Abstract: A composite metallic cast article (A) includes a shell (28) having a predetermined solid phase density. A non removable insert (24) is at least partially embedded within the shell (28). The insert (24) is fabricated from a foamed metal substance having a substantially lower solid phase density than the shell (28). The foamed metal insert (24) may have a layer of skin (26) fused with the molten metal of the shell (28) during the casting process. Tapered locating pins (30) or other spacing elements position the insert (24) within the mold cavity (18) to prevent shift during the casting operation. The foamed metal insert (24) reduces the time and expense involved in removing a traditional casting core after the casting operation is complete. Also, the insert (24) can be completely enclosed within the shell (28) of the article (A), thereby expanding the design capabilities of such cast articles (A).

Abstract: An abrasive machining assembly (10) wherein a worktable (14) is rotatably supported on a frame (12) for rotation about a table axis (A) and a plurality of platens (32) are supported on the worktable (14) with each of the platens (32) being adapted for supporting a workpiece to be machined by a machining disc (38) rotating about a tool axis (B). Each platen (32) is rotatably supported for rotation about a platen axis (C) which is radially spaced from the table axis (A) a different distance than the tool axis (B) whereby each of the platens (32) rotates about a platen axis (C) which is parallel to and offset from the tool axis (B) when positioned in the workstation.

Abstract: An abrasive machining assembly (10) wherein a worktable (14) is rotatably supported on a frame (12) for rotation about a table axis (A) and a plurality of platens (32) are supported on the worktable (14) with each of the platens (32) being adapted for supporting a workpiece to be machined by a machining disc (38) rotating about a tool axis (B). Each platen (32) is rotatably supported for rotation about a platen axis (C) which is radially spaced from the table axis (A) a different distance than the tool axis (B) whereby each of the platens (32) rotates about a platen axis (C) which is parallel to and offset from the tool axis (B) when positioned in the workstation.

Abstract: The subject invention is characterized by a mechanism for moving the tilt plate (45) laterally of the guide posts (38) to a loading position outside the operating area within the assembly so that the attachment surface faces sufficiently upwardly to allow a cope (36) and drag (34) defining a mold to rest thereon under the force of gravity. A plurality of crank arms (48) are fixed to and extend upwardly from one lateral edge of the tilt plate (45) to a distal end. A pair of hydraulic cylinders (51) are disposed above the movable platen (43) with a first connection (52) to the distal ends of the crank arms (48) and a second connection (53) to the movable platen (43) for rotating the crank arms (48) to thereby rotate the tilt plate (45) about a tilt axis (50) between an operating position within the assembly and the loading position outside the assembly and facing upwardly.

Abstract: The invention is characterized by a rack mechanism (60) interconnecting a fixed platen (41) and a movable platen (43) for preventing the movable platen (43) from cocking relative to its guide posts (38) during vertical movement thereof. The rack mechanism (60) includes a gear rack (61) paired with each of the guide posts (38) with the bottom end of each gear rack (61) secured to the movable platen (43), and a spur gear (71) in meshing engagement with each of the gear racks (61) and supported on the fixed platen. A box-like framework interconnects the gear racks (61) and a synchronizing drive system simultaneously rotates the spur gears (71) in unison and includes parallel shafts (72) on opposite sides of the framework with two of the spur gears (71) supported on each of the shafts (72) and in meshing engagement with two of the gear racks (61). The running tolerances between the spur gears (71) and the gear racks (61) can be adjusted by pillow blocks (76) supporting the shafts (72).

Abstract: A casting mold assembly includes cope and drag sections having a casting cavity therebetween and a casting core supported within the cavity. A vertical down sprue extends through the cope section and joins a flow passage extending through the core in prolongation of the down sprue for introducing molten metal directly into the mold cavity to produce a disk brake rotor. A filter is supported in the flow path of the core and a flow control lip is provided at the exit of the flow path to provide a flow constricting gap between the annular lip and an underlying lower cavity wall to slow the flow of metal into the cavity.

