Abstract: Method and apparatus for forming aluminum ingot having shaped ends to avoid alligatoring during rolling.

Abstract: Method and apparatus for forming aluminum ingot having shaped ends to avoid alligatoring during rolling.

Abstract: The present invention relates to efficient furnace capacity utilization in the production of ingots. The present invention includes a crucible and use of the same. The crucible approximately matches the interior shape of the furnace in which the ingots are produced.

Abstract: An ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

Abstract: This invention relates to an apparatus and a method of a crucible design and a tipping mechanism used to cast silicon. The crucible of this invention produces high purity silicon for solar cells and/or solar modules, such as by improving quality and/or reducing impurities in the cast silicon. As impurities concentrate in an uncrystallized portion of the silicon, a portion of the remaining molten silicon is poured or decanted from the main portion of the crucible to a second portion of the crucible.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: An injection mold inner core die is disclosed that uses no additional moving parts and decreases fabrication time required for injection molded pieces such as airbag covers. The injection mold inner core die allows for cost effective revising and re-tooling of the die. The inner core die includes one or more window mold members that extend from the surface of the inner core die. The window mold member is shaped to form a window in solidified injection mold material once the mold is closed. The window mold member includes a pair of parallel ramps that provide a pair of inclined planes for separating material contacting the surface of the inner core die. The inclined planes created by the ramps allows the material to travel up the ramps and frees the material from the window mold member. The ramps run from the surface of the inner core die to the top of the window mold member in a direction in which the molded piece is to be automatically moved for removal from the inner core die.

Abstract: Apparatus for the producing workpieces and blocks from meltable materials in which a liquid starting material is solidified in a directional manner in a casting mold using a cooling device. For the controlled guiding of the solidification front during cooling of the molten material a cooling structure having a plurality of heat conducting bodies is introduced from below into a corresponding recesses of a body assigned to the bottom of the casting mold.

Abstract: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.

Abstract: A method for producing a silicon ingot having a directional solidification structure comprising the steps of: placing a silicon raw material into a crucible of a melting device constructed by mounting a chill plate on an underfloor heater, mounting a crucible with a large cross-sectional area on the chill plate, providing an overhead heater over the crucible, and surrounding the circumference of the crucible with a heat insulator; heat-melting the silicon raw material by flowing an electric current through the underfloor heater and overhead heater; chilling the bottom of the crucible by halting the electric current through the underfloor heater after the silicon raw material has been completely melted to form a molten silicon; chilling the bottom of the crucible by flowing an inert gas through the chill plate; and intermittently or continuously lowering the temperature of the overhead heater by intermittently or continuously decreasing the electric current through the overhead heater, and an apparatus for pro

Abstract: This invention relates to an improved mould for casting a standard Magnesium ingot. The mould is constructed so as to minimize the surface area of the molten Magnesium which is exposed to the surrounding air. This significantly reduces the reliance on costly or harmful gases typically used in the casting process. The vertical mould which is internally tapered, has an open top and a closure at the bottom thereof. The ingot is easily removed from the mould when said closure is opened. The mould is adapted for use as part of an automated process employing a cyclic conveyance system for efficiently producing Magnesium ingots from recycled scrap Magnesium.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: A method of manufacturing an open top, walled member for containing a molten metal, including the steps of forming an inner wall of a mold with a metal sheet and an inner lining covering the sheet, wherein the inner wall defines an inside surface of the walled member and transferring a casting compound between an outer wall of the mold and the inner lining of the inner wall to form the walled member. The metal sheet and inner lining are then removed to allow one to apply heat to dry the casting compound. In the case where the metal sheet includes a plurality of openings, one may also retain the inner wall during the heating step. The heat to dry the casting compound is applied to the inner lining to a sufficient temperature to melt the inner lining and uncover said openings of the metal sheet. The metal sheet is removed when the casting compound is dried.

Abstract: A method of manufacturing an open top, walled member for containing a molten metal, especially a flowing molten metal or reconstructing a worn or damaged member. The method includes the step of forming the inner walls of a mold which define the inner surfaces of the walled member of an open metal mesh screen which is meltable by the molten metal which is to be contained. The next step is to transfer, usually by pumping, an alumina-silicon carbide casting compound into the space between the open mesh metal screen and the outer walls defining the mold, which outer walls may be in situ structures. If an existing walled member is being repaired, any damaged or worn portions of the existing walled member are removed and the casting compound is poured in to replace these portions. The next step is to apply heat to dry the casting compound while the open mesh screen of the mold remains in place in contact with the casting compound.

