Abstract: Low carbon stainless steel parts are formed utilizing a high vacuum of 20" to 29" of mercury during the pouring stage of the lost foam process.

Abstract: A method of making a solid foam material including the steps of heating in a chamber a starting material that is normally solid at room temperature to a temperature that is above its melting point, injecting a blowing liquid into the melted material to produce a mixture; and rapidly decompressing the mixture to produce the solid foam material.

Abstract: The apparatus for casting comprises a pressure vessel and a device for pressurizing the vessel. The pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold adapted to contain a preform disposed in the vessel and in fluidic connection with the chamber by a passage such that melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurizes the vessel. A heating device is disposed in the vessel. There is also a device for directionally solidifying the material in the mold. Additionally, there is a method comprising the steps of loading the pressure vessel by disposing a material within the chamber whereby the material is in fluidic connection with the mold adapted to contain a preform through the passage. The passage has a filter disposed therein.

Abstract: A metal composite material provides improved strength at all temperatures, in particular at those temperatures greater half the melting point of its matrix. The metal composite material is at least 50 volume percent hard particulate material in a matrix which is significantly more ductile than the hard particulate material. At or above 50 volume percent hard particulate material, each particle is surrounded by a thin film of the matrix material. This thin film resists deformation by converting sliding motion between particles into the rotational motion of the particles about each other. The matrix may be made by infiltrating a powder of the particulate material with a charge of the matrix material, for example, by hot isostatically pressing the matrix material into the powder or by melting a block of matrix material on top of the powder and thus infiltrating the powder by gravitational flow of the melted matrix material into the powder.

Abstract: The present invention pertains to an apparatus for casting which includes a melt chamber within which a metal is disposed. The melt chamber includes means for melting the material. A mold chamber is disposed beneath the melt chamber comprised of a mold defining a mold cavity within which the metal is formed and a preform is disposed. There is also a riser cavity fluidically connected to the mold cavity for holding a charge of melted metal. There is also provided means for fluidically connecting the melt chamber to the mold chamber and a valve element for controlling the flow of metal through the connecting means such that when the connecting means is opened, the chambers are fluidically connected and when the connecting means is closed, the chambers are fluidically isolated. The mold chamber has means for evacuating the mold chamber and means for pressurizing the mold chamber such that the melted metal disposed within the riser cavity is forced into the preform.

Abstract: In an improved method and apparatus for investment casting, a pattern (31) is mounted on a sprue base (19) of an spider gasket (12) that is secured to one end of a standard investment flask (11). A solid end cap (13) is secured to the other end of the flask. The end cap is provided with a matrix of holes (15) extending therethrough parallel to the axis of the flask, and a plurality of small diameter rods (16) are slidable secured in the holes in the end cap. The rods are extended into the interior of the flask about the pattern without contacting the pattern. Investment plaster (10) is poured into the flask through the spider assembly to immerse the pattern and rods, and the plaster is allowed to set. The rods are then withdrawn, forming a large plurality of channels (32) extending into or through the investment plaster, reducing the amount of investment plaster required in the flask. The channels greatly accelerate the drying time of the investment, and hasten the subsequent burnout process in a kiln.

Abstract: The present invention involves a method and apparatus for making an intermetallic casting (e.g. a titanium, nickel, iron, etc. aluminide casting) wherein a charge of a solid first metal protected from air as required is disposed in a vessel, and a charge of a second metal that reacts exothermically with the first metal is melted in another vessel. The molten second metal is introduced to the vessel containing the charge of the first metal so as to contact the first metal. The first and second metals are heated in the vessel to exothermically react them and form a melt for gravity or countergravity casting into a mold. The exothermic reaction between the first and second metals releases substantial heat that reduces the time needed to obtain a melt ready for casting into a mold. In particular, the exothermic reaction between the first and second metals, in effect, reduces the residence time of the intermetallic melt in the vessel.

