Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.

Abstract: A method and system of processing castings is provided in which one or more castings are deposited into a mobile furnace and moved from one station to another of a multi-station casting processing system. The interior of the mobile furnace is heated so as to maintain the temperature of the casting within a desired range of temperatures. The multi-station casting processing system may include a casting machine, a fluidized bed and a quench tank. The method may include transferring a casting into the mobile furnace and moving the furnace from one station to another.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: Disclosed is both a process and apparatus for forming a molded article. The molded article is formed in a vertically potted flaskless mold. The flaskless mold is closed having an opening in the top portion that receives a chill for directing the cooling of the molten metal introduced into the mold cavity. After the molten metal solidifies and before the mold is broken down, the chill is removed for reuse in the process.

Abstract: A system for combustion and removal of residual carbon within fly ash particles in which the fly ash particles are fed into a particulate bed within a reactor chamber. The fly ash particles are subjected to heat and motive air such that as the fly ash particles pass through the particulate bed, they are heated to a sufficient temperature to cause the combustion of the residual carbon within the particles. The fly ash particles thereafter are conveyed in a dilute phase for further combustion through the reactor chamber away from the particulate bed and exhausted to an ash capture. The fly ash is then separated from the exhaust air that conveys the ash in its dilute phase with the air being further exhausted and the captured fly ash particles being fed to a feed accumulator for re-injection to the reactor chamber or discharge for further processing.

Abstract: A single furnace system integrates, in combination, two or more distinct heating environments (which in the preferred embodiments include a conduction heating environment and a convection heating environment) integrated such that the multiple environments define a continuous heating chamber through which a moving workpiece (such as a casting) transitions from one heating environment to the other without being exposed to the atmosphere. In accordance with the preferred methods, the transitioning of the casting from one environment to the other is accomplished with no meaningful change in temperature.

Abstract: A system for combustion and removal of residual carbon within fly ash particles in which the fly ash particles are fed into a particulate bed within a reactor chamber. The fly ash particles are subjected to heat and motive air such that as the fly ash particles pass through the particulate bed, they are heated to a sufficient temperature to cause the combustion of the residual carbon within the particles. The fly ash particles thereafter are conveyed in a dilute phase for further combustion through the reactor chamber away from the particulate bed and exhausted to an ash capture. The fly ash is then separated from the exhaust air that conveys the ash in its dilute phase with the air being further exhausted and the captured fly ash particles being fed to a feed accumulator for re-injection to the reactor chamber or discharge for further processing.

Abstract: The method and apparatus for reclaiming substantially pure sand from a heat treating furnace; wherein a casting with sand core and/or sand mold, comprising sand bound by a combustible binder, attached thereto is introduced into the heat treating furnace; or, wherein portions of sand core and/or sand mold that are not attached to a casting are introduced into the heat treating furnace. Wherein, the reclaiming within the furnace is carried out, in part, by a fluidizer that promotes binder combustion by one or more process of agitating, heating, and oxygenating. Wherein, the characteristics of the reclaimed sand are selectively controlled by controlling the dwell time of the sand within the heat treating furnace.

Abstract: An integrated metal processing facility in which molten metal is poured into a series of molds at a pouring station to form metal castings, which are then transferred to a heat treatment line. Prior to introduction of the castings into a heat treatment station of the heat treatment line, the castings are subjected to heating sufficient to arrest cooling of the castings at or above a process control temperature for the metal thereof.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

Abstract: A single furnace system integrates, in combination, two or more distinct heating environments (which in the preferred embodiments include a conduction heating environment and a convection heating environment) integrated such that the multiple environments define a continuous heating chamber through which a moving workpiece (such as a casting) transitions from one heating environment to the other without being exposed to the atmosphere. In accordance with the preferred methods, the transitioning of the casting from one environment to the other is accomplished with no meaningful change in temperature.

Abstract: A single furnace system integrates, in combination, two or more distinct heating environments (which in the preferred embodiments include a conduction heating environment and a convection heating environment) integrated such that the multiple environments define a continuous heating chamber through which a moving workpiece (such as a casting) transitions from one heating environment to the other without being exposed to the atmosphere. In accordance with the preferred methods, the transitioning of the casting from one environment to the other is accomplished with no meaningful change in temperature.