Abstract: A mold for forming an open top, walled member having side walls and a bottom surface for containing a molten metal. The mold including an inner screen having a plurality of openings having inner side walls and a bottom surface. The mold further includes an outer wall, wherein the inner screen and the outer wall are spaced relative to each other to define a space so that the side walls and the bottom surface of the open top, walled member are formed therebetween.

Abstract: A mold for casting metal ingot sows having an aspect ratio of at least 4:1. The mold comprises a bottom wall from which a side wall extends upwardly and outwardly and from which heat transfer structure extends downwardly for transferring heat away from the bottom wall.

Abstract: A mold for the casting of aluminum sow ingots includes a mold box having a bottom wall and side walls that define a generally rectangular mold cavity. The bottom wall includes a central raised longitudinally extending protrusion and side longitudinally extending protrusions adapted to define corresponding depressions in the ingot bottom. The side depressions establish ledges for receiving a pair of fork lift blades or tines entering the ledges from either transverse side of the ingot perpendicular to the ledges. A pair of transversely extending protrusions in the mold bottom wall establish corresponding transverse depressions in the mold bottom that are perpendicular to the central longitudinal depression and equispaced from the central transverse axis by a distance enabling the pair of fork lift blades to enter the transverse depressions from a direction perpendicular to either of the longitudinally extending ingot sides to provide a dual entry feature for ease of handling.

Abstract: An improved method of manufacture is provided for producing a channeled wall thrust nozzle (10) of the type used to define a thrust chamber (12) in a jet or rocket engine. The method utilizes a precision formed mandrel (20) having an external geometry conforming generally to the converging-diverging shape of the desired thrust chamber (12), and further including longitudinally extending slots (24) for receiving channel separation ribs (26) which may be formed by die cutting from sheet stock. The channel spaces (16) between the separator ribs (26) are filled with a removable casting material (30) such as wax, and an outer housing shell (32) for the thrust nozzle is mounted about and secured to the separator ribs. The mandrel (20), which is transversely split at the throat of the thrust chamber (12), is then removed to expose the radially inboard margins of the separator ribs (26) for precision machining, followed by mounting of an inner housing shell (34) to the separator ribs.

Abstract: A sealing structure is disposed between a metal-casting ingot mold bottom portion and a bottom plate to prevent the leakage of molten steel between the mold and plate. A clay rope disposed in a closed configuration corresponding to the bottom of the ingot mold is affixed to the cardboard sheet with an adhesive system. Overlapping portions of the cardboard sheet are grasped to position the clay rope directly under the ingot mold, and the mold is lowered onto the bottom plate. Hot glue (or pressure sensitive adhesive tape and/or white glue) holds the clay rope on the cardboard sheet. The clay rope is offset at a central portion of the sheet to allow folding of the sheet for transport.

Abstract: An ingot mold provided with means affording stress relief thereto for the ingot pouring operation, while maintaining the mold in condition to aid in preventing metal leakage therefrom during the ingot pouring operation and subsequent cooling of the ingot, and providing mold wall support for the ingot until its skin has sufficient structural integrity to support the molten interior of the ingot, and a mold which can be recycled for use in a faster manner as compared to heretofore utilized solid or one-piece type ingot molds. In certain embodiments, the mold is formed of a plurality of completely separate and individual side wall sections defining at least the side periphery of a mold cavity, together with coupling means connecting the wall sections together. The coupling means provide for expansion and contraction of the mold sections relative to one another during the pouring of molten metal into the mold, and the resultant heating and subsequent cooling thereof.

Abstract: A process for casting ingot molds wherein a smooth, rigidized insulative board is used to form the as cast bottom surface of the ingot mold to produce a smooth flat surface which does not require machining and to permit slow cooling and solidification so that a uniform macrostructure and microstructure is effected.

Abstract: Bosses project from the outer surface of the ingot mold and are arranged in a planar zone, each of the bosses contains a channel that has slidably positioned therein an anchor which is projected beyond the outer surface of each boss into each boss. The projecting portions of the anchors are attached to a continuous reinforcement band extending between the projecting portions of the anchors. The continuous reinforcement band is spaced from the ingot mold. Stresses and strains caused by teeming (pouring) hot molten metal into the ingot mold are absorbed by the continuous reinforcement band.

