40. In die opening, following casting, the core 40 is vertically slid and subsequently caused to swing towards an upper outer side to release the core 40 from the cast product. Degree of freedom in metal designing is achieved without excess restriction in the shape or position of the undercut.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: A solid high silicon cast iron elongated anode has a midpoint electrical connection keeping the connection as far as possible from the ends to combat the deleterious pencil effect. The anode is made by casting using a hollow or shell core to form a small axial hole extending from one end. The sand or foundry material of the core is removed and the wall of the hole at the blind end of the hole is at least partially finished to receive a diagonally split slug to which a lead wire is connected. Alternatively the hole is formed by a steel pipe which is left in place as a hole liner. The pipe may be supported by one or more chaplets. The slug is fastened in the blind end of the hole by a driving tool rotating a threaded headed bolt with both axial and rotational force to hold the connection in the blind end of the hole as it is secured in place. The hole is filled with a potting compound sealing the connection in the center of the solid cast iron anode.

Abstract: Partially devitrified silica cores with exceptional high temperature strength are disclosed for foundry use in sand casting of ferrous alloys. Precision cored holes of small size and long length, which heretofore could not be cast accurately or had to be machined because of limitations in existing core technology, are formed using accurately machined extruded porous silica cores fired to eliminate combustibles and partially devitrified (e.g., 15 to 30%) to develop a strong crystalline phase bond that resists viscous flow at a temperature of 1500.degree. C. and to increase the refractoriness of the vitreous silica grains, whereby the permeability and thermal shock resistance are such that the core can be heated very rapidly by molten steel to above 1500.degree. C. without spalling, cracking, sagging, breaking, or loss of integrity and without gas holes, scabs, fissures or other serious casting defects.