Abstract: A shaped metal casting made in an aggregate mold comprises fine solidification microstructure that is finer than the solidification microstructure of an analogous metal casting made from conventional molding processes. The solidification microstructure may be up to five times finer than the solidification microstructure of a conventionally prepared casting. In preferred embodiments, as a result of directional solidification, the fine solidification microstructure is substantially continuous from a distal end of the casting to a proximal end of the casting, and exhibits greatly enhanced soundness. Because of the control of the uniformity of freezing of the casting, its properties are substantially uniform.

Abstract: A quiescent melt handling system includes a melting furnace and a holding furnace communicating with the melting furnace for holding a molten metal melt. The holding furnace has a relatively large surface area and a relatively shallow depth, having a width to depth ratio in the range of 4-100 to 1. Also provided is structure in the holding furnace for separating inclusions from the melt in the holding furnace. A mold communicates with the holding furnace. A counter gravity casting system, which might comprise a vacuum assisted casting system, draws the melt into the mold.

Abstract: A process for the casting of metals includes the steps of providing a mold, delivering a molten metal into the mold, solidifying the molten metal, and removing at least a portion of the mold. The step of removing at least a portion of the mold begins before the step of solidifying the molten metal has been finished. An apparatus to deliver a solvent to a mold is also provided.

Abstract: A mold for the casting of metals including an aggregate comprising a refractory particulate material and a soluble binder which provides for minimal heat transfer between the mold and the molten metal during filling. The aggregate preferably includes at least a proportion of particulate material having a heat diffusivity at least as low as silica sand to reduce the chilling effect of the mold. The mold is removed from the casting the action of a solvent, which simultaneously cools and solidifies the casting at a maximum rate. Processes for forming the mold and the casting of metals using the mold are also disclosed.

Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.

Abstract: An apparatus for dispensing a molten material from a reservoir of molten material includes a dispensing chamber in communication with the reservoir and a first valve adapted to regulate communication of the dispensing chamber with the reservoir. A riser communicates with the dispensing chamber for dispensing the molten material, and a second valve is adapted to regulate communication of the riser with the dispensing chamber. Also disclosed is a method for reducing the inclusion of oxides in a casting of a molten metal.

Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.

Abstract: A process for the casting of metals includes the steps of providing a mold, delivering a molten metal into the mold, solidifying the molten metal, and removing at least a portion of the mold. The step of removing at least a portion of the mold begins before the step of solidifying the molten metal has been finished. An apparatus to deliver a solvent to a mold is also provided.

Abstract: A mold for the casting of metals including an aggregate comprising a refractory particulate material and a soluble binder which provides for minimal heat transfer between the mold and the molten metal during filling. The aggregate preferably includes at least a proportion of particulate material having a heat diffusivity at least as low as silica sand to reduce the chilling effect of the mold. The mold is removed from the casting the action of a solvent, which simultaneously cools and solidifies the casting at a maximum rate. Processes for forming the mold and the casting of metals using the mold are also disclosed.

Abstract: An apparatus for dispensing a molten material from a reservoir of molten material includes a dispensing chamber in communication with the reservoir and a first valve adapted to regulate communication of the dispensing chamber with the reservoir. A riser communicates with the dispensing chamber for dispensing the molten material, and a second valve is adapted to regulate communication of the riser with the dispensing chamber. Also disclosed is a method for reducing the inclusion of oxides in a casting of a molten metal.

Abstract: A method for manufacturing a vehicle wheel includes the steps of providing a wheel rim and a spider and holding the spider inside the wheel rim. The wheel rim and the spider are positioned in a high capacity forming machine. At least one of a portion of the wheel rim located adjacent an outer periphery of the spider and a portion of the outer periphery of the spider is permanently deformed towards the other of the wheel rim and the spider thereby securing the wheel rim to the spider. An apparatus for securing the wheel rim to the spider includes a bottom die, a bottom inside rim stabilizer supported on the bottom die, a spider supported on the bottom inside rim stabilizer, a top inside rim stabilizer and a wheel rim supported by the bottom rim stabilizer and the top inside rim stabilizer. A high capacity forming machine encircles the wheel rim. The high capacity forming machine includes a workpiece which at least sometimes contacts the wheel rim and an electric circuit located adjacent the workpiece.