Abstract: The space between the open bottom mold and the supporting stool used for casting ingots is sealed by placing a thin wall steel tube between the mold and the stool. The weight of the mold partially collapses the tube causing the surfaces of the tube to conform to both the surfaces of the mold and the stool, thus forming a seal.

Abstract: An ingot mold with mold wall and stool shields and the method of installing the mold wall and stool shields to the ingot mold and stoll. The mold wall shield comprises at least two portions connected by a bend. The mold wall shield and the stool shield can be multi-layered to provide a thin envelope or layer of air between the parallel layers. The shields are nailed to the mold or stool by an explosion actuated hammer. The mold wall shield is installed with the bend near the intersection between the mold and the stool. The shields are made of similar material to that being cast and melt due to the heat of the molten metal in the mold.

Abstract: An ingot mold provided with means affording stress relief thereto for the ingot pouring operation, while maintaining the mold in condition to aid in preventing metal leakage therefrom during the ingot pouring operation and subsequent cooling of the ingot, and providing mold wall support for the ingot until its skin has sufficient structural integrity to support the molten interior of the ingot, and a mold which can be recycled for use in a faster manner as compared to heretofore utilized solid or one-piece type ingot molds. In certain embodiments, the mold is formed of a plurality of completely separate and individual side wall sections defining at least the side periphery of a mold cavity, together with coupling means connecting the wall sections together. The coupling means provide for expansion and contraction of the mold sections relative to one another during the pouring of molten metal into the mold, and the resultant heating and subsequent cooling thereof.

Abstract: This invention relates to an improved ingot mold. The only alteration in design involves the outside surface of the ingot mold. The invention involves recesses cast or cut into the outside surface of ingot molds for the specific purpose of accommodating steel reinforcement bands. These recesses allow air spaces to exist between the mold surface and the steel reinforcement bands for the purpose of reducing thermal conduction and to bridge any irregularities in the iron mold surface. They can further allow the band to be applied in such a way that the band does not extend beyond the furthest outside surface of the ingot mold exterior wall. The benefit of this is that the steel band is protected from any abuse that may occur as a result of handling the mold. The further benefit is achieved of protecting the band from molten steel that may splash from the top of the mold during teeming (pouring) or transportation.

Abstract: A method of sealing a joint between component parts of a metal mould for metal casting comprises applying in the area where the seal is desired an elongated sealing element and a compressible cover separating the sealing element from each of the surfaces to be sealed together. The method is especially useful for sealing the joint between an ingot mould for steel ingots and a base plate for the mould.

Abstract: A sectional ingot mold formed of a plurality of side wall sections which when assembled define at least the side periphery of a mold cavity, with means coacting on the side wall sections for coupling the wall sections together into an integral unitary ingot mold; said means, providing for automatic compensation for expansion and retraction of the mold assembly sections when molten metal is poured into the ingot mold by providing for expeditious expansion of the mold assembly sections with respect to one another while aiding in sealing the mold sections from leakage of molten metal during the pouring and cooling of the ingot in the mold. In certain embodiments, yieldable gasket material is disposed between the wall sections at their junctions for aiding in preventing leakage of molten metal from the ingot mold assembly during pouring and solidification of an ingot in the mold.

Abstract: This invention relates to a method for reinforcing and repairing cast iron molds by surrounding the mold with a closely fitted steel plate or plates, connecting the ends of the steel plate or plates to form a continuous band, attaching the continuous band to the cast iron mold and locating spacers between the cast iron mold and the continuous band to elevate the band from the cast iron mold wall surface. This invention further relates to a method for reducing shear stress on the means by which the continuous band is attached to the mold by locating the means of attachment around a corner from the source of stress at an obtuse angle to the mold wall being reinforced.

Abstract: A laminated plate assembly (17) for protecting the mold stool (11) or bottom (125) of an ingot mold (10 or 100) during the pouring of molten metal therein, the assembly comprising spaced-apart plates (20, 21 and 22) secured together by embossments (24) or the like.

Abstract: A casting consisting of a dehydrated agglomerate of particulate material and shaped such that one of its right angle projections is in the form of a trapezoid whose sides include angles greater than 90.degree., the sides being joined by means of curved surfaces.