Abstract: A vacuum die-casting machine has a bellows forming a sealed enclosure between the rear of the fill chamber and the piston rod. A vacuum is applied to the enclosure during evacuation of the die cavity and charging of the fill chamber with molten metal. As the piston moves forward, an inert gas at about atmospheric pressure is introduced into the enclosure and extends into the feed tube.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Particularly, a suitable matrix metal, typically in a molten state, is in contact with a suitable filler material or preform in the presence of a suitable reactive atmosphere in a sealed impermeable container, at least at some point during the process, which permits a reaction to occur between the reactive atmosphere and the molten matrix metal and/or filler material or preform and/or impermeable container, thereby causing molten matrix metal to infiltrate the filler material or preform due to, at least in part, the creation of a self-generated vacuum. Such self-generated vacuum infiltration occurs without the application of any external pressure or vacuum.

Abstract: The process calls for testing and monitoring the pressure levels in different parts of the die casting apparatus during a casting operation, including the die cavity itself and in positive and vacuum pressure lines. The process also includes process steps which cools a vacuum valve adjacent the die cavity and cleans the valve and lines during a casting operation. The process calls for aborting a casting operation at various time during the operation if certain measured parameters are not acceptable.

Abstract: A hydrogen battery alloy is prepared which is substantially free of inclusions of chromium by preparing a first precursor alloy or master alloy containing vanadium, nickel, and chromium using relatively equal amounts of vanadium and nickel and then adding from 5% to 12% by weight of chromium. The alloy materials are introduced into an aluminothermic reaction as vanadium pentoxide, nickel powder and chromium powder with the aluminum metal being in slight excess of its stoichiometric amount. The first precursor alloy described further alloyed with preselected amounts of nickel, zirconium, titanium, cobalt, manganese, aluminum, and chromium to form an alloy suitable for use as an electrode material in rechargeable electrochemical hydrogen storage cells.

Abstract: The apparatus for casting comprises a pressure vessel and a device for evacuating and pressurizing the vessel. The evacuating and pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold with a passage such that the melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurize the vessel. The passage contains a filter such that the melted material is prevented from entering the interior of the mold prior to pressurization. Additionally, the apparatus is comprised of a device for heating material in the chamber and the mold such that material is melted in the chamber and stays melted as it is forced down into mold while the pressurizing device pressurizes the vessel. The heating device is disposed in the vessel.

Abstract: This invention provides improved casting processes, equipment, and products. The invention is especially advantageous for die casting.

Abstract: A method for producing a cast of titanium or a titanium-based alloy by fusing titanium or a titanium-based alloy containing an alloy element in a vacuum furnace while introducing argon gas therein and casting the resultant melt in mold, which method is characterized by adjusting the introduction of the argon gas so that the argon gas pressure (atm) in the furnace assumes the following magnitude proportionately to the alloy element content M (% by weight):Not less than 2.1 when 0.ltoreq.M<5Not less than 1.6 when 5.ltoreq.M<10Not less than 1.5 when 10.ltoreq.M<15Not less than 1.2 when 15.ltoreq.M.

Abstract: The pattern is surrounded by packed unbound molding medium within a container. The gaseous material resulting from the evaporation of the pattern is removed from within the container as the gaseous material permeates through the packed unbound molding medium. The outflow of the gaseous material is regulated to control the rate of displacement of the pattern by the molten metal. The removed gaseous material is cleaned and cooled, thereby forming condensate and detoxified gas. Thereafter the condensate, and detoxified gas are discharged.

Abstract: A vacuum chill device is provided for reducing porosity in a bore wall of a lost foam metal casting. In a preferred embodiment, the chill device is attached to a vaporizable pattern formed of polystyrene or the like and includes a vacuum chamber received in a bore defined by the pattern. The pattern and chill device are embedded in a body of unbonded sand particles or the like, whereupon the refractory body extends therebetween. The vacuum chamber is connected to a vacuum line that leads outside the mold and includes screened orificies through which the vacuum chamber communicates with the surrounding refractory body. During casting, pattern decomposition vapors venting into the bore are drawn through the orifices into the vacuum chamber and exhausted through the vacuum line. Removal of the hot vapors from the bore by the vacuum device accelerates solidification of the bore wall to reduce shrink porosity therein.