Abstract: A casting core 100a, 100b is fabricated entirely of decomposable refractory material such as foundry sand/binder and is formed with a plurality of push rod passage-forming portions (136a, 136b) for forming a corresponding plurality of push rod passages within a cylinder block (26) and a transverse intersecting oil gallery-forming portions (138a, 138b) for forming an associated long and narrow oil gallery within the cylinder block.

Abstract: A portable container 10 for containing liquids has a circular top wall portion 12, a circular exterior bottom wall portion 14, and a cylindrical side wall portion 16 extending vertically between the top wall portion 12 and exterior bottom wall portion 14. The container 10 includes a plurality of forklift tubes 18 attached to the exterior bottom wall portion 14 for receiving the forks 20 of a forklift vehicle 22. The side wall portion 16 has a drain opening 24 and a valve 26 disposed therein for draining the liquids from the container. The container 10 is characterized by an interior false bottom portion 30 abutting the side wall portion 16 and sloping downwardly toward the drain opening 24 for causing complete drainage of the liquids contained within the container 10.

Abstract: A decomposable casting core (56a, 56b) is formed in-situ with a sleeve-like liner member (64) and the assembly mounted within the mold cavity (24) of a cylinder block casting mold (22) for lining piston cylinder chambers (62a, 62b) of a cylinder block (26) cast within the mold (22). The liner member (64) is formed with an inner annular recess (80) which receives a corresponding annular projection (76) of the core (56a, 56b) for preventing the liner (64) from sliding axially on the core (56a, 56b) during casting.

Abstract: A melt-out zinc core is coated with insulating mica material and a graphite release agent and supported within a die cavity of a high pressure squeeze casting apparatus. Molten casting metal having a melting temperature above that of the core is injected into the die and then pressurized to about 15,000 psi to squeeze form the article in the die and around the core. The resultant article and core are then heated to above the melting temperature of the core and the core extracted from the article through cast-in outlet openings formed by the core. The insulating material and release agent are also extracted from the cast article by rinsing the cored passages of the cast article with water.

Abstract: A blow head or gassing head of an automatic core machine, which produces sand casting cores in a core box is formed of a downwardly opening box-like frame having a bottom closure plate. The heads may be alternatively used to respectively deposit a sand and binder material or to flow gas into a sand-filled core box cavity positioned beneath the head. The closure plates are provided with openings through which either the sand-binder material may drop from the blow head frame into the core box cavity or through which gas may flow from the gassing head frame into the cavity. The plate is loosely positioned beneath the frame and is clamped tightly upwardly against the bottom peripheral edge of the head by a spaced pair of elongated, rigid rails which engage and support the opposite side edges of the plate. A rail holding a clamping mechanism selectively moves the rails upwardly for clamping the plate against the frame and downwardly to free the plate relative to the frame.

Abstract: An intake manifold (10) includes cast plenum (12) and flange (14) members defining a plurality of outlet (22) and inlet (24) holes therein. Tubes (16) have opposite first (44) and second (46) ends which are received into the outlet (22) and inlet (24) holes with an interference fit and joined thereto with metallurgical bonds (48,50) comprising a low melting point metal coating material (52), such as zinc, alloyed with the tube metal and each of the plenum and flange metals. The method includes coating the ends (44,46) of the tubes (16) and the walls of the holes (22,24) with the molten coating material (52), heating the plenum (12) and flange (14) to an elevated temperature and then forcing the tubes (16) into the holes (22) to form the metallurgical bonds (48,50).

Abstract: A method of eliminating solidification shrinkage porosity defects in cast metal articles includes disposing an expanded polystyrene chill (36) within a preformed mold cavity (26) and thereafter introducing molten metal into the cavity (26) and vaporizing the chill member (36), whereby the heat of vaporization rapidly cools a localized region of the molten metal adjacent the chill member and accelerates solidification thereof enabling remote still-molten metal to feed solidification shrinkage in this region and prevent the formation of porosity defects that would otherwise result.