Abstract: A vertical, open-ended ingot mold assembly including a mold stool having a relieved portion machined in its base which machined relieved portion has a cavity therein produced by erosion during casting. The useful life of the mold stool is prolonged by providing a quantity of metal particles to fill the cavity and having a plate positioned over the cavity and metal particles, which plate is secured within the cavity by a ring that is within the relieved portion of the mold stool. This ring protects the periphery of the machined relieved portion from erosion during casting and also prevents the plate and metal particles from mingling with the cast metal. For each successive casting operation, the eroded cavity is filled with metal particles and a new plate is positioned thereover. Alternately, the use of metal particles may be avoided by using only a plate of a thickness sufficient to protect the remainder of the mold stool from erosion.

Abstract: A method of repairing an ingot mould for a steelworks which forms cracks, the method comprising applying a patch plate at both sides of the crack, a series of patch plates being provided in succession in the direction of the length of the crack, reinforcement strips curved to match the curvature of the mould wall being provided on the patch plates and being adjusted to positions transversely of the length of the crack and then fixed on the plates.

Abstract: A process for reconditioning an ingot mold of the type including an elongated cavity area having some predetermined volume and at least one open end for purposes of extending the useful life thereof. In accordance with the reconditioning process, a short portion of the mold length is cut-off or machined away at a mold cavity open end to eliminate the usual mold damage which typically occurs at that area after a number of separate casts. The cut-off is effected so that the mold cavity will have some new volume comprising some predetermined reduction of the original volume. This second volume is calculated such that ingots then cast from the reconditioned mold and thereafter processed may be cut into a lesser number of bars having substantially the same size and volume characteristics as those bars cut from ingots cast in the original mold.

Abstract: A sectional ingot mold formed of a plurality of side wall sections which when assembled define at least the side periphery of a mold cavity, with means coacting on the side wall sections for coupling the wall sections together into an integral unitary ingot mold; said means, providing for automatic compensation for expansion and retraction of the mold assembly sections when molten metal is poured into the ingot mold by providing for expeditious expansion of the mold assembly sections with respect to one another while aiding in sealing the mold sections from leakage of molten metal during the pouring and cooling of the ingot in the mold. In certain embodiments, yieldable gasket material is disposed between the wall sections at their junctions for aiding in preventing leakage of molten metal from the ingot mold assembly during pouring and solidification of an ingot in the mold.

Abstract: A mold for casting metals is provided with a roughened surface so that, on first contact of the mold with the melt, heat transfer is controlled in such a way that the melt comes into contact only with the peaks of the projections on the mold surface and an air gap is formed between the melt and the valleys on the surface. The pattern of roughness on the mold surface comprises a uniform arrangement of pyramidal or blunted-cone shaped projections. Neighboring projections are spaced a distance d of 0.05 to 1 mm apart and have a height h of 0.1d<h<d. The pyramid or blunted con surfaces satisfy the condition of 0.05<.function./d.sup.2 <0.5. A process which does not involve deformation is preferred for producing the rough pattern, for example, a photochemical etching process. The molds are suitable for many casting processes, in particular for continuous D.C. ingot or strip casting with moving molds and caterpillar track type mold belts.

Abstract: A method for ingot casting using a vertical, open-ended mold removably positioned on a mold stool, a closed-bottom mold or a plug-bottom mold wherein steel particles are used to fill a relieved portion of the bottom typically resulting from erosion thereof during casting; a metal plate is used to close this relieved portion, thereby preventing comingling of the steel particles and metal being cast; this practice prolongs the life of mold stools and mold bottoms without requiring expensive replacement.

Abstract: A high melting temperature metal, casting mold is made of sheet metal embedded in a supporting mass of refractory particles preventing deformation of the sheet metal under the weight of the cast metal and conducting heat from the sheet metal at a rate preventing complete melting of the sheet metal.

Abstract: In bottle top molds a plug is used as a closure for the opening in the top wall of the molds through which the molten metal is poured. The surface of the opening tends to become eroded by the molten metal flowing into the mold and, as a result, the plug no longer forms an effective closure rendering the mold unusable. To prolong the useful life of the mold, a ring-shaped member is secured to the top wall of the mold in register with the opening and covering the eroded surface. The ring-shaped member is configured to receive the plug so that it continues to form a closure for the mold.