Abstract: The bottom of a solid metal charge melts to fill a form below the charge. During melting, usually, the metal that enters the form remains continuous with an unused solid part of the charge. After cooling, the formed metal is removed together with the unused part of the charge--and usually with the form too. They are separated later or in a different operation, and another charge is positioned immediately for melting into another form, so the useful duty cycle is very high. A preferred form of the invention uses an upper melting chamber and a lower forming chamber, separated by a horizontal wall but communicating by an aperture through the wall. The charge and form are placed against the wall from below to block the aperture. The charge preferably extends up through the aperture into or toward the melting chamber, where an arc electrode or other heater melts the top of the charge, particularly near its center.

Abstract: Hard difficult-to-roll alloys are shaped by forming a mold of plastic, especially a polyacrylate, with a highly smooth surface onto which the alloy is deposited by low-temperature arc vapor deposition. The alloy layer is then separated from the plastic substrate and subjected to heat treatment to increase its density.

Abstract: In a lost foam investment casting process, the foam pattern is vacuum evaporated from the mold prior to pouring the metal.

Abstract: Method and apparatus for producing an investment casting from molten material by filling a cavity in a mold with the molten material utilizing at least one porous member in the inlet conduit system of the mold, the porous member enabling evacuation of the mold cavity, through the inlet conduit system and the porous member, and having a structure including pores small enough subsequently to support the molten material upon the porous member by surface tension, with the molten material closing off essentially all atmospheric communication between the inside and the outside of the mold cavity, to thereby prevent passage of the molten material into the mold cavity until the method and apparatus subsequently raises the pressure outside the mold to provide a higher pressure outside the mold cavity and create a differential pressure between the inside and the outside of the mold cavity sufficient to overcome the surface tension and urge the molten material to pass through the pores of the porous member and fill the

Abstract: An improved lost foam pour box and lost foam casting process wherein the improvements are positioning one or more fluid permeable separators, such as well points, within the contained volume of the box so that the gasses generated in the lost foam casting process can be vented to the exterior of the box by passing through the separators. By positioning the separators within the box, a larger box can be used and more castings can be made within with reduced burn-in and porosity defects in the resulting castings.

Abstract: Metal material is melted by moving the magnetic flux of electromagnets virtually perpendicular to an arc column to apply Lorentz force to the arc column and the metal material so that the arc column can move over the metal material surface. The movement direction and speed of the arc column are determined by detecting the arc voltage of the arc column. Feed back control is performed by comparing the obtained detection data with preset data so that optimum control is performed, and the molten metal is poured into a casting mold.

Abstract: A mold and method for producing, or casting a high-melting metal article from a high-melting metal having a melting point of about 900.degree. to 1600.degree. C.

Abstract: This invention relates to an elongated heating manifold member for injection molding and a method of making it. Channels are cut into the steel body to run parallel to a hot runner passage extending through the body. An electric heating element is centrally located in the channels using small spacer clips to provide a space around the heating element, and the channels are sealed at the ends. A highly conductive material such as a copper alloy is cast into the space around the heating element in a vacuum furnace. This forms an integral unit with the copper alloy fused to both the heating element and the steel body which substantially improve heat transfer in the manifold member. This avoids the creation of "hot spots" which otherwise may result in the heating element burning out, and maintains an even temperature along the hot runner passage which reduces deterioration of the melt due to overheating.

Abstract: A casting apparatus having a casting chamber which may be sealingly closed is provided. The casting chamber is evacuated and then an inert gas or a reducing gas is introduced prior to the casting operation. A ladle for containing a one-shot molten metal is disposed on the casting chamber to be evacuated simultaneously with the evacuation of the casting chamber and then surrounded by an inert or reducing gas atmosphere during the casting operation.

Abstract: Process for the production of precision castings with well-defined reproduction of detail and a great accuracy of measurement, by which the pattern to be reproduced is equipped with a drainage apparatus, having at least one duct extending outside the molding box, and the molding material containing phosphate as the bonding agent is poured in the molding box and solidified. After the pattern is removed from the solidified mold, by the introduction of compressed gas, the water of the solidified material is pressed out, and after calcining at a temperature of at least 250.degree. C., the mold is connected to a vacuum line and evacuated. The molten metal mass is then poured into the mold while the vacuum is maintained and solidified.