Abstract: Provided is a five-in-one process/integrated furnace system that (i) receives and heat treats a casting, (ii) removes sand core materials from the casting, (iii) actively reclaims sand from the sand core materials, (iv) substantially cools the reclaimed sand, and (v) removes fines from the reclaimed sand. The furnace system includes a heating chamber disposed above and contiguous with a cooling chamber. The heating chamber and cooling chamber are preferably constructed so that heat and gasses pass therebetween. The heating chamber is preferably in the general form of a heat treating furnace. The heating chamber receives and heat treats metal castings. During the heat treating process, sand core materials are dislodged from the castings and enter into a sand reclaiming region. A hot fluidized bed functions to reclaim sand from the sand core materials within the heating chamber.

Abstract: The method and apparatus for reclaiming substantially pure sand from a heat treating furnace; wherein a casting with sand core and/or sand mold, comprising sand bound by a combustible binder, attached thereto is introduced into the heat treating furnace; or, wherein portions of sand core and/or sand mold that are not attached to a casting are introduced into the heat treating furnace. Wherein, the reclaiming within the furnace is carried out, in part, by a fluidizer that promotes binder combustion by one or more process of agitating, heating, and oxygenating. Wherein, the characteristics of the reclaimed sand are selectively controlled by controlling the dwell time of the sand within the heat treating furnace.

Abstract: Provided is a process/integrated furnace system that (i) receives and heat treats a casting, (ii) removes sand core materials from the casting, and (iii) actively reclaims sand from the sand core materials. The furnace system includes a heating chamber that receives and heat treats metal castings. During the heat treating process, sand core materials are dislodged and fall from the castings into a sand reclaiming region. A hot fluidized bed functions to reclaim sand from the fallen sand core materials within the heating chamber. The fallen sand core materials are not evenly distributed across the zones within the heating chamber. To compensate for the uneven distribution, sand discharge weirs and leveling bars divide the hot fluidized bed in to different bed zones having different dwell times.

Abstract: The method and apparatus for reclaiming substantially pure sand from a heat treating furnace; wherein a casting with sand core and/or sand mold, comprising sand bound by a combustible binder, attached thereto is introduced into the heat treating furnace; or, wherein portions of sand core and/or sand mold that are not attached to a casting are introduced into the heat treating furnace. Wherein, the reclaiming within the furnace is carried out, in part, by a fluidizer that promotes binder combustion by one or more process of agitating, heating, and oxygenating. Wherein, the characteristics of the reclaimed sand are selectively controlled by controlling the dwell time of the sand within the heat treating furnace.

Abstract: An improved method and apparatus for heat treating metal castings with sand cores provides for removal of the sand core and recovery of the sand core material for reuse. The method and apparatus eliminate the need for removing the sand core from the casting prior to heat treatment and thus eliminate the labor, expense, and possible damage to the casting incidental to conventional core removal techniques such as chiseling and shaking. The method involves heating the casting with sand core therein to a temperature sufficient to burn off the binder component of the sand core. The sand comprising the sand core is then blown out of the casting by directing a flow of air over the workpiece. The sand thus dislodged is then collected for reuse. According to the disclosed apparatus, the castings are heated in a furnace having fans for directing a flow of air over the workpieces.

Abstract: An improved method and apparatus for heat treating metal castings with sand cores provides for removal of the sand core and recovery of the sand core material for reuse. The method and apparatus eliminate the need for removing the sand core from the casting prior to heat treatment and thus eliminate the labor, expense, and possible damage to the casting incidental to conventional core removal techniques such as chiseling and shaking. The method involves heating the casting with sand core therein to a temperature sufficient to burn off the binder component of the sand core. The sand comprising the sand core is then blown out of the casting by directing a flow of air over the workpiece. The sand thus dislodged is then collected for reuse. According to the disclosed apparatus, the castings are heated in a furnace having fans for directing a flow of air over the workpieces.

Abstract: Waste gasses generated in the process of manufacturing cores and castings are collected and inventively routed to a heat treating furnace for incineration. Additionally, as a portion of the waste gas is being routed, it is put to use in the reclaiming of uncured scrap materials and the reclaiming of sand within the furnace. Additionally, provisions are made for decreasing the height of the furnace by decreasing the height of hoppers therein and increasing the size of the base of the hoppers to maintain proper flow of reclaimed sand and portions of core materials being reclaimed therein toward the base of the hopper. Multiple fluidizers are employed in the base of the hopper to accommodate for the increased size of the base of the hopper and maintain optimum flow of materials toward the base and optimum fluidization of the materials within the hopper.