Abstract: A method for metallurgically bonding cast-in-place cylinder liners 12 to a cylinder block 38 includes first coating the outer surface of the liners 12 with a low melting point molten metal material 14 and allowing it to solidify. The coated liners 12 are then positioned within a cylinder block casting mold 22 and molten cylinder block metal introduced into the mold 22. At a time prior to the cylinder block metal contacting and surrounding the coated liners 12, induction heating coils 28 are activated to premelt the coating material 14. The molten cylinder block metal then contacts and mixes with the molten coating metal 14 to form a metallurgical bond between the liners 12 and cylinder block 38 upon solidification.

Abstract: A vacuum-assisted countergravity casting apparatus 10 includes a casting mold 14 disposed on a cheek mold member 28 and supported within a vacuum box 40. The mold 14 includes bottom feed gates 24 communicating with a cavity 22 within the mold 14. The cheek mold member 28 has distribution channels 30 formed in its upper surface 32 and includes a bottom ingate passage 34. A feed stalk 42 is connected to the ingate passage 34 for immersion into an underlying supply of molten metal 12. Actuation of vacuum pump 52 produces a vacuum within the vacuum chamber 46 and draws the molten metal upwardly to fill the cavity 22. Once filled, the mold 14 is pushed sideways on the cheek 28 by ram 68 causing the feed gates 24 to move out of registry with the distribution channels 30. The molten metal is thereby retained in the cavity 22 without assistance from the vacuum.

Abstract: A countergravity low-pressure casting apparatus (10) includes a feedback control system (98) which continuously measures the actual pressure of metal being pumped into a mold (12) and controls the voltage applied to an electromagnetic pump (66) to conform the actual metal pressure with the ideal metal pressure versus casting cycle time fill schedule (96).

Abstract: A permanent metal mold (12) has a casting cavity (18) within which variable thickness molten metal articles (20) are cast. Portions (26) of the casting cavity walls (16) are formed oversized and lined with sand (44) to conform with the external size and shape of certain thick (46) and thin (48) sections of the cast article (20). The thickness of the sand liner (44) is reversely correlated to the thick (46) and thin (48) sections of the article (20) to cause these sections (46, 48) to cool at different rates in order to achieve an approximately equalized cooling time of these sections (46, 48). Other portions (50, 52) of the casting cavity walls (16) are formed bare of the sand liner (44) and conform with the external size and shape of other corresponding sections (54, 56) of the cast article (20).

Abstract: A sleeve of woven heat resistant material is axially compressed (22) to enlarge its cross-sectional area and perimeter. A support element (24) is disposed within the sleeve (22) to support it in its enlarged perimeter condition (26). The sleeve-covered support element (18) is then disposed in a cavity (14) of a casting mold (12) and molten metal (36) is cast into the cavity (14) and around the sleeve-covered support element (18). The molten metal (36) is allowed to solidify to form a cast article (16). The support element (24) is then withdrawn from within the sleeve (22), leaving the sleeve (22) within and adhered to the walls of the passageway (20) of the article in the expanded perimeter condition (26). A tension force A is applied to the sleeve (22) forcing it to stretch into a smaller cross-sectional area and perimeter (28) and causing the sleeve (22) to detach from the casting (16) for easy removal.

Abstract: A method for metallurgically bonding a cylinder liner 22 within a clinder block 14 of an automotive engine includes coating the outer surface of the liner 22 with a low melting point molten metal coating material 24, such as a zinc, as well as cylinder walls of the block 14 and then allowing the coatings to solidify. The block 14 and liner 22 are then heated to an elevated temperature and the liner 22 press-fit into the block 14. This causes the coating materials to alloy with the liner and block metal as well as one another, forming a metallurgical bond between the block 14 and liner 22 when cooled.

Abstract: A method for eliminating porosity defects in aluminum cylinder blocks (22) having cast-in-place metallurgically bonded cylinder liners (12) includes coating the liners (12) with a low melting point molten metal such as zinc and thereafter removing a virtually entire outer layer of pure Zn, which would otherwise melt during casting and invade the block metal, leaving behind shrinkage defects in the resultant cylinder block (22).