Abstract: A method for converting a locomotive traction motor originally equipped with sleeve bearings to roller bearings is provided. The ensuing method includes removing all parts of the original motor leaving only the motor frame. Recesses are then machined in the motor frame at both the pinion end and commutator end. The recesses are sized accordingly, to receive the roller bearings, which have a larger diameter then the sleeve bearings. Upper and lower frame inserts, each having an additional mounting opening, are then mounted to the machined frame to increase the strength and stiffness around the machined regions. A replacement axle is then equipped with the roller bearings, a pair of labyrinth seals, a gear and a pair of wheels. A pair of bearing housings may then be placed over the roller bearings. Each bearing housings has a reservoir that when the traction motor is assembled, is in communication with the roller bearings.

Abstract: A stationary die for a horizontal die casting machine has an oscillatable molten metal injector below the die that oscillates from an acute angle outside the die for filling with molten metal to an acute angle under the die or injecting the molten metal into the die. The stationary die has an annular docking block at the same acute angle to the horizontal as the axis of the shot sleeve under the die. The edge of the aperture at the outer end of the docking block is adjacent to and substantially in the plane of the parting surface of the stationary die so that the docking block per se projects outwardly from the surface. Correspondingly, the adjacent parting surface of the movable die is provided with a cavity for fitting this projection of the docking block, but since the surfaces of this docking block are at convergent acute angles, they provide no restriction to the movement of the movable die.

Abstract: A horizontally movable die has a bottom slide and cooperates with a stationary die in a die casting machine, which machine has a vertical injector for molten metal mounted underneath the dies and oscillatable to an acute angle to the vertical from under the dies for filling with molten metal. The outwardly movable shot sleeve of the injector seats in two semi-annular docking blocks, one mounted in the stationary die and the other mounted on an outward projection or extended portion of the slide on the movable die. Thus, when the dies are closed, the two semi-annular docking blocks for the shot sleeve form an aperture completely within the stationary die, which aperture communicates with an outwardly tapered trough duct that extends to the casting between the dies. This trough configuration forms a sprue in the stationary die that permits the separation of the movable die from the stationary die and then the retraction of the bottom slide without obstruction by any part of the sprue or the casting.

Abstract: This disclosure concerns a casting die for a cylinder, including engine blocks having a plurality of cylinders such as for internal combustion engines, including an expendable core for forming a jacket around the cylinders. This core has a printout portion at one end of the cylinder which is held in place by a cooperating flange on a mandrel that fits inside the cylinder. This mandrel may hold a liner for the cylinder. A dowel is provided in one of the die parts for insertion into the hollow mandrel. The mandrel is held in position by being clamped between the two opposing die parts, and the flanges of the core printout portion may be loosely held in the printout cavity of one of the die parts which preferably also contains one or more locating pins for bridging at least part of the gap between the printout portion and the printout cavity in the die for better positioning the core in the die.

Abstract: A method for producing high pressure die castings with undercut regions comprises forming an expendable coated core of specific composition, placing it in the die in a die casting machine, injecting molten metal into the die to form the casting and separating the casting from the die and the core from the casting. The composition of the expendable coated core comprises a base sand core held together by a resin binder; a first, bottom, hard refractory coating comprising fused silica and a refractory binder containing at least two of the following additives: a suspension agent, a dispersant, a wetting agent, and an anti-skinning agent; and a second, top, soft, or release coating containing a release material selected from the group consisting of anhydrous powdered aluminum, graphite, talc, titanium dioxide and zircon, and a resinous binder containing at least two different compounds selected from the group of additives consisting of a suspension agent, a dispersant, and an anti-settling agent.

Abstract: The disclosure concerns a process of producing expendable coated cores for castings comprising mixing sand with a resinous binder, polymerizing the binder, and then washing the resulting bound sand core with an organic solvent to remove unpolymerized residuals from the surface of the core before applying a coating to the core.

Abstract: The hollow frusto-conical expendable core is used for forming a jacket around a cylinder in a casting die for forming a cylinder block. The core has a printout portion comprising an inwardly extending annular flange connected to the narrower end of the frusto-cone by circumferentially spaced axially extending legs. The core may comprise a plurality of frusto-cones for a corresponding plurality of cylinders in an engine block with their axes parallel in a common plane with the annular flanges of their printout portions integrally connected for strengthening the multi-cylinder jacket core.

Abstract: The locating pins have notched ends, each of which simultaneously restricts the movement of an expendable core in two orthogonal directions in a die casting die. A plurality of these pins alone and with other pins project into the space between the printout cavity in a die casting die and the printout portion of an expendable core positioned in that cavity. Other pins having flat ends locate the core in only one directional line. Still other pins having tapered ends require special pockets in the printout section of the core, which pockets have sides that must be formed adjacent to the tapered surfaces of these pins. The configurations of the space around the printout portions of the cores permit molten metal injected into the die to produce a skin or skull over the printout portions, which skin can have thicker ribs or portions through it for further reinforcing the printout portions.

Abstract: The coatings are for an expendable sand core for die casting dies, which sand core has spaces between its contacting sand grains at least partially filled with resin binder. The first, base, hard, or refractory coating for this core is applied from an aqueous suspension comprising a finely ground refractory of fused silica, a refractory binder, and at least two different compounds selected from the groups of compounds or additives consisting of: (1) a suspension agent, (2) a dispersant, (3) a wetting agent, and (4) an anti-skinning agent. The refractory in the first coating may also include a minor amount, i.e. less than 50%, of another refractory oxide. The amount of binder in the first coating is less than about 15% by weight of the total liquid suspension, and the amount of additives is less than about 1.5% and usually less than 1% by weight of the total liquid suspension.

Abstract: The disclosure concerns a square die-cast elevated floor plate having a top continuous or perforated panel reinforced underneath by a polygonal tessellation grid of ribs. All of the ribs of the grid, including their integral ejector pin bosses, and, if desired, the peripheral ribs or border flange, are of the same depth; however, concentric rows of polygons in the tessellation pattern have their ribs gradually increasing in thickness from the border flange to the center of the plate. The polygons in the pattern may comprise squares and octagons in which alternate sides of the octagons have a ratio of one to the square-root-of-two, and the sides of the squares correspond to the sides having the square-root-of-two length. The continuous or perforated top panel may be formed integrally or adhered to the tessellation rib pattern. The rib pattern with its integral ejector pin bosses is preferably symmetrical for at least 180.degree. rotation of its die.