Abstract: A casting system includes an enclosure for covering a bowl-shaped entry port to an investment cavity for use in the lost-wax casting process. A delivery system is provided for delivering an inert gas to the enclosure to displace the original atmosphere which is driven out an exit port. The gas delivery system also provides a high-pressure environment in the enclosure for forcing molten metal, contained in the entry port, to pass by sprues into the mold cavity. Induction heating is provided for melting a solid metal ingot, controlled by a timer and pyrometer to occur prior to the injection, as well as during and optionally subsequent to the injection of compressed inert gas. The casting system is particularly useful for light-weight metals which can be cast only with difficulty in a centrifuge and is also modified for application to glass ingots and metals which do not heat well by induction.

Abstract: A fiber reinforced metal is made by introducing an array of fibers into a die, charging the die with molten metal by vacuum infiltration and then applying pressure by means of an inert gas to improve the penetration of the molten metal into the fiber array. Apparatus for producing a reinforced metal cylinder comprises a cylindrical former (2) onto which a composite fiber (3) of boron, silicon and carbon is wound. The former (2) forms an inner closure member for the die defining a cylindrical die cavity (8) with an outer die body (4). A central cavity (15) within the former (2) is for insertion of a heating element to facilitate the flow of metal through the cavity (8). The die cavity is evacuated via conduit (16) and molten metal is then drawn into the cavity via the passage (7). After charging the die with molten metal the conduit (16) is connected to a source of high pressure nitrogen.

Abstract: A ceramic mould is supported on a stainless steel platform carried at the upper end of a water-cooled tube surrounded by a copper cylinder containing alumina powder of approximately 100 .mu.m particle size which is fluidized by an inert gas. Metal in the mould is melted by a furnace which surrounds the mould and the mould is progressively withdrawn into the fluidized bed by which heat is extracted and transferred to water cooled coils surrounding the copper cylinder. In a modification, the inert gas is drawn from the fluidized bed by way of a filter and vacuum pump whereby the outlet pressure is reduced to about 1 torr. This reduces the risk of contamination of the alloy and permits re-use of expensive cooling gases.

Abstract: A target body composed of a select target material is attached to a cooling plate for sputtering systems in such a manner that substantially no bubbles, pores or oxide layers are present in the ultimate solder joint between the surfaces joined together. A pre-soldered target body and a corresponding presoldered cooling plate are exposed, in a vacuum, to a temperature above the melting point of the solder utilized so that degasification of the liquified solder occurs and any oxide layers present are decomposed and purged from the solder. Upon cooling in vacuum, the solder resolidifies and excludes any air bubbles, pores or oxide layers. A frame body with a two-step recess, with a lower recess or opening snugly fitting about a cooling plate and an upper opening freely fitting about the solder joint can be used to practice this technique. A subsequent reflow soldering can likewise occur in vacuum at a temperature above the melting point of the solder utilized.

Abstract: A mold structure for casting large metallic parts such as ingots so as to avoid the formation of the "shrinkage pipe" which normally develops on the exposed top surface of such castings during their solidification comprises a cap for placement on a mold which includes a diaphragm having a front surface located to intercept radiation emitted from the top surface of the cooling metal mass and to re-emit radiation back thereto, and a reflector for returning radiation emitted from the back surface of the diaphragm such as an infrared reflector or a stack of baffles. The cap may include a cooler for cooling the reflective surface and suitable ports which allow the interior of the mold and cap to be evacuated. Portions of the mold adjacent its open top may be provided with insulation to prevent heat loss from the metal by conduction. A heater for providing make-up heat to the top surface of the metal mass may also be included in the structure.

Abstract: Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low BTU gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollution is reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved.

Abstract: A method of preparing a charge of super alloy material for use in metal casting is disclosed. Thin wall tubes consisting of one of the metallic elements of the alloy material, or an alloy of such element are provided. If an alloy tube is selected, all elements in the tube alloy must also be materials included in the overall formulation of the alloy material. The type and quantity of the materials contained in the tubes is deducted from the quantities set forth in the overall formula and the balance of the formula is melted and poured under vacuum as a core in the tube using the tube as a mold. The resulting master charge is cut into unit charges each of a predetermined weight. These unit charges are then used in a subsequent casting operation by melting the entire unit charge under vacuum to cast precision products of an alloy which consists of the mixed and alloyed materials of both the tube and the core.