Abstract: A mould for the electroslag casting of faceted metal ingots has longitudinal flutes on the internal surfaces of at least two walls thereof. The depth of these flutes decreases in a horizontal direction from the middle of the walls to the corners of the mould chamber.

Abstract: A mould assembly for casting molten metal which comprises a book mould, the upper parts of the walls of the upwardly open cavity of which are lined with hot top lining material and wherein extending across the width of the cavity there are one or more bridges of hot top lining material maintaining the hop top lining material along the longer walls of the cavity in contact with those longer walls.

Abstract: A casting chill mold is provided for producing elongate metal ingots having a length to diameter ratio in excess of 10:1 in which the wall thickness of the mold is substantially no greater than that required to enable the walls to withstand the hydrostatic pressure of the melt upon the occurrence of thermal stress. Preferably the mold is surrounded by a spaced supporting framework contacting the outer surface of the mold at spaced discrete small area points of contact.

Abstract: An ingot mold of the bottle-top type and method for its use wherein the primary pipe or shrinkage cavity at the top of the ingot is decreased in length and a solid bridge is formed between the primary and secondary pipe cavities, sealing off the secondary cavity. The cast ingot is cropped in the area of the solid bridge between the primary and secondary pipe cavities, leaving the secondary cavity sealed such that it can be welded without oxidation during hot rolling to increase the ingot yield.

Abstract: A shock absorber pad of molded fibers for the drop casting of ingots, comprising a plate of molded fibers having an assembly of truncated cups disposed in files and rows connected by thick webs along their upper edges. The webs are perforated between the cups and have concave cylindrical ribs for stiffening purposes. The cups and ribs in one file or row are so dimensioned as to nest into the cups and ribs of the opposite edge of an adjacent pad. The bottoms of the cups can be solid or perforate.

Abstract: The invention is concerned with an ingot casting mould closed at both its ends and comprising a first section the bottom wall of which is provided with a refractory layer, intended to receive a molten metal stream, a second section having an inclined bottom rising progressively from the adjacent edge of this layer and a third section having a flat bottom connected to the upper edge of the inclined bottom of said second section. This ingot casting mould is particularly suitable for the casting of materials such as ferromanganese which are highly corrosive with respect to cast iron.

Abstract: A big-end-down ingot mold has a heat insulating chamber which, when the ratio of the width of the wider walls to that of the narrower walls of the mold is less than 1.7:1, is formed in each of the four side walls and, when the ratio is 1.7:1 or more, is formed in each of the two opposed wider walls and whose horizontal sectional areas each gradually increase from below toward above. By means of the heat insulating chambers the solidification rate of the molten metal is regulated to prevent the formation of secondary pipes and segregation around the pipes within an ingot cast in the mold.

Abstract: For forming a lifting lug upon an ingot mould, either as a replacement for a broken-off lug on an existing mould or as a lug on a newly-produced mould formed in the first instance without lugs, a mounting plate is secured to the mould by fasteners driven through said plate and into the mould; then an array of fillets is welded to the plate in correspondence with and in conformity with the desired lug configuration; whereafter a consolidating plate is positioned to overlie the outer edges of the fillets and is welded to the latter.

Abstract: A method for repairing eroded bottoms of ingot molds by forming a casting space in the bottom of the mold at the point of erosion, the casting space having an hour-glass type shape, placing the ingot mold on a molding platform so as to close off the bottom of the casting space with a refractory material, placing a protective layer of a compactable refractory material about the interior of the mold and introducing to the casting space an alumino-thermic material and then igniting said alumino-thermic material such that the weld metal from the reaction thereof completely fills the casting space. Methods for repairing the bottoms of closed bottom as well as plug bottom molds are disclosed.

Abstract: Blank metal ingots particularly steel of uniform weight per piece and cross section are formed with a mold which is made up of a plurality of superposed vertical sections which together define an interior mold cavity of uniform cross section over its total height. The steel which is produced in a known steel making method is first tapped into a casting ladle which is provided with a refractory lining. A plurality of mold sections are built up one after the other over a casting plate and the steel is directed upwardly through a bottom opening on the plate into the mold cavity and as soon as the mold is completely filled the slide plate is closed. For casting ingots of round or polygonal cross section with diameters of 200 to 350 millimeters the steel is bottom poured into the mold cavity at a rate of rise of from 30 to 80 centimeters per minute and the surface of the melt is not covered but is maintained as cold as possible.