Abstract: The present invention comprises a process of forming a copper base alloy composite which is reinforced by graphite fibers, wherein the fibers are first coated with a continuous coating of an alloy constituent and then continuously coated with a coating of copper or a copper base alloy. The coated fibers are then heated in a vacuum under applied load, in combination with copper or a copper base alloy at a temperature above the melting point of the copper or copper base alloy but below the melting point of the alloy to be formed from the copper or copper base alloy and the alloy constituent with which said graphite fiber has first been coated.

Abstract: A low vacuum is applied to selected surface areas of a resin bonded sand mold to draw ambient air into selected portions of the mold. The air entering the mold burns out a significant portion of the resin binder to form a low BTU gas fuel and to recover casting heat for use in a waste heat boiler or other heat abstractions device. Therefore, foundry air pollution is reduced, the burned out portion of the molding sand is recovered for immediate reuse, and a savings in fuel and energy.

Abstract: A valve element is formed with a groove or notch in the region of the valve seat. The valve element is then introduced into a crucible pot which has the outer shape of the valve, when coated, and a cover is placed thereover completing the shape of the valve, when coated. Granular coating material, for example "Colmonoy 6" (0.75% C, 4.25% Si, 13 to 20% Cr. remainder Ni, 4.75% Fe and 3% B), is placed on the valve element, the cover is then placed thereover, leaving a small gap of the thickness of the coating around the valve element. The assembly is then subjected to vacuum, about 10.sup.-6 -10.sup.-7 torr, and heated to liquefaction temperature of the armor-coating material, which will fill the space between the valve element and the crucible pot and cover, thus coating the valve element with a thin coating therearound, and a thick layer in the region of the groove of the valve element, which may be in the order of millimeters, whereas the remainder may be in the order of thousandths of a millimeter.

Abstract: The invention relates to a process and apparatus for manufacturing silicon astings or moldings, having a columnar structure of single-crystal regions of crystal with a preferential crystallographic orientation, and which can be manufactured cheaply and in large numbers in a semi-continuous mode of production. Liquid silicon is cast in a casting station, under an inert gas and preferably under reduced pressure, preferably in graphite molds which are exposed to a temperature gradient of 200.degree. to 1,000.degree. C. After cooling, the silicon is withdrawn automatically via a transport chamber connected to the casting station into special cooling stations, while the casting station is reloaded with an empty mold for repeating the process. The silicon blocks which have preferably been produced by this procedure are use as basic material for inexpensive solar cells having efficiencies of more than 10%, after they have been sawn into individual small wafers and have been doped and lead-bonded.

Abstract: A shaped metal base component is formed, such as by casting or forging. The component is then thinly coated with a material, such as a ceramic material, having a higher melting point than the material of the shaped component. The coated component is then heated under zero gravity conditions up to a temperature which is below the melting point of the coating, but which is high enough to soften the component, the coating maintaining the shape of the component during the heating step. After completion of the heating step, the coated component is cooled under zero gravity conditions. The forming and coating of the component take place on earth, and the steps of heating and cooling the coated component are performed in space. After cooling the coated component, the coating is either stripped off the component or left on the component to form an integral part of the shaped body.

Abstract: The installation comprises a pressure tight casing with vacuum melting and casting chambers communicating with each other via a pressing chamber. The vacuum melting chamber accommodates an electrode holder arranged above a melting pot. Located under the melting pot is a pouring device with funnels, one of which is inserted into a hole in the shell of the pressing chamber. The vacuum melting chamber incorporates an appliance for cleaning the used funnels and a mechanism for moving the funnels. The pressing chamber communicates with the pressmould. One half of the pressmold is secured on an immovable vertical plate and the other half is mounted on a movable vertical plate. The movable vertical plate travels over horizontal guides.

Abstract: The present method and apparatus for die casting of metals such as aluminum, is especially suitable for casting under vacuum. The casting is performed under such operating conditions that a contact between the molten metal being cast and the free atmosphere is avoided all the way from the melt to the casting proper. For this purpose, the present casting apparatus includes a closeable and evacuable transport container connected to the casting apparatus proper by a coupling which is also evacuable. The transport container is placed on a filling chamber and the evacuating apparatus is arranged to simultaneously evacuate the filling chamber, the transport container and the coupling between the transport container and the filling chamber proper. The evacuation takes place in a direction opposite to the flow direction of the metal being cast. If desired, further evacuating means may be provided for evacuation of the filling chamber and the die in the direction of the metal flow.

Abstract: A superconductive film of Nb.sub.3 Ge is produced by providing within a vacuum chamber a heated substrate and sources of niobium and germanium, reducing the pressure within the chamber to a residual pressure no greater than about 10.sup.-5 mm Hg, introducing nitrogen into the resulting evacuated chamber in controlled amounts and vaporizing the niobium and germanium to deposit a film of Nb.sub.3 Ge on the heated substrate.

Abstract: A superconductive film of Nb.sub.3 Ge is produced by providing within a vacuum chamber a heated substrate and sources of niobium and germanium, reducing the pressure within the chamber to a residual pressure no greater than about 10.sup.-5 mm Hg, introducing air into the resulting evacuated chamber in controlled amounts and vaporizing the niobium and germanium to deposit a film of Nb.sub.3 Ge on the heated substrate.

Abstract: A superconductive film of Nb.sub.3 Ge is produced by providing within a vacuum chamber a heated substrate and sources of niobium and germanium, reducing the pressure within the chamber to a residual pressure no greater than about 10.sup.-5 mm Hg, introducing oxygen into the resulting evacuated chamber in controlled amounts and vaporizing the niobium and germanium to deposite a film of Nb.sub.3 Ge on the heated substrate.

Abstract: Apparatus comprising a crucible, a level-determining tank, a vacuum pump, an injection cylinder, a mould and appropriate interconnecting pipes. Molten metal is kept under vacuum throughout except that in a modification a gas may be deliberately introduced into the mould to provide a surface treatment of the casting.

Abstract: In a method for casting metal alloys, a molten metal alloy is introduced into a mold of a desired configuration containing a core material fabricated to a desired shape from titanium nitride while maintaining the mold under a vacuum. After allowing the mold to cool slowly to room temperature, the casted metal alloy with the core material exposed at one end is removed from the mold and immersed in a boiling caustic solution, thereby causing the titanium nitride core material to decompose. The casting so obtained has a smooth inner surface, an indication that no chemical reactions have occurred between the alloy and the core material.

Abstract: A process for casting steel ingots, wherein the steel from a ladle is cast under vacuum through the lid of a container which can be evacuated, into a mould, and wherein covering powder or anti-piping compound, respectively, is evenly applied upon the surface of the molten steel in the mould while the vacuum is maintained.

Abstract: In a process for casting a plate grid for a lead-acid storage battery comprising the steps of preparing a casting die assembly including two interengagable die halves between which is formed a casting cavity to cast a plate grid therein and pouring a molten metal of lead or lead alloy into said casting cavity to form said plate grid therein, an air in said casting cavity is vented through gaps between said die halves and then through a narrow air passage in at least one venting member received in either of said die halves so that said venting member is flush with the casting surface of the corresponding die half, said venting member at the top surface having cavity forming portions operatively associated with said die halves.

Abstract: A system for centrifugal casting of induction melted metal includes a crucible and a porous mold secured to a casting arm. The casting arm is secured to a hollow rotatable shaft which includes two separate fluid channels extending axially therethrough. The shaft is supported on a rotary valve which provides separate flow communication with each flow channel. One flow channel provides pressurized argon to the crucible to prevent oxide formation during casting. The other channel provides a vacuum to the exterior of the mold to draw gasses out of the metal, aid in the argon flow into the mold, and to augment the centrifugal flow of the molten metal into the mold.

Abstract: A vacuum sealing for the discharge nozzle of a casting ladle as for liquid steel is disclosed. The vacuum sealing, which prevents the penetration of atmospheric gases through the porous refractory discharge nozzle, is arranged in a vacuum-tight manner below the discharge nozzle. The vacuum sealing consists of clingy plastic films or thin metal sheets.